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24V battery charger circuit

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avz

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Hi
I have at my work a walk behind forklift that operates on 24V kead acid battery. it has a charger but the control unit of the charger - it seems to me like a mechanical some sort of timer with some sort of current sense - dosn't work. I've bypassed it and got the battery charged, but it's not a good solution. the charger is made of a 3 phase transformer with 3 diodes to rectifie the current and a resistor to control the charging rate. could you advise me how to build a control circuit - taking into consideration the fact that when I've charged it - the reading on the ampermeter showed 62A. it's fsd - 100A.
Thanks.
 
lead-acid batteries are usually charged with a constant-voltage supply by for a vehicle battery like yours there may be some more complication in terms of topping up charge etc.

These **broken link removed**

There are a number of risks associated with overcharging a lead acid battery, and the capital cost of the battery is probably quite high. For a company if it's a critical part of the workflow you're probably better getting a commercial unit on the one you have repaired rather than going DIY. I would imagine health and safety might have a similar view...

Sounds like the control unit is basically a timer, the sensor would probably be a voltage sensor to quit when the battery is charged and the timer as a backstop in case you had a dud battery that will never reach full charged terminal voltage. If timer is a mechanical sort that has seized up you can sometimes get these going again by isolating the power and then stripping down the unit - the oil/grease gets gungy and thick with age. There's usually a synchronous motor driving a gear chain, and when the grease gets too waxy the motor stalls. Clean with IPA and see if it gets going again - stalling the clock motor doesn't usually knacker it.

It's probably worth bearing it mind something charging at up to 100A on the low voltage side and running off three-phase AC doesn't leave you much room for error ;)
 
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