INTELLIGENT LEAD ACID BATTERY CHARGER
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- Marshall Norris
- 7 years ago
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1 Total solder points: 150 Skill level : Beginner Advanced INTELLIGENT LEAD ID BATTERY CHARGER Features: Suitable for 6V and 12V sealed and open leadacid batteries Fully automatic charge and maintenance cycle Status indicators for charge, float and endofcharge Protected against polarity reversal Simply connect and forget Specifications : Charge current : 0.3 or 1A selectable Power supply : 2x9V/25VA (our type MST) Dimensions (wxdxh): 97 x 140 x40mm / 3.8 x 5.5 x1.6 Not suitable for nonrechargeable or NiCd/NiMH batteries modifications reserved Options : Transformer prim. 230V sec. 2x9V/25VA: MST Enclosure: TKAUS22G Power cord: NETSNOER ILLUSTRATED MANUAL H8012PED1
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3 1. Assembly (Skipping this can lead to troubles! ) Ok, so we have your attention. These hints will help you to make this project successful. Read them carefully. 1.1 Make sure you have the right tools: A good quality soldering iron (25 40W) with a small tip. Wipe it often on a wet sponge or cloth, to keep it clean; then apply solder to the tip, to give it a wet look. This is called thinning and will protect the tip, and enables you to make good connections. When solder rolls off the tip, it needs cleaning. Thin raisincore solder. Do not use any flux or grease. A diagonal cutter to trim excess wires. To avoid injury when cutting excess leads, hold the lead so they cannot fly towards the eyes. Needle nose pliers, for bending leads, or to hold components in place. Small blade and phillips screwdrivers. A basic range is fine. For some projects, a basic multimeter is required, or might be handy Assembly Hints : Make sure the skill level matches your experience, to avoid disappointments. Follow the instructions carefully. Read and understand the entire step before you perform each operation. Perform the assembly in the correct order as stated in this manual Position all parts on the PCB (Printed Circuit Board) as shown on the drawings. Values on the circuit diagram are subject to changes. Values in this assembly guide are correct* Use the checkboxes to mark your progress. Please read the included information on safety and customer service * Typographical inaccuracies excluded. Always look for possible last minute manual updates, indicated as NOTE on a separate leaflet. 3
4 1.3 Soldering Hints : Mount the component against the PCB surface and carefully solder the leads Make sure the solder joints are coneshaped and shiny Trim excess leads as close as possible to the solder joint 4
5 AXIAL COMPONENTS ARE TAPED IN THE CORRECT MOUNTING SEQUENCE! START REMOVE THEM FROM THE TAPE ONE AT A TIME! 1. JUMPER WIRES J1 J2 J3 2. ¼W RESISTORS R2: 27K ( ) R3: 120K ( ) R4: 180K ( ) R5: 10K (1 0 3 B) R6: 270K ( ) R7: 10K (1 0 3 B) R8: 1K5 (1 5 2 B) R9: 1K (1 0 2 B) R10: 10K (1 0 3 B) R11: 4K7 (4 7 2 B) R12: 1K (1 0 2 B) R13: 10K (1 0 3 B) R14: 10K (1 0 3 B) R15: 33K (3 3 3 B) R16: 10K (1 0 3 B) R17: 1M (1 0 5 B) R18: 680 (6 8 1 B) R19: 15K (1 5 3 B) R20: 10K (1 0 3 B) R21: 10K (1 0 3 B) R22: 220K (2 2 4 B) R23: 2K2 (2 2 2 B) R24: 2K2 (2 2 2 B) R25: 12K (1 2 3 B) R26: 1M (1 0 5 B) R27: 1K (1 0 2 B) R28: 2K2 (2 2 2 B) 3. ½W RESISTORS R... R1: 47K ( ) R29: 1.5 (1 5 B B 9) R30: 1.8 (1 8 B B 9) R31: 2.2 (2 2 B B 9) 5
6 4. DIODES (Watch the polarity!) 6. TRANSISTORS CATHODE D... D1: 1N4148 D2: 1N4148 D3: 1N4148 D4: 1N5400 1N5408 D5: 1N5400 1N5408 D6: 1N5400 1N5408 D7: 1N5400 1N5408 D8: 1N5400 1N5408 T1: BC547 T2: BC547 T3: BC547 T4: BC547 T5: BC547 T6: BC VOLTAGE REFERENCE 5. IC SOCKET (Watch the position of the notch!) VR... IC1 : 14P VR1: LM385Z TERMINAL BLOCKS SK1: 2P SK2: 2P 6
7 9. SWITCHES 12. LEDS (Watch the polarity!) SW... COLOUR=2...5 SW1: SINGLE POLE (ONON) SW2: SINGLE POLE (ONON) 10. ELECTROLYTIC CAPI TORS (Watch the polarity!) CATHODE CATHODE LD... C... C1: 2µ2 C2: 4700µ/35V 11. POWER TRANSISTOR M4 NUT LOCK WASHER LD1: 3mm LED RED (2) LD2: 3mm LED RED (2) LD3: 3mm LED YELLOW (4) LD4: 3mm LED GREEN (5) 13. IC (Watch the position of the notch!) TRANSISTOR HEATSINK IC1: LM324, LM224 PCB M4 BOLT T7: MJ3001, MJ4035, BDX87, 2N6057, 2N6058, 2N6059, 2N6283, 2N6284 or EQ. 7
8 14. CONNECTION, TESTING AND USE Connection : The unit can be connected as shown on drawing 15. Make sure your assembly complies with the local safety regulations. For improved safety, use a nonconductive enclosure. Enclosure : Drawing 17 provides a drill pattern for our optional enclosure (ref. TKAUS22G). The included adhesive front panel label can be used to mark the position of the holes to be drilled. Position the label on the front panel and fix it temporary with tape. Mark the center of the holes with a center punch. Remove the label and drill the holes. Pay attention to the correct diameter. Make sure all holes are free of burrs. Degrease the front panel before sticking the label onto it. The label edges will need to be trimmed with a sharp cutter. Drawing 16 provides an internal view of the finished unit. Whatever enclosure you use, make sure it is well ventilated, as the heatsink might run hot during charging. Testing : Perform all tests as shown below, before the first use of the unit. It allows you to check every function of your charger kit. Use the supplied 5W dummy load resistors and a reliable multimeter. 13.6V= Vdc L ON POWER CU N 12V Put SW2 in the 12V position. Measure the voltage across the output terminals. Output voltage should be 13.6V / 0.2V. 6.8V= Vdc L ON POWER CU N 6V 8
9 Put SW2 in the 6V position. Measure the voltage across the output terminals. Output voltage should be 6.8V / 0.2V 14.7V= Vdc L ON POWER CU 33 Ω N >4Ah 12V Put SW2 in the 12V position, put SW1 in the >4Ah position. Connect the supplied 33Ω/5W resistor to the output terminals. Measure the voltage across the resistor. It should read 14.7V / 0.2V Vdc 7.3V= L ON POWER CU Ω 33 N >4Ah 6V Put SW2 in the 6V position, put SW1 in the >4Ah position. Connect the supplied 33Ω/5W resistor to the output terminals. Measure the voltage across the resistor. It should read 7.3V / 0.2V Adc 1A= 10A L ON 8.2 Ω POWER CU N >4Ah 12V Put SW2 in the 12V position, put SW1 in the >4Ah position. Connect the supplied 8.2Ω resistor in series with the multimeter. Switch the multimeter to the 10A DC position. It should read 1A / 0.1A. 9
10 Adc 0.3A= 10A L ON 8.2 Ω POWER CU N <4Ah 12V Put SW2 in the 12V position, put SW1 in the <4Ah position. Connect the supplied 8.2Ω resistor in series with the multimeter. Switch the multimeter to the 10A DC position. It should read 0.3A / 0.03A. If any of the measurements show a considerable difference with the reference values, please recheck the entire assembly, and pay special attention to resistor values. Use : Perform the necessary settings before you hookup the battery to the unit : Select the appropriate charge current and voltage according to the capacity of the battery. Batteries < 4Ah : 0.3A charge current Batteries > 4Ah : 1A charge current You can easily estimate the charging time with the following formula : Approx. charging time (hours) = (battery capacity (Ah) / charging current (A)) x 1.2 Pay attention to the polarity when you hookup a battery to the charger. Switch on the unit, to start the charging cycle. Batteries should be charged in a well ventilated area, because of the possible emission of gases. Do not cover the unit during charging, as it might result in overheating or even fire. 10
11 Operation : When a discharged battery is connected to the unit, it starts charging it with the maximum current (0.3A for batteries <4Ah, 1A for batteries >4Ah), until the battery voltage reaches 14.7V (7.35V for a 6V battery). Once this voltage is established, the charger adjusts the charge current, in order to keep this voltage steady. At the end of the charging cycle, when the charge current has dropped significantly, the output voltage is dropped to 13.6V (6.85V for a 6V battery). This allows the battery to remain hookedup to the charger without any risk for an indefinite time. Should the battery discharge, then the charge cycle will restart automatically. Troubleshooting : If you have successfully completed the above tests, there is not much that can go wrong. If the unit never leaves the charge cycle, this could point to either a defective battery, a too low charge current setting, or a battery with a too large capacity. 15. CONNECTION DIAGRAM L Fuse 0.25A Slow ON/OFF R1823A/B 9V POWER CU 9V N 25VA TRANSFORMER CU 11
12 16. ASSEMBLING RED BLK SOLDER 30mm M3 BOLT M3 NUT PCB 20mm SPER BOTTOM STRAIN RELIEF BUSHING INLET M3 LOCK WASHER M3 NUT 10mm M3 BOLT TRANSFORMER 2x9V/25VA VELLEMAN P8012'1 LEADID BATTERY CHARGER 10mm M3 BOLT M3 NUT M3 WASHER e T7 b c BOTTOM c R25 R3 R9 SK1 R8 D5 D7 D6 D4 C2 VR1 D1 R12 R13 R14 R29 R30 R31 T3 T4 R11 1 R15 R22 R23 R24 IC1 R19 R26 R27 R6 R7 SW1 SW2 J1 C1 D2 D3 R2 R1 R5 R4 T1 T2 WRONG POLARITY R17 R18 R28 T5 R21 SK2 R10 D8 T6 LD1 LD2 LD3 LD4 CHARGE STANDBY CHARGE 6/12V CU BATTERY CAPITY SELECT </>4Ah VOLTAGE SELECT R16 J2 R20 J3 END OF CHARGE ON/OFF SWITCH 12
13 Ø3 Ø3 Ø3 Ø3 17. DRILL PATTERN ENCLOSURE TKAUS22G 38 CUT 133,5 24, BOTTOM 12,5 REAR PANEL 20 36,5 20 Ø ,5 24,5 FRONT PANEL 20 17,5 17, ,5 Ø12 Ø6,5 Ø6, ,5 21,5 All distances are expressed in mm 13
14 18. PCB LAYOUT VELLEMAN P8012'1 LEAD ID BATTERY CHARGER e c T7 b c SK1 R29 R30 R31 D5 D4 BATTERY CAPITY SELECT </>4Ah SW1 D7 D6 R1 R2 R3 VOLTAGE SELECT J1 6/12V C2 SW2 R8 VR1 R4 R5 R6 R9 R7 D1 R12 R13 R14 T3 T1 T2 WRONG POLARITY C1 T4 R10 R11 D2 D3 R15 R16 R17 R18 J2 1 R22 R23 R24 IC1 T5 R25 R21 R20 R19 R26 R27 R28 T6 CU SK2 LD1 LD2 LD3 LD4 CHARGE FLOAT CHARGE J3 D8 END OF CHARGE 14
15 19. DIAGRAM I<0.007C END OF CHARGE R M 1/4 LM324 A R R28 2K2 LED3G LD4 END OF CHARGE R15 33K 50mV OPEN: < 4Ah (Imax=0.3A) CLOSE: > 4Ah (Imax=1A) SW1 R31 2.2/0.6W R30 1.8/0.6W R29 1.5/0.6W LEADID BATTERY E1 6/12V R20 10K R16 10K R21 0.7V 10K R27 1K R22 220K R25 12K R19 15K LED3Y LD3 R23 2K2 CURRENT LIMIT (0.1C) 8 A3 1/4 LM R26 T5 BC547B LED3R LD2 R24 2K2 7 1M A2 1/4 LM mV I<0.02C Vo Vo CHARGE T7 1N5400 D8 C1 R10 R1 R3 2u2 10K 47K 120K R9 1K T4 BC547B SW2 6V FLOAT CHARGE D1 1N4148 T3 BC547B R12 1K 1N4148 D2 LD1 LED3R R13 10K 1N4148 D3 R2 27K 12V T1 BC547B R4 180K T2 R6 270K R7 10K BC547B R5 10K R14 10K T6 BC557B WRONG POLARITY MJ3001 R8 1K A1 1 1/4 LM324 A1...A4 = IC1 R11 4K7 VOLTAGE REGULATOR VR1 LM D6 1N5400 D7 1N5400 C2 4700u/35V 1N5400 D4 D5 1N V/1.3A 15
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