Total solder points: 150 Difficulty level: beginner 1 2 3 4 5 advanced Intelligent lead acid battery charger K8012 nd sealed a V 2 1 d n for 6V a id batteries Suitable d-ac open lea ILLUSTRATED ASSEMBLY MANUAL H8012IP - 1
Features & Specifications Features: Suitable for 6V and 12V sealed and open lead-acid batteries. Fully automatic charge and maintenance cycle. Status indicators for charge, float and end-of-charge Protected against polarity reversal Specifications: Power Supply: 2 x 9V/25VA Charge current : 0,3 or 1A selectable Dimensions (wxdxh): 97 x 140 x 41mm / 3,8 x 5,5 x 1,6" Not suitabel for non-rechargeable or NiCd/NiMH batteries ! Options: Transformer prim. 230V - sec.
Assembly hints 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.
Assembly hints 1.
Construction 1. Jumper wires 3. Metal film resistors (1%) R... J1 J2 J3 2. Diodes (150mA). Watch the polarity ! CATHODE R1 R2 R3 R4 R6 : : : : : 47K 27K 120K 180K 270K 4. 1/4W resistors R... D...
Construction 6. IC socket. Watch the position of the notch! 8. Transistors T1 T2 T3 T4 T5 T6 : BC547 : BC547 : BC547 : BC547 : BC547 : BC557 C1 : 2µ2 9. Reference diode IC1 : 14P 7. Diodes (3A). Watch the polarity ! CATHODE 11. Electrolytic capacitor. Watch the polarity ! D... 6 : : : : : 1N5400 ... 1N5408 1N5400 ... 1N5408 1N5400 ... 1N5408 1N5400 ... 1N5408 1N5400 ... 1N5408 12. Switches SW1 : ON - ON SW2 : ON - ON SW... VR... VR1 : LM385Z-2.5 10. Screw connectors D4 D5 D6 D7 D8 C...
Construction 14. Power transistor 15. LEDs. Watch the polarity! T1 : MJ3001 or 2N6284G COLOUR=2...5 CATHODE LD1 LD2 LD3 LD4 : RED : RED : YELLOW : GREEN 3mm CATHODE 16. IC. Check the position of the notch ! IC1: LM324 or eq.
Testing 17. 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. -1- Put SW2 in the 12V position. Measure the voltage across the output terminals. Output voltage should be 13.6V +/- 0.2V. Fig. 1.0 -2- Put SW2 in the 6V position. Measure the voltage across the output terminals. Output voltage should be 6.8V +/- 0.2V Fig. 2.
Testing -3- Put SW2 in the 12V position, put SW1 in the >4Ah position. Connect the supplied 33Ω/5Ω resistor to the output terminals. Measure the voltage across the resistor. It should read 14.7V +/- 0.1V Fig. 3.0 -4- Put SW2 in the 6V position, put SW1 in the >4Ah position. Connect the supplied 33Ω/5Ω resistor to the output terminals. Measure the voltage across the resistor. It should read 7.3V +/- 0.1V Fig. 4.
Testing -5- 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. Fig. 5.0 -6- 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 multimeter to the ‘10A DC’ position. It should read 0.3A +/- 0.03A.
Optional enclosure 18. Building into an optional enclosure Figure 7 & 8 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.
Optional enclosure Fig. 8.
Optional enclosure Figure 9.0. provides an internal view of the finished unit. Fig. 9.
Connection & Use 19. Connection & Use Connection: The unit can be connected as shown on figure 10. Fig. 10 Make sure your assembly complies with the local safety regulations. For improved safety, use a non-conductive enclosure.
Connection & use 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.
Operation & troubleshooting 20. Operation & troubleshooting 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.
PCB 21.
Schematic diagram 22. Schematic diagram.
VELLEMAN Components NV Legen Heirweg 33 9890 Gavere Belgium Europe www.velleman.be www.velleman-kit.com Modifications and typographical errors reserved © Velleman Components nv. H8012IP - 2010 - ED1 (rev.