Very fast charging of deep cycle batteries.

Submitted: Thursday, Oct 18, 2012 at 11:52
ThreadID: 98620 Views:10384 Replies:6 FollowUps:12
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The following results of my new battery setup may interest those wanting a fast charging system.
SOC = State of Charge DOD = Depth of Charge (I use a battery down to 50%)

My Fullriver AGM has been retired. It used to take about 6 hours for a 90% SOC charge plus a run overnight to fully charge it - this was too slow for me. When camping and running off the genset, the battery was rarely up to 90% SOC and never up to full charge, until I returned to mains power.

I now charge a Lifeline 150 Ah battery with three 40 Amp battery chargers (non-smart, cheap constant voltage type) that run in parallel with each other – I purchased the CH 40 type chargers from eBay at $95 each. Each is switched individually so as to allow variation of either the load on the genset or the charge rate to the battery. A 150 Ah was used but a 100 Ah Lifeline would have also been suitable with this setup.

Testing on a 240 volt mains supply
With the battery discharged to 50% DOD, and 3 chargers switched on, the charge rate starts at approximately 100 Amps tapering off to 25 Amps in the first hour - achieving about 90% SOC. In the next hour 25 Amps tapers to 5 amps - getting close to full charge in 2 hours. The internal temperature of the battery rose 6 degrees and stabilised at 26 degrees during the first hour.

During these tests the battery was discharged to 50% with a 25 Amp load – charge rates could increase if discharged at a lower rate.

Running on a 2.4 kva Yamaha Genset
The overload breaker tripped out with 3 chargers connected to the 50% DOD battery. When using the genset, I have to start with only 2 chargers connected, at an initial charge rate around 70 Amps - I continue with the 2 for about 10 minutes before switching in the 3rd charger.

Lifeline states that, with repetitive deep cycling, a high charging regime is more beneficial to the cycle life of their battery than low charging rates.

If you go for a system like this, you need to ensure that you check batteries specifications and stay within their specified charging rates. If you can’t obtain these details, doesn’t use the battery as it could overheat dangerously.
You also need to source constant voltage chargers that will run in parallel – many smart chargers won’t do so. (I brought one in initially and tested it before I put together the rest of the system)
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Reply By: member - mazcan - Thursday, Oct 18, 2012 at 12:43

Thursday, Oct 18, 2012 at 12:43
hi dennis
quiet interesting i had never considered that 3 chargers could be used at one time
my initial thoughts was that the battery would boil severely which would destroy it in the not to distant future but 26 deg isnt too bad as most under bonnet temps would be a lot higher than that on any vehicle with a dual bat set-up
although im aware that we can have solar and alternator charges going into a battery together or solar and dc/dc at the same time
i have used solar and a twin charger which is dc/dc in a different formrunning from vehicle alternator
but it appears from your article that the lifeline battery's are made to take this punishment
if the battery's can sustain this
it looks like it will be a great benefit as charging times have always been a bone of contention
what is the warranty period for the lifeline and where do you buy them
cheers barry
AnswerID: 496907

Follow Up By: Dennis Ellery - Thursday, Oct 18, 2012 at 12:51

Thursday, Oct 18, 2012 at 12:51
I purchased mine online from Everybattery - sent to Perth from Victoria.
These charge rates are within Lifelines specifications and they provide a 5 year warranty for non-commercial use.

Regards Dennis
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FollowupID: 772633

Follow Up By: member - mazcan - Thursday, Oct 18, 2012 at 12:54

Thursday, Oct 18, 2012 at 12:54
hi
wow thats a dam good warranty
cheers
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Follow Up By: Dennis Ellery - Thursday, Oct 18, 2012 at 13:30

Thursday, Oct 18, 2012 at 13:30
I doubt that will be for under bonnet use – My warranty is 5 years for Marine and RV applications
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Follow Up By: Member - Phil G (SA) - Thursday, Oct 18, 2012 at 15:59

Thursday, Oct 18, 2012 at 15:59
5 year is pro-rata.
12mths is the full replacement warranty
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Reply By: TerraFirma - Thursday, Oct 18, 2012 at 13:33

Thursday, Oct 18, 2012 at 13:33
Life in the fastlane..! Throw me a Lifeline at the speed of sound..! LOL

Interesting Dennis, you sure are hitting those babies with some horsepower, 6 degree jump is pretty good.

On a percentage ratio how much quicker do you think the Lifeline's would charge over the Fullrivers?
AnswerID: 496910

Follow Up By: Dennis Ellery - Thursday, Oct 18, 2012 at 14:00

Thursday, Oct 18, 2012 at 14:00
If you use the same 20amp charger maybe not much – I couldn’t put the Fullriver on the three 40 amp chargers or it could have gone into orbit.
But if you have the power to pump into the Lifeline I’d say 500% compared to my old setup with a 20 amp smart charger.

Here is a extract from Lifelines Technical Manual No 6-0101
“The most efficient method of charging Lifeline® AGM batteries is to use a 3 stage charging profile. In the first stage, a constant current is applied until the voltage reaches a pre-set limit. The first stage is often called the Bulk charging stage. In the second stage, the voltage is held constant at the same pre-set limit until the charging current tapers to a very low value, at which point the battery is fully charged. The second stage is often called the Absorption charging stage. A voltage limit of 14.3 volts ± 0.1 volts (7.15 ± 0.05 volt for a 6 volt battery) should be used when the battery temperature is 77°F (25°C). The battery is fully charged when the current drops below 0.5% of the battery's rated capacity (0.5A for a 100Ah battery). In the third stage, the charging voltage is reduced to a lower value that minimizes the amount of overcharge, while maintaining the battery at 100% state of charge. This third stage is often called the Float charging stage. A float voltage of 13.3 ± 0.1 volts (6.65 ± 0.05 volts for a 6 volt battery) should be used when the battery temperature is 77°F (25°C).”
“The charging current during the Bulk stage should be set as high as practical; higher current levels mean faster recharge time. For repetitive deep cycling, chargers should have an output current of at least 0.2C (20 Amps for a 100 Ah battery). If the output current is less than this value, the cycle life of the battery may be negatively affected. Due to the low impedance design, Lifeline® batteries can tolerate in-rush current levels as high as 5C (500A for a 100Ah battery).”
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Reply By: Rockape - Thursday, Oct 18, 2012 at 13:38

Thursday, Oct 18, 2012 at 13:38
Dennis,
thanks for your research and post.

I see the batteries aren't cheap but with a 5 year warranty it looks like they stand by their product.

RA.

AnswerID: 496911

Follow Up By: Dennis Ellery - Thursday, Oct 18, 2012 at 15:07

Thursday, Oct 18, 2012 at 15:07
My prime consideration was their ability to absorb energy quickly but pricewise taken over its lifespan is good - the 150 Ah Lifeline I am using has a 1100 cycle life at 50% - my Fullriver was 500 cycles at 50% - I have seen others at 300.
Regards Dennis
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Reply By: Member - lyndon NT - Thursday, Oct 18, 2012 at 22:06

Thursday, Oct 18, 2012 at 22:06
Really interesting info, thanks for the information, very informative. I wonder what Peter the battery Guru who advertises on this site has to say?

Cheers

Lyndon
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Decide now what you will,
Place faith not in tomorrow
For the clock may then be still

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AnswerID: 496939

Follow Up By: Dennis Ellery - Friday, Oct 19, 2012 at 12:00

Friday, Oct 19, 2012 at 12:00
Hi Lyndon - that’s a bit be naïve.
The system works because of the batteries ability to absorb large amounts of energy quickly.
Whether it’s Peter or any other battery supplier, it is not in their best interests to promote Lifelines capabilities– unless they market them of course.
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Reply By: Wolfy03 - Thursday, Oct 18, 2012 at 23:55

Thursday, Oct 18, 2012 at 23:55
Peter,
May i ask what made you go down this path with your charging set up....why not just have one charger for all jobs? Is this something you have researched or heard being done for...just curious to find out more background behind it.

I am currently in the market for a battery charger but keen to find out more with your system before parting with the hard earned cash!
Thankyou for the report though...very informative!

Troy
AnswerID: 496943

Follow Up By: Dennis Ellery - Friday, Oct 19, 2012 at 11:50

Friday, Oct 19, 2012 at 11:50
Hi Troy
I’m Dennis not Peter
No I hadn’t heard of this being done before – technically it’s not big challenge, if you use constant voltage chargers with approximately the same output. The three chargers I used vary a bit, one is a 14.25V another at 14.40V and the other at 14.48V
Reasons for me not going for a single charger are:
The 100 Amp battery chargers that I looked were smart chargers designed for marine operations – in excess of $1000 and too bulky for a caravan (At that stage I didn’t look at whether my genset could handle them, but it appears a 2.4 kva genset would have kicked out on overload at start-up, if the battery was heavily discharged).
There is a Projector 50 amp smart charger on the market for about $500 - a bit small for my purposes.
Smart chargers are not the most efficient way to charge a Lifeline quickly.
Going down the path with three non-smart 40 amp chargers means I could shed some of the load on the genset when required. (Charging a heavily discharged battery or having other loads connected to the genset at the same time)
I had to take a punt, risk my $95, and buy in a 40 amp charger and test it to see whether it was likely to run in parallel with a similar charger.
If you are in Perth – you are quite welcome to look at my setup.
If you buy a big charger – make sure your geneset can handle it.
Regards Dennis
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Reply By: Battery Value - Saturday, Oct 20, 2012 at 17:27

Saturday, Oct 20, 2012 at 17:27
Hi Dennis,

interesting and meaningful test you did there.
To sum up your test setup:
3x40A chargers on a 50% discharged 150Ah battery

I'm curious why the charging rate only reached 100A and not 120A?

Anyway, @ 100A charging current the specific charging rate in this test is 100A/150Ah or 0.66/hr.

Since I've got the means I hope you don't mind me copying your setup for a comparison test on another high current AGM design by a European manufacturer.

This battery is rated 70Ah.
For a level playing field, I used 2x25A chargers on it which brings the specific charging rate to almost the same @ 0.71/hr (in fact this is a somewhat harder rate).

The battery also was discharged to about 50% SOC before recharging commenced with the bulk rate set to 50A.
A temperature sensor was attached to the battery, and another one shows the ambient, both @ 27°C before charging commences.

At the start both sensors show 27°C.
After 20 mins the battery temp peaks @ 31°C
after 30 mins down a bit @ 30°C
after 40 mins down again @ 29°C
after 50 mins unchanged @ 29°C

So this baby only briefly got 4°C warmer @ a somewhat harder specific charging rate.

Looking at the charging times:
after one hour, you still noticed 25A of charging current which brings the specific charging rate to 25A/150Ah or 0.17/hr.

On this 70Ah baby, the charging rate has dropped to 3.3A after 50 mins, say conservatively 3A after one hour, which brings the specific charging rate in @ 0.043/hr.

So the 70Ah baby gets to above 95% almost twice as fast, and develops less heat!

There must be a reason why BMW and Co use this battery for things like brake recuperation.

link to photos

cheers, Peter



AnswerID: 497022

Follow Up By: Dennis Ellery - Saturday, Oct 20, 2012 at 22:28

Saturday, Oct 20, 2012 at 22:28
Hi Peter
I am sure you have top quality batteries – no doubt about it, if as you say if BMW use them.
My requirement was for long life, deep cycle batteries with high charge acceptance.
I appreciate you have done your own tests but I needed manufacturer’s detailed engineering specifications such as Lifelines Document No. 6-0101 – some 30 pages of data and graphs.
I considered your batteries, but though they were cheap, the limited data you provided was a glossy 4 page brochure short on engineering data.
Regard Dennis
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FollowupID: 772796

Follow Up By: Dennis Ellery - Sunday, Oct 21, 2012 at 11:16

Sunday, Oct 21, 2012 at 11:16
Hi Peter,
I didn’t have time to answer you fully last night.
We seem to be going off the thread a bit – you are focused on promoting your battery’s capabilities over Lifeline. I am not wedded to Lifeline, there are other batteries such as Optima that would have done the same job.
I am not convinced your battery would - as it’s designed for operating a motor vehicle - not for repetitive deep cycle work.
If that was the case, the manufacturers would have produced specifications supporting deep cycle work.
As a minimum this would have to include; Temperature, Voltage and Amperage limits, DOD v Lifespan graphs, Voltage v capacity graphs etc.
Reputable deep cycle battery manufactures such as Fullriver, Lifeline, Trogan and Optima, to mention a few, provide this information so that systems can be engineered professionally.
Your personal tests are not a substitute for published engineering date and I doubt the battery’s manufacturer would accept them in the case of a warranty claim.
Regards Dennis
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FollowupID: 772813

Follow Up By: Battery Value - Sunday, Oct 21, 2012 at 21:38

Sunday, Oct 21, 2012 at 21:38
....Reputable deep cycle battery manufactures such as Fullriver, Lifeline, Trogan and Optima, to mention a few, provide this information so that systems can be engineered professionally.
Your personal tests are not a substitute for published engineering date and I doubt the battery’s manufacturer would accept them in the case of a warranty claim......

So my tests are no substitute for published engineering data eh?

But they are every bit as good as your own published tests and it shows that your batteries don't live up to mine in this department o:)

On a side note: I worked for almost two decades in Germany doing service and startups of NC/CNC/PLC equipment, part of them in the domestic car industry.
And believe me, companies like Bimmer can't afford to settle for second best when it comes to outsourcing part of their operations, including parts supplies and manufacturing which has to be done at state of the art.

Do you really think, they'd select a battery for their start/stop systems and brake recuperation with only a lacklustre cycle life performance?
These things are subject to thousands or even tens of thousands of micro cycles with all its associated mechanical strain on the battery grids.
Mechanical grid fatigue is the major stress factor in this regards.
Consequently they select a design which offers maximum grid flexibility which guarantees a great number of cycles, without running into embrittlement and active mass separation problems.

And you guys think, just because someone publishes 30 pages of 'engineering data' everything is honky dory - didn't you call someone else a bit naive earlier in the thread?
Sorry if this was a bit harsh, but look the yanks to date, haven't learned how to build proper cars (among other things). All they can do is offer joint ventures to allow foreign manufacturers access to their own market, and in return benefit from technology transfer. See Daimler Chrysler (Jeep) engines engineered and made in Germany, so is the gearbox, made by ZF.

Same goes for car batteries: didn't know how to make them half decent, so Johnson Controls come along and buy top notch German battery maker VARTA.
And because Banner Batteries have very advanced automated battery production methods, which someone like East Penn can't resist to get their hands on, they also formed a joint venture in order to give their stone age facilities a bit of a technological boost.

Wake up guys.







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Follow Up By: Dennis Ellery - Monday, Oct 22, 2012 at 10:29

Monday, Oct 22, 2012 at 10:29
Hi Peter
I wouldn’t hesitate to use your battery in my wife’s sedan.

I wouldn’t use it as follows:

As a starter in my 4WD, used in hot norwest summers over 1000ks of corrugated roads and miles from the nearest service station.

In repetitive deep cycle environments.

You may think your batteries can do everything, but your manufacturer’s specifications don’t support these applications.

Peter, this thread is too old to be of interest to anybody so I won't waste any more of your time by replying further.

Regards Dennis
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FollowupID: 772873

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