Electronic – Lead-acid battery charging fixed current stage specification

battery-charginglead-acidrms

This post doesn't question the charging process or its theory. I seek to understand how to read the battery manufacturer's requirement of fixed current stage.

They prescribe a current to be held at specific value, let's call it I_fixed. I am assuming that to be a true DC current, which would be easy to comply with.

Now for reasons not important to discuss here, many chargers just rectify transformer output and give pulsating DC voltage. I control this with thyristors for each half-wave, thus current is pulsating. In order to measure the charging current, I decided to use RMS calculation from 256 samples I take each half-wave.

In short: Am I following correctly the manufacturer's specification to control the RMS current value to match their value? Is I_rms == I_fixed?

EDIT:
Note that I have no choice with the hardware, I can only modify the software. The battery is lead-acid 36V 215Ah, voltage after thyristors is 36Vrms = 51Vpeak, pulsating 120 times for 60Hz AC. I control the pulse width for each half-wave pulse. The Irms I use now to charge goes from 0…21.5A

enter image description here

Pardon for hand-made chart… I noted this down during one test cycle. the current is what I calculated form the above described RMS current. Voltage is measured every 16th half-wave with no charge current present in 64 samples then averaged.

Example charging process

Best Answer

Lead acid 36V would have 18 cells, assuming that 12V lead acid has 6 cells.

Stage2:

The correct setting of the charge voltage limit is critical and ranges from 2.30V to 2.45V per cell. So 18 x 2.40 = 43,2V

Stage 3:

The recommended float voltage of most flooded lead acid batteries is 2.25V to 2.27V/cell., therefore 2.25 x 18 = 40.5V.

Source of the article enter image description here

Based on recommendations you exceed all limits, but this recommendations are for common flooded lead acid battery. You should find what is the type of your battery: flooded, AGM, ...has additives: Calcium, Antimony,...

It is very possible that your voltage measuring method isn't very good. When you measure the open circuit voltage you get surface charge voltage, which can fool you. It would be necessary to load the battery with a known low resistance, for example 15 ohm and low Rdson MOSFET, for very short pulse duration and sample the voltage.

You can improve your circuit with adding a series choke and freewheeling diode, if you wish to have almost DC current. Source enter image description here

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