Repairing a lead acid battery charger

Aug 31, 2007 23 Replies

For what it's worth, I've successfully reanimated a sealed lead acid battery that was kept totally discharged for maybe a year (zero volts), at least it's good enough for what I need it for anyway.

To begin with, the battery was high impedance and wouldn't accept any significant charging current at the proper voltage. What I did is connect it to a current limited laboratory supply, initially set to a low current limit (100mA for a 7AH battery) and I turned the voltage up to about 8 volts per cell. The low current limit is to prevent too much heat from being generated in the battery due to the high voltage. The battery passed only a very small current at first, in spite of the very high charging voltage.

After some hours, the current built up until the current limit was reached and the voltage gradually dropped down to the normal charging voltage, and I was able to put an amp or two into the battery, at which point I set the voltage limit to the rated float charging voltage printed on the battery. I waited a couple of days till the battery had accepted a charge, then I tried it out under heavy load, and it has been satisfactory ever since.

Another time I was unsuccessful in reviving a battery because it developed a shorted cell either before, during or after the revival procedure. Since it was given to me as dead, it is quite possible that it had the shorted cell before it was allowed to get deep-discharged.

Chris

Thats about 2 1/2 times per year. If it was charged properly after each use, then there may be hope for it.

Yes, if you replace it with an identical or equivalent battery, you need a charger with greater capacity, even for float charging.

Better still is to review what you are doing with the battery and perhaps come up with something different. That's an expensive battery - and you might be able to do whatever it is you are doing for a whole lot less money.

Ed

>

I successfully repaired the battery charger!

I then decided to see if I could test my old (presumed "dead") 2V battery with it.

The open circuit voltage of the battery was about one volt. I connected it up to the battery charger and switched on at the "2V" setting. The charge current was a steady 1A but I now measured the voltage across the battery terminals at 0.5V and falling (the voltage fell below 0.4V before I switched off).

I changed the range to "12V" and switched on again. The charging current fell to 280mA and the terminal voltage was measured at 0.67V. The terminal voltage is still falling but quite slowly (

If the voltage of the battery under charge is going below the open-circuit voltage of the battery, then it suggests that you have connected the battery charger backwards, or the charger is still defective. If this is what happened, then of course stop it ASAP as it will tend to kill the battery.

(The only other possibility that I can think of is if the battery had previously been charged backwards, then its terminal voltage would be negative (i.e. the wrong polarity compared to the markings on the battery) and would go towards zero when the battery is charged with the correct polarity.)

Chris

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