There are two distinct varieties of chargers: the personal chargers and the industrial chargers. The personal charger is sold in attractive packaging and is offered with such products as mobile phones, laptops and video cameras. These chargers are economically priced and perform well when used for the application intended. The personal charger offers moderate charge times.

In comparison, the industrial charger is designed for employee use and accommodates fleet batteries. These chargers are built for repetitive use. Available for single or multi-bay configurations, the industrial chargers are offered from the original equipment manufacturer (OEM). In many instances, the chargers can also be obtained from third party manufacturers. While the OEM chargers meet basic requirements, third party manufacturers often include special features, such as negative pulse charging, discharge function for battery conditioning, and state-of-charge (SoC) and state-of-health (SoH) indications. Many third party manufacturers are prepared to build low quantities of custom chargers. Other benefits third party suppliers can offer include creative pricing and superior performance.

Not all third party charger manufacturers meet the quality standards that the industry demands, The buyer should be aware of possible quality and performance compromises when purchasing these chargers at discount prices. Some units may not be rugged enough to withstand repetitive use; others may develop maintenance problems such as burned or broken battery contacts.

Uncontrolled over-charge is another problem of some chargers, especially those used to charge nickel-based batteries. High temperature during charge and standby kills batteries. Over-charging occurs when the charger keeps the battery at a temperature that is warm to touch (body temperature) while in ready condition.

Some temperature rise cannot be avoided when charging nickel-based batteries. A temperature peak is reached when the battery approaches full charge. The temperature must moderate when the ready light appears and the battery has switched to trickle charge. The battery should eventually cool to room temperature.

If the temperature does not drop and remains above room temperature, the charger is performing incorrectly. In such a case, the battery should be removed as soon as possible after the ready light appears. Any prolonged trickle charging will damage the battery. This caution applies especially to the NiMH because it cannot absorb overcharge well. In fact, a NiMH with high trickle charge could be cold to the touch and still be in a damaging overcharge condition. Such a battery would have a short service life.

A lithium-based battery should never get warm in a charger. If this happens, the battery is faulty or the charger is not functioning properly. Discontinue using this battery and/or charger. It is best to store batteries on a shelf and apply a topping-charge before use rather than leaving the pack in the charger for days. Even at a seemingly correct trickle charge, nickelbased batteries produce a crystalline formation (also referred to as ‘memory’) when left in the charger. Because of relatively high self-discharge, a topping charge is needed before use. Most Li-ion chargers permit a battery to remain engaged without inflicting damage. There are three types of chargers for nickel-based batteries. They are:

Slow Charger — Also known as ‘overnight charger’ or ‘normal charger’, the slow-charger applies a fixed charge rate of about 0.1C (one tenth of the rated capacity) for as long as the battery is connected. Typical charge time is 14 to 16 hours. In most cases, no full-charge detection occurs to switch the battery to a lower charge rate at the end of the charge cycle. The slow-charger is inexpensive and can be used for NiCd batteries only. With the need to service both NiCd and NiMH, these chargers are being replaced with more advanced units. If the charge current is set correctly, a battery in a slow-charger remains lukewarm to the touch when fully charged. In this case, the battery does not need to be removed immediately when ready but should not stay in the charger for more than a day. The sooner the battery can be removed after being fully charged, the better it is.

A problem arises if a smaller battery (lower mAh) is charged with a charger designed to service larger packs. Although the charger will perform well in the initial charge phase, the battery starts to heat up past the 70 percent charge level. Because there is no provision to lower the charge current or to terminate the charge, heat-damaging over-charge will occur in the second phase of the charge cycle. If an alternative charger is not available, the user is advised to observe the temperature of the battery being charged and disconnect the battery when it is warm to the touch.

The opposite may also occur when a larger battery is charged on a charger designed for a smaller battery. In such a case, a full charge will never be reached. The battery remains cold during charge and will not perform as expected. A nickel-based battery that is continuously undercharged will eventually loose its ability to accept a full charge due to memory.

Quick Charger — The so-called quick-charger, or rapid charger, is one of the most popular. It is positioned between the slow-charger and the fast-charger, both in terms of charging time and price. Charging takes 3 to 6 hours and the charge rate is around 0.3C. Charge control is required to terminate the charge when the battery is ready. The well designed quick-charger provides better service to nickel-based batteries than the slow-charger. Batteries last longer if charged with higher currents, provided they remain cool and are not overcharged. The quickchargers are made to accommodate either nickel-based or lithium-based batteries. These two chemistries can normally not be interchanged in the same charger.

Fast Charger — The fast-charger offers several advantages over the other chargers; the obvious one is shorter charge times. Because of the larger power supply and the more expensive control circuits needed, the fast-charger costs more than slower chargers, but the investment is returned in providing good performing batteries that live longer. The charge time is based on the charge rate, the battery’s SoC, its rating and the chemistry. At a 1C charge rate, an empty NiCd typically charges in a little more than an hour. When a battery is fully charged, some chargers switch to a topping charge mode governed by a timer that completes the charge cycle at a reduced charge current. Once fully charged, the charger switches to trickle charge. This maintenance charge compensates for the self-discharge of the battery.

Modern fast-chargers commonly accommodate both NiCd and NiMH batteries. Because of the fast-charger’s higher charge current and the need to monitor the battery during charge, it is important to charge only batteries specified by the manufacturer. Some battery manufacturers encode the batteries electrically to identify their chemistry and rating. The charger then sets the correct charge current and algorithm for the battery intended. Lead Acid and Li-ion chemistries are charged with different algorithms and are not compatible with the charge methods used for nickel-based batteries.

It is best to fast charge nickel-based batteries. A slow charge is known to build up a crystalline formation on nickel-based batteries, a phenomenon that lowers battery performance and shortens service life. The battery temperature during charge should be moderate and the temperature peak kept as short as possible.

It is not recommended to leave a nickel-based battery in the charger for more than a few days, even with a correctly set trickle charge current. If a battery must remain in a charger for operational readiness, an exercise cycle should be applied once every month.

Simple Guidelines

A charger designed to service NiMH batteries can also accommodate NiCd’s, but not the other way around. A charger only made for the NiCd batteries could overcharge the NiMH battery.

While many charge methods exist for nickel-based batteries, chargers for lithium-based batteries are more defined in terms of charge method and charge time. This is, in part, due to the tight charge regime and voltage requirements demanded by these batteries. There is only one way to charge Li-ion/Polymer batteries and the so-called ‘miracle chargers’, which claim to restore and prolong battery life, do not exist for these chemistries. Neither does a superfast charging solution apply.

The pulse charge method for Li-ion has no major advantages and the voltage peaks wreak havoc with the voltage limiting circuits. While charge times can be reduced, some manufacturers suggest that pulse charging may shorten the cycle life of Li-ion batteries. Fast charge methods do not significantly decrease the charge time. A charge rate over 1C should be avoided because such high current can induce lithium plating. With most packs, a charge above 1C is not possible. The protection circuit limits the amount of current the battery can accept. The lithium-based battery has a slow metabolism and must take its time to absorb the energy.

Lead acid chargers serve industrial markets such as hospitals and health care units. Charge times are very long and cannot be shortened. Most lead acid chargers charge the battery in 14 hours. Because of its low energy density, this battery type is not used for small portable devices.