If your battery charger is entering the float stage too early, then there is a good chance that you have a loose connection somewhere between the charger and your battery. When a charger starts up, it tries to push as much current as possible into the battery based on the battery voltage it reads. As battery charges and the voltage rises, the rate of current will slow down due to the resistance building in the battery. Eventually the charger will fill the battery and enter the float stage to keep it maintained.
If there is a loose connection somewhere in the charge circuit, the charger will attempt its normal charge routine but the loose connection will begin to heat up as the current is pushed through it. This build of heat will cause the resistance to increase and the charger will begin the reduce the flow of current as the voltage begins to rise. This will result in the charger mistaking the resistance from the poor connection for a full battery and cause it to go into float before the battery is fully charged.
If you find your charging is going into float too early, double check all of your connections to make sure they are tight. Ensure that all crimped or soldered connections have been properly made as well. A build up of heat is an indicator of a poor connection, so feel any connection points for warmth or use a thermal camera.
For more information on making good quality cable connections, click here.
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