Download intelligent lead acid battery charger

Total solder points: 150
Skill level :
Beginner 1o 2o 3þ 4o 5o Advanced
INTELLIGENT LEAD ACID BATTERY CHARGER
K8012
Features:
þ Suitable for 6V and 12V sealed and open lead-acid batteries
þ Fully automatic charge and maintenance cycle
þ Status indicators for charge, float and end-of-charge
þ Protected against polarity reversal
þ Simply connect and forget
Specifications :
þ Charge current : 0.3 or 1A selectable
þ Power supply : 2x9V/25VA (our type 2090250MST)
þ Dimensions (wxdxh): 97 x 140 x40mm / 3.8”x 5.5”x1.6”
þ Not suitable for non-rechargeable or NiCd/NiMH batteries
modifications reserved
Options :
þ Transformer prim. 230V - sec. 2x9V/25VA: 2090250MST
þ Enclosure: TKAUS22G
þ Power cord: NETSNOER
ILLUSTRATED MANUAL
H8012P-ED1
5%
1%
4K7= ( 4 - 7 - 2 - B )
I
P
C CODICE CODIGO
DE
O COLORE
D
CORES
E
0
1
2
3
4
5
6
7
8
9
A
B
Nero
Marrone
Rosso
Aranciato
Giallo
Verde
Blu
Viola
Grigio
Bianco
Argento
Oro
Preto
Castanho
Encarnado
Laranja
Amarelo
Verde
Azul
Violeta
Cinzento
Branco
Prateado
Dourado
COLOR= 2… 5
4K7= ( 4 - 7 - 0 - 1 - 1 )
E
CODIGO
DE COLORES
Negro
Marrón
Rojo
Naranjado
Amarillo
Verde
Azul
Morado
Gris
Blanco
Plata
Oro
SF
VÄRI
KOODI
Musta
Ruskea
Punainen
Oranssi
Keltainen
Vihreä
Sininen
Purppura
Harmaa
Valkoinen
Hopea
Kulta
S
DK
N
FÄRG FARVE FARGE
SCHEMA KODE KODE
Svart
Brun
Röd
Orange
Gul
Grön
Blå
Lila
Grå
Vit
Silver
Guld
Sort
Brun
Rød
Orange
Gul
Grøn
Blå
Violet
Grå
Hvid
Sølv
Guld
Sort
Brun
Rød
Orange
Gul
Grønn
Blå
Violet
Grå
Hvidt
Sølv
Guldl
D
FARB
KODE
Schwarz
Braun
Rot
Orange
Gelb
Grün
Blau
Violet
Grau
Weiss
Silber
Gold
GB
F
COLOUR CODIFI-
CODE
CATION
DES
COULEURS
Black
Brown
Red
Orange
Yellow
Green
Blue
Purple
Grey
White
Silver
Gold
Noir
Brun
Rouge
Orange
Jaune
Vert
Blue
Violet
Gris
Blanc
Argent
Or
NL
KLEUR
KODE
C
O
D
E
Zwart
Bruin
Rood
Oranje
Geel
Groen
Blauw
Paars
Grijs
Wit
Zilver
Goud
0
1
2
3
4
5
6
7
8
9
A
B
__________________________________________________________________________________________________________________________________________________________
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 (2540W) 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 raisin-core solder.
any flux or grease.
Do not use
• 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 multi-meter is required, or might be handy
0.0
00
1.2 Assembly Hints :
þ Make sure the skill level matches your experience, to avoid disappointments.
þ Follow the instructions carefully. Read and understand the entire step before
you perform each operation.
þ Perform the assembly in the correct order as stated in this manual
þ Position all parts on the PCB (Printed Circuit Board) as shown on the drawings.
þ Values on the circuit diagram are subject to changes.
þ Values in this assembly guide are correct*
þ Use the check-boxes to mark your progress.
þ 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
_______________________________________________________________________________________________________________________________________________________
1.3 Soldering Hints :
Mount the component Make sure the solder Trim excess leads as
against the PCB surface joints are cone-shaped close as possible to the
and carefully solder the and shiny
solder joint
leads
4
__________________________________________________________________________________________________________________________________________________________
AXIAL COMPONENTS ARE
TAPED IN THE CORRECT
MOUNTING SEQUENCE !
START
REMOVE THEM FROM THE TAPE
ONE AT A TIME !
1. JUMPER WIRES
q
q
q
J1
J2
J3
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
R2: 27K (2 - 7 - 0 - 2 - 1)
R3: 120K (1 - 2 - 0 - 3 - 1)
R4: 180K (1 - 8 - 0 - 3 - 1)
R5: 10K (1 - 0 - 3 - B)
R6: 270K (2 - 7 - 0 - 3 - 1)
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
2. ¼W RESISTORS
R...
q R1: 47K (4 - 7 - 0 - 2 - 1)
q R29: 1.5 (1 - 5 - B - B - 9)
q R30: 1.8 (1 - 8 - B - B - 9)
q R31: 2.2 (2 - 2 - B - B - 9)
5
_______________________________________________________________________________________________________________________________________________________
4. DIODES (Watch the polarity!)
CATHODE
q
q
q
q
q
q
q
q
6. TRANSISTORS
D...
D1: 1N4148
D2: 1N4148
D3: 1N4148
D4: 1N5400 …1N5408
D5: 1N5400 …1N5408
D6: 1N5400 …1N5408
D7: 1N5400 …1N5408
D8: 1N5400 …1N5408
q
q
q
q
q
q
T1: BC547
T2: BC547
T3: BC547
T4: BC547
T5: BC547
T6: BC557
7. VOLTAGE REFERENCE
5. IC SOCKET (Watch the position of the notch !)
VR...
q IC1 : 14P
q VR1: LM385Z2.5
8. TERMINAL BLOCKS
q SK1: 2P
q SK2: 2P
6
__________________________________________________________________________________________________________________________________________________________
9. SWITCHES
12. LEDS (Watch the polarity!)
SW...
COLOUR=2...5
q SW1: SINGLE POLE (ON-ON)
q SW2: SINGLE POLE (ON-ON)
CATHODE
10. ELECTROLYTIC CAPACITORS (Watch the polarity!)
CATHODE
LD...
C...
q
q
q
q
q C1: 2µ2
q 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
q IC1: LM324, LM224
PCB
M4 BOLT
q T7: MJ3001, MJ4035, BDX87,
2N6057, 2N6058, 2N6059,
2N6283, 2N6284 or EQ.
7
_______________________________________________________________________________________________________________________________________________________
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 non-conductive 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 multi-meter.
13.6V=
K8012
Vdc
ON
L
AC
+
ACCU
AC POWER
N
AC
-
12V
Put SW2 in the 12V position. Measure the voltage across the output terminals. Output voltage should be 13.6V +/- 0.2V.
6.8V=
K8012
Vdc
ON
L
AC
+
ACCU
AC POWER
N
AC
-
6V
8
__________________________________________________________________________________________________________________________________________________________
Put SW2 in the 6V position. Measure the voltage across the output terminals. Output voltage should be 6.8V +/- 0.2V
14.7V=
K8012
Vdc
ON
AC
+
AC POWER
33 Ω
L
ACCU
N
AC
-
>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
7.3V=
K8012
Vdc
ON
AC
+
ACCU
AC POWER
N
AC
33
Ω
L
-
>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
1A=
K8012
Adc
10A
ON
L
AC
AC POWER
N
+
8.2 Ω
ACCU
AC
-
>4Ah 12V
Put SW2 in the 12V position, put SW1 in the >4Ah position. Connect the
supplied 8.2Ω resistor in series with the multi-meter. Switch the multi-meter
to the ‘10A DC’ -position. It should read 1A +/- 0.1A.
9
_______________________________________________________________________________________________________________________________________________________
0.3A=
K8012
Adc
10A
ON
L
AC
AC POWER
N
+
8.2 Ω
ACCU
AC
-
<4Ah 12V
Put SW2 in the 12V position, put SW1 in the <4Ah position. Connect the
supplied 8.2Ω resistor in series with the multi-meter. Switch the multi-meter
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 hook-up 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 hook-up 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
__________________________________________________________________________________________________________________________________________________________
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 hooked-up 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
K8012
Fuse
L
0.25A Slow
ON/OFF
AC
R1823A/B
+
9V
ACCU
AC POWER
9V
N
25VA TRANSFORMER
AC
-
-
+
ACCU
11
ON/OFF SWITCH
BOTTOM
10mm M3 BOLT
M3 NUT
M3 WASHER
2x9V/25VA
TRANSFORMER
SK1
</>4Ah SW1
BATTERY
CAPACITY
SELECT
R29
R30
R31
D4
D5
AC
D6
D7
J1
VOLTAGE
SELECT
SW2
C2
e
R8
VR1
c
T7
R11
T4
C1
b
c
R9
WRONG
POLARITY
T1 T2
T3
R19
LD3
R28
J3
LD4
END OF CHARGE
T6
R21
R20
R26
R27
STANDBY
CHARGE
LD2
T5
R18
IC1
R22
R23
R24
CHARGE
LD1
1
J2
R15
R16
R17
VELLEMAN P8012'1 LEAD-ACID BATTERY CHARGER
M3 LOCK WASHER
M3 NUT
10mm M3 BOLT
R1
R2
R3
6/12V
R10
R4
R5
R6
R7
D1
R12
R13
R14
D2
D3
D8
+
AC INLET
R25
ACCU
SK2
12
-
STRAIN RELIEF BUSHING
BOTTOM
20mm SPACER
M3 NUT
PCB
30mm M3 BOLT
SOLDER
BLACK
RED
_______________________________________________________________________________________________________________________________________________________
16. ASSEMBLING
__________________________________________________________________________________________________________________________________________________________
38
17. DRILL PATTERN ENCLOSURE ‘TKAUS22G’
,5
Ø3
Ø3
,5
Ø3
,5
,5
Ø3
CUT
,5
Ø3
133,5
13
73
24,5
,5
Ø3
12,5
90
BOTTOM
20
9
Ø
3,5
,5
Ø3
REAR PANEL
36,5
20
1
Ø1
32
5
3,
Ø
33
,5
Ø3
17
27,5
FRONT PANEL
17,5
17,5
6,5
Ø
,5
Ø6
11
10
10
Ø3
Ø3
Ø3
25,5
Ø3
21,5
27,5
33
Ø1
2
20
24,5
All distances are expressed in mm
13
_______________________________________________________________________________________________________________________________________________________
18. PCB LAYOUT
VELLEMAN P8012'1 LEAD ACID BATTERY CHARGER
c
e
T7
b
D8
R19
J2
VR1
R11
R26
R27
-
IC1
D1
R12
R13
R14
R22
R25
R4
R5
R6
R7
R1
R2
R3
1
T3
</>4Ah SW1
J1
6/12V
D2
D3
VOLTAGE
SELECT
SW2
T1 T2
WRONG
POLARITY
R28
C2
R29
R30
R31
14
R18
T4
R23
R24
LD1
CHARGE
LD2
+
D4
R20
ACCU
D5
R10
R9
D6
R21
SK2
AC
BATTERY
CAPACITY
SELECT
R15
R16
R17
C1
D7
R8
SK1
c
T6
J3
T5
END OF CHARGE
LD3
FLOAT
CHARGE
LD4
AC
18V/1.3A
1N5400
D5
D4
1N5400
4700u/35V
C2
1N5400
D7
D6
1N5400
A1
3
1
1/4 LM324
A1...A4 = IC1
4
2
4K7
R11
LM385-2.5
VR1
VOLTAGE REGULATOR
1K5
R8
MJ3001
T3
LED3R
LD1
D3
1N4148
WRONG POLARITY
BC547B
D2
1N4148
1K
R12
BC547B
T1
27K
10K
6V
R2 12V
SW2
R13
10K
2u2
BC547B
R10
T4
D8
1N5400
C1
1N4148
D1
1K
R9
T7
T2
180K
R4
47K
R1
10K
R5
10K
BC547B
R7
270K
R6
LED3Y
T6
BC557B
10K
R14
2K2
R24
A3
A2
6
5
9
I<0.02C
Vo→ 7.35 → 6.85
Vo→14.7 →13.6
130mV
1/4 LM324
7
1M
R26
1/4 LM324
8
10
CURRENT LIMIT (0.1C)
CHARGE
LD2
LED3R
BC547B
T5
2K2
R23
FLOAT
CHARGE LD3
120K
R3
12K
R25
220K
R22
1K
R27
0.7V
6/12V
E1
15K
R19
10K
R21
10K
R16
10K
R20
-
LEAD-ACID BATTERY
+
AC
2.2/0.6W
R31
SW1
1.8/0.6W
R30
1.5/0.6W
R29
OPEN: < 4Ah (Imax=0.3A)
CLOSE: > 4Ah (Imax=1A)
50mV
33K
R15
14
LD4
LED3G
2K2
R28
END OF CHARGE
680
11
A4
R18
13
12
1M
1/4 LM324
R17
I<0.007C
END OF
CHARGE
__________________________________________________________________________________________________________________________________________________________
19. DIAGRAM
15