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Frequently asked questions for industrial battery chargers: part-1
04 Nov 2021
From our long experience of providing industrial battery charger solutions to our customers and partners, we have seen that there are some basic questions that are always asked. Here we are sharing some of the common questions and their answers regarding the rectifier chargers for your convenience.


How are “equalize”, “boost” and “fast charge” charging different?

Each of these terms describes the same function of the DC UPS/battery chargers where the charger temporarily elevates the battery’s voltage above the float level. There are different uses for elevated charge voltage, as shown below:


Commonly understood meaning of the term:

Equalize – Periodic “topping up” of battery capacity, and correct cell capacity differences
Boost – Can refer to “equalize,” “fast charge,” and sometimes both

Fast charge – Faster recharge of a discharged battery


What does “equalize” charging do, and why is it needed?

All batteries, even those assembled into unitized blocks, are all built of individual battery cells connected in series to obtain the required DC voltage. Like all manufactured products, there is variation between the capacities of each cell in the battery. As the battery ages, this variation increases. Since the battery is a chain of cells that is only as strong as the weakest link some scheme is required to ensure that all cells stay at peak capacity.


A scheme called “equalizing” is commonly used in both lead-acid and nickel cadmium batteries. Equalizing temporarily elevates the charging voltage of the entire battery string above the normal “float” voltage. The elevated charging voltage allows all cells, including the weak ones, to accept more current from the charger than they would at float voltage. A consequence of the elevated equalize voltage is that all cells in the battery are overcharged. This is acceptable for short periods provided the battery has sufficient electrolyte.


Overcharging greatly increases the rate at which the water in battery electrolyte is electrolyzed into oxygen and hydrogen gas. Since low electrolyte level will permanently damage the battery it is important to limit when, and for how long, the battery is charged at the equalize voltage.


What is “fast charging”?

Batteries, like all electrical conductors, suffer from resistance in their conductive metals. Ohm’s law says that resistance increases in proportion to current flow through the battery (or any other imperfect conductor). This means that the more amperes of charge we attempt to apply to the battery the more will be lost due to internal heating.

“Fast charging” temporarily increases the charger’s output voltage to compensate for the battery’s internal resistance. This allows the battery to continue accepting maximum current from the charger for a longer time – instead of reducing its charge acceptance early as it would if charged at normal float voltage.


What is the correct charging voltage?
The value of both float and equalize/boost/high rate voltages is determined by the battery manufacturer, and depends on the chemistry and construction of the battery. Deviating from the recommended values, except where needed to adjust for temperature, will under or overcharge the battery – both of which will reduce the battery’s life and performance.

Conclusion:
EverExceed has a vast experience when it comes to industrial charger solutions, and we are satisfying our partners and customers pain points with the most efficient and precise state of art thyristor based battery charger solution consistently. If you have any requirement or any kind of query regarding the industrial battery charger, feel free to communicate with our dedicated team at marketing@everexceed.com

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