High Current Battery Chargers from 5KW to 2MW

Rugged High Current Battery Chargers

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.

For Your Application

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

Custom Products Designed for You

PCTI's custom 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. If you need help in specifying your battery charger, contact usrequest a quote, or download our battery charger brochure.

Standard 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

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

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
  • Overvoltage
  • Overtemperature
  • 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


  • 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

Codes and Standards

  • IEC
  • NEMA
  • NEC
  • IEEE

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