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Transcript
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