High Current Battery Chargers from 5KW to 2MW


PCTI offers rugged high current battery chargers to meet all of your high-current industrial charging applications from 25 to 2000A and up to 1000V. Our standard battery charger includes a battery eliminator, float and equalize adjustments, manual equalize timer, automatic shutdown and restart under a variety of fault conditions, low ripple, and paralleling capability. Options include computer interface, discharge capability, DC circuit breaker, temperature compensation circuit and more.

PCTI’s high current battery chargers and systems are at work today in a variety of industrial, commercial, and military applications. Each unit is based on standard designs and custom engineered to meet your specific application.

PCTI’s high current battery chargers are built to customer order from a range of standard power and control modules, and offer high performance, high reliability and sophisticated control systems. A variety of computer interfaces are available to meet all of your power supply programming and control requirements. For high power and typical project profiles, click the buttons at the top right. If you need help in specifying your battery charger, request a quote or download our battery charger brochure.

General Specifications

The following specifications outline our up to 2000 KW battery chargers product line. Please contact PCTI for options not listed here or for assistance regarding your particular application.

Input Voltages ( +10%, 50/60Hz )
Single: 110, 115, 120, 130, 200, 208, 230
Three: 208, 220, 230, 380, 415, 440, 460, 480, 575
Voltage: 48V, 80V, 125V, 250V to 600V and others as requested
Current: 25 to 2000A
Voltage Adjust: + 5% of rated output voltage for any load variation from 0 to 100% with separate equalize and float voltage settings
Efficiency: 85% minimum
Standard Features
Six-pulse or 12 pulse thyristor bridge rectifier
Constant Current Control
Constant Voltage Control
Automatic Crossover
Regulated Voltage
Regulated Current
Automatic Phase Selection
Soft Start with batteries disconnected
Automatic Restart to Float Mode after loss and restoration of AC input power
Manual selection of float or equalize charge mode
Float Voltage Control per NEMA PE-5 depending on battery type
Equalize Voltage Control per NEMA PE-5 depending on battery type
Battery Charger can act as a DC power supply with batteries disconnected
Standard Protection
AC input circuit breaker
AC and DC surge protection up to 5000 volts.
Automatic Equalize Control automatically places charger in float mode after an AC power failure or charger shutdown
Overcurrent/Overload: 120% for 2 hours
Input and Output MOVs
Front Panel Devices

Float Level Control Potentiometer

Equalize Level Control Potentiometer

Equalizing Timer 0 to 24 hours operable in the manual equalize mode

On/Off Switch

Float/Equalize Selector Switch

AC power ON Indicator

Analog or Digital Voltmeter

AC power ON Indicator

Analog or Digital Ammeter

Float Charge Selected Indicator

Equalize Charge Selected Indicator

Rectifier Failure Alarm Indicator

Input AC Failure Alarm Indicator

DC Undervoltage Alarm Indicator

DC Overvoltage Alarm Indicator

Note: Alarms can provide front panel indication, remote indication, audible alarm and/or shutdown of the battery charger
depending on customer requirements

Computer Interface/Remote Capability

Analog Signals: 4-20mA, 0-5V, 0-10V

Computer Interface: ethernet, profibus, Modbus, CANbus, IEEE 488.2 / GPIB, RS232, RS485

Functions: Start/Stop, Reset, Fault, Current Adjust, Voltage Adjust, Fault Indication, Float selected, Equalize selected


Enclosure Type: Nema 1 indoor, Nema 12 dust resistant, Nema 3R outdoor or Nema 4

Airtight (with air to air heat exchanger)

Cooling: Forced Air Cooling or Natural Convection

Altitude: To 10,000 ft without derating

Temperature: Operating: 0 to 50°C; Storage: -40°C to 65°C

Humidity: Up to 90% non-condensing

Standard Conformance



Optional Features

DC Output Circuit Breaker

Battery Eliminator

Very low ripple

Optional alarm conditions: Output circuit breaker off, Over temperature, Ground Fault Failure

Audible alarm horn

Remote/local selector switch

Remote Control via analog signal or Computer Interface (RS232, IEEE488, GPIB)

Equalize Timer 0 to 24 hours

Blocking Diode to block feed-back through the charger during AC power failure, being remotely turned off, charger internal failure, or other shutdown conditions

Output diode for reverse polarity protection

Battery Temperature Compensation

Parallel and Load Sharing

Delayed Start (charge during off-peak hours)

Ground Fault Protection and/or detection

Battery discharge back to the power line

Computer Interface/Remote Capability: Analog Signals: 4-20mA, 0-5V, 0-10V or IEEE 488.2, RS232, RS485, GPIB