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.

Following are our standard specifications.

Contact us for options not listed here or for assistance regarding your particular application.

Input

Voltage: +10%
• Single phase: 110, 115, 120, 130, 200, 208, 230
• Three phase: 208, 220, 230, 380, 415, 440, 460, 480, 575
Frequency: 50/60Hz
Power factor: 0.7 minimum

Output

Voltage:
• 48V
• 80V
• 125V
• 250V to 600V
• Other voltages as requested
Current:
• 50A to 50,000A
Current limit adjust:
• 90% to 120% of full-rated output to be maintained
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

• 6- or 12-pulse thyristor bridge rectifier
• 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
• Built-in test (BIT)
• Ethernet/IP

Environmental/Mechanical

NEMA/IP enclosure ratings:
• NEMA 12 (IP20)
• NEMA 3R (IP54)
• NEMA 4 (IP55)
• NEMA 4X (IP56)
• other ratings available upon request
Operating temperature:
• -5°C - 40°C
Storage temperature:
• -10°C - 65°C
Humidity:
• Up to 90% non-condensing

Protection

• AC input circuit breaker
• AC and DC surge protection up to 5,000V
• Automatic equalize control automatically places charger in float mode after an AC power failure or charger shutdown
• Overcurrent/overload (125% for 2 hours)
• Overvoltage
• Overtemperature
• Input & output MOVs

Remote Capability/Computer Interface

Computer interface:
• Ethernet/IP
• Modbus TCP
• SNMP
• CANbus,
• IEEE 488.2 / GPIB
• RS232
• RS485
Functions:
• Start/stop
• Reset
• Fault
• Inhibit
• Current adjust
• Voltage adjust
• Fault indication (UV, OV, OC, other)
Analog signals:
• 4mA - 20mA
• 0V - 5V
• 0V - 10V

Standard Front Panel Devices

• Power on indicator
• Run indicator
• Current/voltage trim adjust
• Start/stop pushbutton
• Reset pushbutton
• Fault indicator
• Input circuit breaker

Smart Panel (HMI/digital control panel)

• Output voltage
• Output amperage
• Undervoltage indicator
• Overvoltage indicator
• Overcurrent indicator
• Overtemperature indicator
• Float/equalize mode selector
• Summary fault indicators
• Output current limit adjust
• TCP/IP/Ethernet interface
• Internal communication ports - USB, RJ45 (Ethernet)
• External communication ports - USB, RJ45 (Ethernet)
• Data logging: up to 64GB storage for event log/diagnostics

Codes & Standards

• IEC
• NEMA
• NEC
• IEEE
• MIL-SPEC

DSP Control Technology

• Increased performance
• One programmable chip with the functionality of conventional control components
• SCR preregulator to achieve high efficiency, low ripple, precise regulation, and low output noise
• Coarse and fine adjustments are available for both current and voltage
• Event and data logging to continuously monitor equipment operating status as well as internal control parameters

Options

• DC output breaker
• Optional alarm conditions (consult factory)
• Remote/local selector switch
• Output diode for reverse polarity protection
• Battery temperature compensation
• Battery discharge back into power line
• Blocking diode to block feedback through the charger during AC power failure or other shutdown conditions
• Equalize timer 0 to 24 hours
• Parallel & load sharing
• Delayed start (charge during off-peak hours)
• Ground fault protection and/or detection
• Emergency mushroom power off pushbutton
• 12- or 18-pulse input rectification for low input current
• Active input current filter
• Push to test indicators
• Mobile options (casters, pneumatic tires, towable, trailer- or rack-mounted, etc.)