Velleman K8012 User manual

Intelligent lead acid battery charger
K8012
ILLUSTRATED ASSEMBLY MANUAL H8012IP - 1
Total solder points: 150
Difficulty level: beginner 12345 advanced
Suitablefor6Vand12Vsealedand
openlead-acidbatteries

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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 !
Features & Specifications
Options:
 Transformer prim. 230V - sec. 2x9V/25VA: 2090250MST
 Enclosure: TKAUS22G
 Power cord: NETSNOER

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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 youto make goodconnections. 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
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
1.2 Assembly Hints :
⇒ Make sure the skill level matches your experience, to avoid disappointments.
⇒ Follow the instructions carefully. Read and understand the entire step before you perform each operation.
⇒ Perform the assembly in the correct order as stated in this manual
⇒ Position all parts on the PCB (Printed Circuit Board) as shown on the drawings.
⇒ Values on the circuit diagram are subject to changes.
⇒ Values in this assembly guide are correct*
⇒ Use the check-boxes to mark your progress.
⇒ Please read the included information on safety and customer service
* Typographical inaccuracies excluded. Always look for possible last minute manual updates, indicated as ‘NOTE’ ona separate leaflet.
0.000

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Assembly hints
1.3 Soldering Hints :
1- Mount the component against the PCB surface and carefully solder the leads
2- Make sure the solder joints are cone-shaped and shiny
3- Trim excess leads as close as possible to the solder joint
REMOVE THEM FROM THE TAPE ONE AT A TIME !
AXIAL COMPONENTS ARE TAPED IN THE COR-
RECT MOUNTING SEQUENCE !

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 R1 : 47K (4 - 7 - 0 - 2 - 1)
 R2 : 27K (2 - 7 - 0 - 2 - 1)
 R3 : 120K (1 - 2 - 0 - 3 - 1)
 R4 : 180K (1 - 8 - 0 - 3 - 1)
 R6 : 270K (2 - 7 - 0 - 3 - 1)
3. Metal film resistors (1%)
R...
Construction
 D1 : 1N4148
 D2 : 1N4148
 D3 : 1N4148
2. Diodes (150mA).
Watch the polarity !
D...
CATHODE
 J1
 J2
 J3
1. Jumper wires
 R5 : 10K (1 - 0 - 3 - B)
 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)
4. 1/4W resistors
R...
 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)
 R29 : 1.5 (1 - 5 - B - B - 9)
 R30 : 1.8 (1 - 8 - B - B - 9)
 R31 : 2.2 (2 - 2 - B - B - 9)
5. Metal film resistors (5%)
R...

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Construction
 T1 : BC547
 T2 : BC547
 T3 : BC547
 T4 : BC547
 T5 : BC547
 T6 : BC557
8. Transistors
 IC1 : 14P
6. IC socket. Watch the
position of the notch!
 C1 : 2µ2
11. Electrolytic capacitor.
Watch the polarity !
C...
 SK1 : 2p (AC)
 SK2 : 2p (Accu)
10. Screw connectors
 D4 : 1N5400 ... 1N5408
 D5 : 1N5400 ... 1N5408
 D6 : 1N5400 ... 1N5408
 D7 : 1N5400 ... 1N5408
 D8 : 1N5400 ... 1N5408
7. Diodes (3A). Watch the
polarity !
D...
CATHODE
 VR1 : LM385Z-2.5
9. Reference diode
VR...
 SW1: ON - ON
 SW2: ON - ON
12. Switches
SW...
 C2 : 4700µF/35V
13. Electrolytic capacitor.
Watch the polarity !
C...

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 T1 : MJ3001
14. Power transistor
 IC1: LM324 or eq.

16. IC. Check the position of the notch !
Construction
 LD1 : RED
 LD2 : RED
 LD3 : YELLOW
 LD4 : GREEN
15. LEDs. Watch the polarity!
COLOUR=2...5
CATHODE CATHODE
3mm

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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.
-2- Put SW2 in the 6V position. Measure the voltage across the output
terminals. Output voltage should be 6.8V +/- 0.2V
17. Testing
Testing
Fig. 1.0
Fig. 2.0

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-3- Put SW2 in the 12V position, put SW1 in the >4Ah position. Connect
the supplied 33Ω/5Ωresistor to the output terminals. Measure the
voltage across the resistor.
It should read 14.7V +/- 0.1V
-4- Put SW2 in the 6V position, put SW1 in the >4Ah position. Connect
the supplied 33Ω/5Ωresistor to the output terminals. Measure the
voltage across the resistor. It should read 7.3V +/- 0.1V
Testing
Fig. 4.0
Fig. 3.0

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-5- Put SW2 in the 12V position, put SW1 in the >4Ah position. Connect the supplied
8.2Ωresistor in series with the multimeter. Switch the multimeter to the ‘10A DC’ -
position. It should read 1A +/- 0.1A.
-6- Put SW2 in the 12V position, put SW1 in the <4Ah position. Connect the supplied
8.2Ωresistor in series with the multi-meter. Switch the multimeter to the ‘10A DC’ -
position. It should read 0.3A +/- 0.03A.
Testing
Fig. 5.0
Fig. 6.0
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.

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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.
Degrease the front panel before sticking the label onto it. The label edges will need to be trimmed with a sharp cutter.
Fig. 7.0

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Optional enclosure
Fig. 8.0

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Optional enclosure
Figure 9.0. provides an internal view of the finished unit.
 Make sure it is well ventilated, as the
heatsink might run hot during charging
Fig. 9.0

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Connection: The unit can be connected as shown on figure 10.
Make sure your assembly complies with the local safety regulations. For improved safety, use a non-conductive enclosure.
19. Connection & Use
Connection & Use
Fig. 10

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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 :
 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.
Approx. charging time (hours) = (battery capacity (Ah) / charging current (A)) x 1.2
Connection & use

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20. Operation & troubleshooting
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.
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.

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PCB
21. PCB

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22. Schematic diagram.
Schematic diagram

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Modifications and typographical errors reserved
© Velleman Components nv.
H8012IP - 2005 - ED1
VELLEMAN Components NV
Legen Heirweg 33
9890 Gavere
Belgium Europe
www.velleman.be
www.velleman-kit.com
5410329 290719