Total solder points: 150 Skill level : Beginner 1o 2o 3þ 4o 5o Advanced
ILLUSTRATED MANUAL H8012P-ED1
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
5%
4K7= ( 4 - 7 - 2 - B )
1%
4K7= ( 4 - 7 - 0 - 1 - 1 )
COLOR= 2… 5
I P E SF S DK N D GB F NL CODE
CODICE COLORE
CODIGO DE
CORES
CODIGO DE COL-
ORES
VÄRI KOODI
FÄRG SCHEMA
FARVEKODE
FARGEKODE
FARB KODE
COLOUR CODE
CODIFI-CATION DES COU-LEURS
KLEURKODE
CODE
0 Nero Preto Negro Musta Svart Sort Sort Schwarz Black Noir Zwart 0 1 Marrone Castanho Marrón Ruskea Brun Brun Brun Braun Brown Brun Bruin 1 2 Rosso Encarnado Rojo Punainen Röd Rød Rød Rot Red Rouge Rood 2 3 Aranciato Laranja Naranjado Oranssi Orange Orange Orange Orange Orange Orange Oranje 3 4 Giallo Amarelo Amarillo Keltainen Gul Gul Gul Gelb Yellow Jaune Geel 4 5 Verde Verde Verde Vihreä Grön Grøn Grønn Grün Green Vert Groen 5 6 Blu Azul Azul Sininen Blå Blå Blå Blau Blue Blue Blauw 6 7 Viola Violeta Morado Purppura Lila Violet Violet Violet Purple Violet Paars 7 8 Grigio Cinzento Gris Harmaa Grå Grå Grå Grau Grey Gris Grijs 8 9 Bianco Branco Blanco Valkoinen Vit Hvid Hvidt Weiss White Blanc Wit 9 A Argento Prateado Plata Hopea Silver Sølv Sølv Silber Silver Argent Zilver A B Oro Dourado Oro Kulta Guld Guld Guldl Gold Gold Or Goud B
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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 suc-cessful. 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 en-ables you to make good connections. When solder rolls off the tip, it needs cleaning.
• Thin raisin-core 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 can-not 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 re-
quired, or might be handy 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.
0.000
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4
1.3 Soldering Hints :
Mount the component against the PCB surface and carefully solder the leads
Make sure the solder joints are cone-shaped and shiny
Trim excess leads as close as possible to the solder joint
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5
AXIAL COMPONENTS ARE TAPED IN THE CORRECT MOUNTING SEQUENCE !
START
REMOVE THEM FROM THE TAPE
ONE AT A TIME !
1. JUMPER WIRES
q J1 q J2 q J3
2. ¼W RESISTORS
R...
q R1: 47K (4 - 7 - 0 - 2 - 1)
q R2: 27K (2 - 7 - 0 - 2 - 1) q R3: 120K (1 - 2 - 0 - 3 - 1) q R4: 180K (1 - 8 - 0 - 3 - 1) q R5: 10K (1 - 0 - 3 - B) q R6: 270K (2 - 7 - 0 - 3 - 1) q R7: 10K (1 - 0 - 3 - B) q R8: 1K5 (1 - 5 - 2 - B) q R9: 1K (1 - 0 - 2 - B) q R10: 10K (1 - 0 - 3 - B) q R11: 4K7 (4 - 7 - 2 - B) q R12: 1K (1 - 0 - 2 - B) q R13: 10K (1 - 0 - 3 - B) q R14: 10K (1 - 0 - 3 - B) q R15: 33K (3 - 3 - 3 - B) q R16: 10K (1 - 0 - 3 - B) q R17: 1M (1 - 0 - 5 - B) q R18: 680 (6 - 8 - 1 - B) q R19: 15K (1 - 5 - 3 - B) q R20: 10K (1 - 0 - 3 - B) q R21: 10K (1 - 0 - 3 - B) q R22: 220K (2 - 2 - 4 - B) q R23: 2K2 (2 - 2 - 2 - B) q R24: 2K2 (2 - 2 - 2 - B) q R25: 12K (1 - 2 - 3 - B) q R26: 1M (1 - 0 - 5 - B) q R27: 1K (1 - 0 - 2 - B) q R28: 2K2 (2 - 2 - 2 - B)
3. ½W RESISTORS
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)
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6
4. DIODES (Watch the polarity!)
D...CATHODE
q D1: 1N4148 q D2: 1N4148 q D3: 1N4148 q D4: 1N5400 …1N5408 q D5: 1N5400 …1N5408 q D6: 1N5400 …1N5408 q D7: 1N5400 …1N5408 q D8: 1N5400 …1N5408
5. IC SOCKET (Watch the posi-tion of the notch !)
q IC1 : 14P
6. TRANSISTORS
q T1: BC547 q T2: BC547 q T3: BC547 q T4: BC547 q T5: BC547 q T6: BC557
7. VOLTAGE REFERENCE
VR...
q VR1: LM385Z2.5
8. TERMINAL BLOCKS
q SK1: 2P q SK2: 2P
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7
9. SWITCHES
SW...
q SW1: SINGLE POLE (ON-ON) q SW2: SINGLE POLE (ON-ON)
10. ELECTROLYTIC CAPACI-TORS (Watch the polarity!)
C...
q C1: 2µ2 q C2: 4700µ/35V
11. POWER TRANSISTOR
M4 NUT
M4 BOLT
LOCK WASHER
TRANSISTOR
HEATSINK
PCB
q T7: MJ3001, MJ4035, BDX87,
2N6057, 2N6058, 2N6059, 2N6283, 2N6284 or EQ.
12. LEDS (Watch the polarity!)
COLOUR=2...5
LD...
CATHODECATHODE
q LD1: 3mm LED RED (2) q LD2: 3mm LED RED (2) q LD3: 3mm LED YELLOW (4) q LD4: 3mm LED GREEN (5)
13. IC (Watch the position of the notch!)
q IC1: LM324, LM224
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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 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 di-ameter. Make sure all holes are free of burrs. Degrease the front panel be-fore 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.
N -AC
12V
ONL
AC POWER
AC
VdcK8012
ACCU
+
13.6V=
Put SW2 in the 12V position. Measure the voltage across the output termi-nals. Output voltage should be 13.6V +/- 0.2V.
N -AC
6V
ONL
AC POWER
AC
VdcK8012
ACCU
+
6.8V=
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9
Put SW2 in the 6V position. Measure the voltage across the output termi-nals. Output voltage should be 6.8V +/- 0.2V
N -AC
ONL
AC POWER
AC
VdcK8012
ACCU
+
14.7V=
12V>4Ah
33Ω
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
N -AC
ONL
AC POWER
AC
VdcK8012
ACCU
+
7.3V=
6V>4Ah
Ω33
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
N -AC
ONL
AC POWER
AC
AdcK8012
ACCU
+
1A=
10A
12V>4Ah
Ω8.2
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.
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10
L
N
AC POWER
AC
AC
+
-
ACCU
K8012
ON
0.3A=Adc
10A
Ω8.2
<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 refer-ence 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.
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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 volt-age 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 cur-rent 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 defec-tive battery, a too low charge current setting, or a battery with a too large capacity.
15. CONNECTION DIAGRAM
R1823A/B
ON/OFF
0.25A Slow
FuseL
N
AC POWER
9V
9V
AC
AC
+
-
ACCU
ACCU
- +
K8012
25VA TRANSFORMER
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12
16. ASSEMBLING
R25
AC
R8
b
e c
c
SK1
R3
VR
1
T3R9
R13
R11 R12
T4
R26
R27
R24
R23R
15
R22
R7
R19
IC1
1
D5
D4
C2
D7
D6
SW
1S
W2
R31
R30
R29
LD1
LD2
LD3
LD4
C1
D1D2D3
T1
T2
R5R4
R6
R2R1
T5
T6
R18
R17
R28
R21
SK2
-
R14R10
D8
6/12V
</>4
Ah
EN
D O
F C
HA
RG
E
CH
AR
GE
ST
AN
DB
YP
OLA
RIT
YW
RO
NG
+
ACCU
VE
LLE
MA
N P
8012
'1 L
EA
D-A
CID
BA
TT
ER
Y C
HA
RG
ER
VO
LTA
GE
SE
LEC
T
SE
LEC
TC
AP
AC
ITY
BA
TT
ER
Y
J2
J3
T7
CH
AR
GE
R20
R16
J1
M3
NU
T
20m
m S
PA
CE
R
PC
B
BO
TT
OM
30m
m M
3 B
OLT
SO
LDE
R
RE
D
BLA
CK
M3
LOC
K W
AS
HE
R
10m
m M
3 B
OLT
M3
NU
TA
C IN
LET
TR
AN
SF
OR
ME
R2x
9V/2
5VA
ON
/OF
F S
WIT
CH
ST
RA
IN R
ELI
EF
BU
SH
ING
M3
WA
SH
ER
BO
TT
OM
10m
m M
3 B
OLT
M3
NU
T
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13
17. DRILL PATTERN ENCLOSURE ‘TKAUS22G’
CUT
Ø3,5
Ø3,5Ø3,5
Ø3,5Ø3,5
Ø3,5
Ø3,5
Ø3,5
12,5
73
38
133,
590
1324,5
9
BOTTOM
Ø3Ø3Ø3Ø3
Ø6,5Ø6,5
Ø12
20 25,510101117,517,5
21,527
,533
Ø11Ø3,5
Ø3,5
20 2036,5
24,527,51732
33
REAR PANEL
FRONT PANEL
All distances are expressed in mm
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14
18. PCB LAYOUT
R25
AC
R8
b
e
c
c
SK
1
R3
VR1
T3
R9
R13
R11
R12
T4
R26R27
R24R23
R15
R22R7
R19
IC11
D5
D4 C2
D7
D6
SW1 SW2
R31R30R29
LD1 LD2 LD3 LD4
C1
D1
D2
D3
T1 T2
R5
R4
R6
R2
R1
T5
T6
R18R17
R28
R21S
K2
-R14
R10
D8
6/12
V</>4AhEND OF CHARGE
CHARGE FLOATPOLARITYWRONG
+AC
CU
VELLEMAN P8012'1 LEAD ACID BATTERY CHARGER
VOLTAGESELECT
SELECTCAPACITYBATTERY
J2
J3
T7
CHARGE
R20R16
J1
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15
19. DIAGRAM
LM38
5-2.
5V
R1
R8
1K5
1/4
LM32
4
A1
R11
4K7
R9
1K
MJ3
001
T7
C2
4700
u/35
V
D8
1N54
00
BC
547B
T3
R1
47K
R2
27K
R6
270K
BC
547B
T2
1/4
LM32
4A2
R7
10K
R26
1M
R27
1K
R31
2.2/
0.6W
1/4
LM32
4
A3
-
+ E1
6/12
V
R14
10K
14
12 13
1/4
LM32
4
A4
R25
12K
R17
1M
R18
680
R19
15K
R21
10K
R15
33K
R22
220K
AC
AC
VO
LTA
GE
RE
GU
LAT
OR
CU
RR
EN
T L
IMIT
(0.1
C)
I<0.
02C
Vo→
7.3
5 →
6.8
5V
o→14
.7 →
13.6
I<0.
007C
EN
D O
F
CH
AR
GE
D4
1N54
00
D5
1N54
00D
71N
5400D6
1N54
00
0.7V
130m
V
50m
V
LD4
LED
3G
R28
2K2
11
42 3
1
10 98 7
5 6
C1 2u
2R
312
0K
SW
2
12V6V
R30
1.8/
0.6W
R29
1.5/
0.6W
SW
1
OP
EN
: < 4
Ah
(Im
ax=0
.3A
)C
LOS
E: >
4A
h (I
max
=1A
)
R23
2K2
LD3
LED
3Y
BC
557BT6
BC
547BT1
R4
180K
R5
10K
LD2
LED
3R
R24
2K2
BC
547B
T5D
11N
4148
BC
547B
T4
R10
10K
R13
10K
D3
1N41
48R
12 1K D2
1N41
48
LD1
LED
3R
CH
AR
GE
WR
ON
G P
OLA
RIT
Y
EN
D O
F C
HA
RG
E
CH
AR
GE
FLO
AT
LEA
D-A
CID
BA
TT
ER
Y
A1.
..A4
= IC
1
18V
/1.3
A
R16 10
K
R20 10
K