APTP Articles

Power Under Pressure: Designing for AS4044:2024 in Substation Environments

Compliant systems for high-visibility, high-resilience infrastructure

The release of AS4044:2024 represents a decisive shift in how stationary battery charger systems are specified, validated, and integrated into essential infrastructure. For engineers operating in substation environments, the standard sets a clearer expectation: charger systems must support not only stable DC output, but also traceable compliance, telemetry integration, and environmental hardening.

Where past standards offered baseline safety guidance, AS4044:2024 positions the charger as a frontline infrastructure component — one that is observable, auditable, and embedded in sitewide continuity planning.

Why AS4044:2024 Demands a Different Design Approach

In substation and switching applications, battery chargers are no longer passive backup devices. They are interlocked with control systems, automation logic, and emergency failover protocols — and the cost of misalignment is measured in outages, not inconvenience.

AS4044:2024 introduces requirements that directly address operational reliability and real-world performance in harsh or high-dependency environments. These include:

  • Stable float and boost voltage regulation under fluctuating load
  • SCADA-compatible alarm states with remote reset logic
  • Electromagnetic compatibility (EMC) for electrically dense environments
  • Ingress protection (IP) and thermal range compliance
  • Factory Acceptance Testing (FAT) with verifiable documentation

“The updated standard redefines compliance — moving beyond electrical function into the realm of system accountability, telemetry integration, and lifecycle assurance.”

Building Compliance into the System Architecture

Rather than treating compliance as a retrofit, AS4044:2024 reinforces the need for purpose-designed systems — engineered from the outset to meet performance, monitoring, and integration requirements.

Engineering considerations include:

  • Native Modbus TCP/IP or DNP3 support for SCADA/PLC observability
  • Modular architecture for service redundancy and on-site component swap-out
  • Structured event logging with timestamped diagnostics and local access
  • Voltage and temperature compensation under dynamic load conditions
  • High-visibility fault indicators and user-defined alarm mapping

Intelepower’s site audit and specification process ensures that these considerations are not only engineered into the product — they’re validated against environmental and load profiles before installation begins.

The Role of SCADA Visibility in Compliance

In modern substations, visibility is critical — not just for performance tracking, but for event diagnosis and compliance documentation. AS4044:2024-compliant chargers must operate as native elements in the control topology, not as isolated boxes.

This requires the ability to:

  • Broadcast live status and diagnostic flags to the site SCADA
  • Support alarm acknowledgement and resets remotely
  • Maintain deterministic communication during switching events
  • Log faults and resets locally for field servicing

These features reduce operational blind spots and allow the charger to function as a responsive, intelligent component within the substation control ecosystem.

About the Author

Century Yuasa