Ramsey Electronics Model No. ad BATTERY CONDITIONER/ RAPID CHARGER NiC Dr. NiCad Dr.
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Ramsey Publication No. MDN1 Price $5.00 KIT ASSEMBLY AND INSTRUCTION MANUAL FOR Dr. NiCad NiCad BATTERY CHARGER/CONDITIONER TABLE OF CONTENTS Introduction to the DN1 ................. 4 How it works.................................. 6 Parts list ........................................ 8 Schematic diagram ....................... 9 Parts Layout diagram .................. 11 DN1 Assembly instructions ......... 12 Setup configurations .................... 16 Troubleshooting ...........................
INTRODUCTION With today’s ever changing technologies, more appliances depend on battery power to enable their use. While this gives us greater freedom, it is often at the high cost of purchasing portable energy, or batteries, to run our portable electronic gismos. Consider the cost of energy from our local electric company, about 8¢ for a KW hour, or about 450,000 joules of energy for a penny. On the other hand, that 500 mA-H NiCad that you just purchased for about $1.
oxidation reduction or “redox" chemical reaction in the cell, we effectively decrease the chemically active surface area inside the cell. The lower this surface area, the shorter the battery’s life. Since you don’t try to recharge conventional batteries, you’ve never noticed this property until you started to use rechargeable NiCad batteries.
We designed our kit to change quickly and easily adapt to a variety of cell or battery pack types for anything from video camcorders to cordless phones. You can configure it for the number of batteries in your pack, discharge and charging rate. We’ll discuss this later as we’re assembling these sections of the circuit. DN1 CIRCUIT DESCRIPTION Before we get into the technical jargon, let’s take a walk around the BQ2003 Integrated Circuit .
Since we want the voltage appearing at the IC to be equivalent to one cell, we first must “divide” the cell voltage by the number of cells in the pack. The ladder resistors R2 -R24 form an effective voltage divider circuit so that the BAT (pin 7) voltage will be about 1.25 V per cell. The switch can increase or decrease the BAT voltage by adding or subtracting “rungs” from the voltage divider ladder. Another divider network consists of resistors R14 and R16.
DN1 PARTS LIST RESISTORS 1 2 3 2 4 2 1 1 11 270 ohm [red-violet-brown] (R12) .5 ohm ½ Watt [green-black-silver] (R26, 27) 10 ohm [brown-black-black] (R 2, 10, 22) 470 ohm [yellow-violet-brown] (R3, 7) 1K ohm [brown-black-red] (R1, 5, 9, 25) 10K ohm [brown-black-orange] (R11, 20) 10K ohm 1% [brown-black-black-red] (R16) 17.
DN1 • 9
RAMSEY Learn-As-You-Build KIT ASSEMBLY There are numerous solder connections on the DN1 printed circuit board. Therefore, PLEASE take us seriously when we say that good soldering is essential to the proper operation of your Doctor Nicad! • • • • Use a 25-watt soldering pencil with a clean, sharp tip. Use only rosin-core solder intended for electronics use. Use bright lighting. A magnifying lamp or bench-style magnifier may be helpful. Do your work in stages, taking breaks to check your work.
DN1 PARTS FINDER DIAGRAM DN1 • 11
1. Identify and install DPDT switch S2. Be sure to push the switches flat to the circuit board. Solder all six connections. 2. Install the other DPDT toggle power switch S3. Once again, be sure to push the component flush to the circuit board before soldering. We’ll start our “learn-as-you build” instructions with the power supply section of the circuit. 3. Install the 2.5 mm power connector in the J3 position. 4. Install D6, a 1N4002 type diode.
11. Install R1, 1K ohm [brown-black-red]. 11. Install Q1, the power FET transistor [marked 7035]. Form the leads as shown prior to installation. Bolt the Power FET regulator to the circuit Tab board. 12. Install L1, the large axial leaded wire wound inductor. Solder Connections 13. Install D1, 1N4937 fast recovery diode. Observe the correct polarity! Note also that this is another “stand up” diode, so form the leads as before for a proper fit. 14. Identify Q2, a 2N3904 NPN transistor.
23. Select two of the 1uF electrolytic capacitors and solder the ground leads together.Install them as C3. Bend the ground leads away from U1. 24. Install C1, the remaining 1uF capacitor. The positive side should be facing R5. 25. Install the Benchmark BQ2003 IC. Notice that one end of the chip is marked with a dot, notch, or band. Be sure to orient this end as shown in the parts diagram. Pin 1 is located directly below the notch when the IC is positioned so that the notch is to the left.
present, giving us an accurate representation of one cell contained in the pack. 33. Install R21, 47K ohm [yellow-violet-orange]. 34. Install DIP switch S1 (D)ual (I)nline (P)ackage. Make sure that the switchable contacts face toward the outside of the circuit board, allowing for easy changing of number of cells to charge. 35. Install 47K ohm resistors R19, R18, R17, R15, R13, R8, R6, and R4 [yellow-violet-orange].
CONGRATULATIONS You have just completed your DN1 NiCad battery conditioner unit. Take a well deserved break now. Give your eyes a rest. When you return, be sure to check over your work on the entire circuit board. Energizing the circuit board with solder “bridges” or misplaced components can damage your kit. Don’t throw away all your scrap component leads just yet, however, you’ll still need a couple to set up your kit for its final operation.
Fill in the chart with the ratings imprinted on your batteries. This should help you to determine the proper jumper settings Battery Type Number of Cells Charge Capacity (A• Hr) Charge Current (mA) Time Out Setting (Min.) DN1 FINAL ASSEMBLY INSTRUCTIONS Use scrap resistor leads to form the proper “jumper” wires to configure your conditioner.
SETTING UP THE SWITCHES You’ll need to configure the row of DIP switches for your battery pack now. Since the minimum number of cells is at least one, the conditioner is already set up for a single battery to begin with. Switch No. 10 is reserved for the discharging current setup. When it is closed the Doctor is in low current discharge mode, or about 140 mA drain from your batteries. When Switch No. 10 is opened the discharging current is increased to 280 mA, or the high current discharge.
Charger Status Status LED “ON” time Status LED “OFF” time No Battery No Light No Light Battery Connected Awaiting Command 1/8 sec. 1/8 sec. Discharging 1 3/8 sec 1/8 sec. Continuous N/A Charge Complete 1/8 sec. 1/8 sec.` Topping Off 1/8 sec. 1/8 sec. Fast Charging indicator. By changing the ON / OFF times this LED becomes a charging status indicator! Use the following chart for an indication of what the doctor is telling you. POWER SUPPLY CONSIDERATIONS The power supply used for the Dr.
begin the Fast Charging mode. The Benchmark IC will constantly monitor the pack and turn off the fast charge when the cells are charged just to full capacity. Once this is accomplished, it will periodically “top off” the cells with a high current burst, and allow a slight trickle charge to flow. Unfortunately, about the only thing to do for this initial check out is to watch the lights blink - but it is also a good time to “measure” the capacity of your cell.
handled by the doctor, but if you have several packs, be sure to rotate them (or maybe buy a few more Dr. NiCad Chargers). BATTERY REPAIR ??!! Many times we have older batteries or packs that don’t seem to hold a charge at all, but they were so expensive that we couldn’t bear to toss them in the trash. Well, your frugality (some people call it being cheap) has finally paid off! Most of these extreme memory conditions can be “cycled” right out of the pack. Simply configure your Dr.
Use a methodical, logical troubleshooting technique. Most problems can be solved using common sense. A volt-ohm meter and a clear head are usually all that are needed to correct any problem. Please understand that it is nearly impossible to “troubleshoot” by phone; any specific questions should be documented and sent to us by mail. The Benchmarq IC has been double checked to its ensure reliability and probably isn’t the problem if your kit doesn’t run. COMMON QUESTIONS Q.
The Ramsey Kit Warranty Please read carefully BEFORE calling or writing in about your kit. Most problems can be solved without contacting the factory. Notice that this is not a "fine print" warranty. We want you to understand your rights and ours too! All Ramsey kits will work if assembled properly. The very fact that your kit includes this new manual is your assurance that a team of knowledgeable people have field-tested several "copies" of this kit straight from the Ramsey Inventory.
DN1 Dr. NiCad BATTERY CONDITIONER Quick Reference Page Guide Introduction to the DN1 ........................ 4 How it works......................................... 6 Parts list ............................................... 8 Schematic diagram .............................. 9 Parts Layout diagram ......................... 11 DN1 Assembly instructions ................ 12 Set-up configurations .......................... 16 Troubleshooting .................................. 21 Ramsey kit warranty ..........
