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555 Timer Madness
Blog Lead battery regenerator using 555
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  • Author Author: JWx
  • Date Created: 18 Oct 2022 12:19 PM Date Created
  • Views 27083 views
  • Likes 11 likes
  • Comments 11 comments
  • 555timermadnessch
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Lead battery regenerator using 555

JWx
JWx
18 Oct 2022

When trying to revive degraded lead-acid battery (that were left without charging for too long and entered deep undercharge condition) old wisdom (from the times when buying new car battery was near impossible so people have gone great lengths to restore even worst cases) suggests using charge cycles interrupted by discharging. Using that principle chargers of old were using unfiltered rectified current and some load connected parallel to charged battery - in that config every cycle cell was charged (when input voltage exceeded cell voltage) and discharged into load (when rectified voltage  was below cell's voltage).

Modern chargers are working different way - usually as constant current source with voltage limit.

As I have decided to try to revive some old standby battery (left in unpowered equipment for several years) I have learned limits of this method - battery charged somewhat and then stopped. To my surprise, discharging battery using old lamp as load enabled it to consume more energy during next charging cycle - and this experience have led to creation of this circuit. Schematics is very simple and standard:

schematics

Every minute or so (555 frequency of 13mHz with duty cycle of 95%) generator disconnects battery from charger and discharges it for several seconds through small car lamp. D2 prevents reverse current flow when charger is disconnected.

It seems that after every discharging event charging current increases a bit - maybe (let's hope) because internal resistance of battery lowers?

Described experiment goes on for some time without dramatic improvements but it is only an experiment - "what happens to  otherwise dead battery when treated this way?"

Below some photos of this module connected to DYI (LM317 based) battery charger and proof-of-work movie:

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  • JWx
    JWx over 2 years ago in reply to Sworks72

    Nothing is guaranteed of course, some degradation processes are considered irreversible  - old procedures suggested for example (for batteries that could be opened for inspection) checking crystallization type that happened on plates: when crystals are fine grained there is a chance of dissolving them during charging but when crystals are bigger cell was considered beyond repair...

    Another suggested approach is charging with small current (<< 1/10C) until fully charged in hope of gently dissolving crystalized sulfur.

    My test battery seems to be better than before but still not fully operational (high leakage current and internal resistance) - it may take long time (if ever) to get any results...

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  • Sworks72
    Sworks72 over 2 years ago

    Thanks for the info bro!! I've been trying to learn how to revive a $400 battery I left for too long. You're a champ!!

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  • JWx
    JWx over 2 years ago in reply to dougw

    There is something similar for lead-acid cells - when one cell is shorted (that can be diagnosed as battery behaving as fully charged despite obtaining voltage lower than nominal voltage by number of shorted cells) some people advice using high current to melt - and hopefully destroy - conductive sediments/damaged plate fragments...

    Never tried it - but my (former) car battery recently developed shorted cell (it still provides high current but at 10.5V not 12.6V so it is unusable for car use) - so maybe there is possibility to test it (or leave it as is in some sort of backup power supply, customized for 10.5V cell)

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  • dougw
    dougw over 2 years ago

    I can remember rejuvenating NiCad batteries with high current to burn shorting dendrites in the battery. This is a whole other technique I was not familiar with.

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  • beacon_dave
    beacon_dave over 2 years ago in reply to JWx

    The one-way valve is often just a rubber cap.

    Remove the cap and you can access to the cell just like an older unsealed battery.

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