Velleman K8012 User manual

Total solder points: 150
Skill level :
Beginner 1o2o3þ4o5oAdvanced
ILLUSTRATED MANUAL H8012P-ED1
INTELLIGENT LEAD ACID BATTERY CHARGER
K8012
Features:
þSuitable for 6V and 12V sealed and open lead-acid batteries
þFully automatic charge and maintenance cycle
þStatus indicators for charge, float and end-of-charge
þProtected against polarity reversal
þSimply connect and forget
Specifications :
þCharge current : 0.3 or 1A selectable
þPower supply : 2x9V/25VA (our type 2090250MST)
þDimensions (wxdxh): 97 x 140 x40mm / 3.8”x 5.5”x1.6”
þNot suitable for non-rechargeable or NiCd/NiMH batteries
modifications reserved
Options :
þTransformer prim. 230V -sec. 2x9V/25VA: 2090250MST
þEnclosure: TKAUS22G
þPower cord: NETSNOER

5%
4K7= ( 4 - 7 - 2 - B )
1%
4K7= ( 4 - 7 - 0 - 1 - 1 )
COLOR= 2… 5
IPESF SDK NDGB FNL
C
O
D
E
CODICE
COLORE
CODIGO
DE
CORES
CODIGO
DE COL-
ORES
VÄRI
KOODI FÄRG
SCHEMA
FARVE
KODE FARGE KODE FARB KODE
COLOUR
CODE CODIFI-
CATION
DES
COU-
LEURS
KLEUR
KODE
C
O
D
E
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 :
þMake sure the skill level matches your experience, to avoid disappointments.
þFollow the instructions carefully. Read and understand the entire step before
you perform each operation.
þPerform the assembly in the correct order as stated in this manual
þPosition all parts on the PCB (Printed Circuit Board) as shown on the drawings.
þValues on the circuit diagram are subject to changes.
þValues in this assembly guide are correct*
þUse the check-boxes to mark your progress.
þPlease 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

__________________________________________________________________________________________________________________________________________________________
5
AXIAL COMPONENTS ARE
TAPED IN THE CORRECT
MOUNTING SEQUENCE !
START
REMOVE THEM FROM THE TAPE
ONE AT A TIME !
1. JUMPER WIRES
qJ1
qJ2
qJ3
2. ¼W RESISTORS
R...
qR1: 47K (4 -7 -0 -2 -1)
qR2: 27K (2 -7 -0 -2 -1)
qR3: 120K (1 -2 -0 -3 -1)
qR4: 180K (1 -8 -0 -3 -1)
qR5: 10K (1 -0 -3 -B)
qR6: 270K (2 -7 -0 -3 -1)
qR7: 10K (1 -0 -3 -B)
qR8: 1K5 (1 -5 -2 -B)
qR9: 1K (1 -0 -2 -B)
qR10: 10K (1 -0 -3 -B)
qR11: 4K7 (4 -7 -2 -B)
qR12: 1K (1 -0 -2 -B)
qR13: 10K (1 -0 -3 -B)
qR14: 10K (1 -0 -3 -B)
qR15: 33K (3 -3 -3 -B)
qR16: 10K (1 -0 -3 -B)
qR17: 1M (1 -0 -5 -B)
qR18: 680 (6 -8 -1 -B)
qR19: 15K (1 -5 -3 -B)
qR20: 10K (1 -0 -3 -B)
qR21: 10K (1 -0 -3 -B)
qR22: 220K (2 -2 -4 -B)
qR23: 2K2 (2 -2 -2 -B)
qR24: 2K2 (2 -2 -2 -B)
qR25: 12K (1 -2 -3 -B)
qR26: 1M (1 -0 -5 -B)
qR27: 1K (1 -0 -2 -B)
qR28: 2K2 (2 -2 -2 -B)
3. ½W RESISTORS
qR29: 1.5 (1 -5 -B -B -9)
qR30: 1.8 (1 -8 -B -B -9)
qR31: 2.2 (2 -2 -B -B -9)

_______________________________________________________________________________________________________________________________________________________
6
4. DIODES (Watch the polarity!)
D...
CATHODE
qD1: 1N4148
qD2: 1N4148
qD3: 1N4148
qD4: 1N5400 …1N5408
qD5: 1N5400 …1N5408
qD6: 1N5400 …1N5408
qD7: 1N5400 …1N5408
qD8: 1N5400 …1N5408
5. IC SOCKET (Watch the posi-
tion of the notch !)
qIC1 : 14P
6. TRANSISTORS
qT1: BC547
qT2: BC547
qT3: BC547
qT4: BC547
qT5: BC547
qT6: BC557
7. VOLTAGE REFERENCE
VR...
qVR1: LM385Z2.5
8. TERMINAL BLOCKS
qSK1: 2P
qSK2: 2P

__________________________________________________________________________________________________________________________________________________________
7
9. SWITCHES
SW...
qSW1: SINGLE POLE (ON-ON)
qSW2: SINGLE POLE (ON-ON)
10. ELECTROLYTIC CAPACI-
TORS (Watch the polarity!)
C...
qC1: 2µ2
qC2: 4700µ/35V
11. POWER TRANSISTOR
M4 NUT
M4 BOLT
LOCK WASHER
TRANSISTOR
HEATSINK
PCB
qT7: MJ3001, MJ4035, BDX87,
2N6057, 2N6058, 2N6059,
2N6283, 2N6284 or EQ.
12. LEDS (Watch the polarity!)
COLOUR=2...5
LD...
CATHODE CATHODE
qLD1: 3mm LED RED (2)
qLD2: 3mm LED RED (2)
qLD3: 3mm LED YELLOW (4)
qLD4: 3mm LED GREEN (5)
13. IC (Watch the position of the
notch!)
qIC1: 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
ON
L
AC POWER
AC
Vdc
K8012
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
ON
L
AC POWER
AC
Vdc
K8012
ACCU
+
6.8V=

__________________________________________________________________________________________________________________________________________________________
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
ON
L
AC POWER
AC
Vdc
K8012
ACCU
+
14.7V=
12V>4Ah
33 Ω
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
ON
L
AC POWER
AC
Vdc
K8012
ACCU
+
7.3V=
6V>4Ah
Ω
33
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
ON
L
AC POWER
AC
Adc
K8012
ACCU
+
1A=
10A
12V>4Ah
Ω8.2
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 multi-meter
to the ‘10A DC’ -position. It should read 1A +/-0.1A.

_______________________________________________________________________________________________________________________________________________________
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 8.2Ωresistor 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.

__________________________________________________________________________________________________________________________________________________________
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
Fuse
L
N
AC POWER
9V
9V
AC
AC
+
-
ACCU
ACCU
-+
K8012
25VA TRANSFORMER

_______________________________________________________________________________________________________________________________________________________
12
16. ASSEMBLING
R25
AC
R8
b
e
c
c
SK1
R3
VR1
T3
R9
R13
R11
R12
T4
R26 R27
R24 R23
R15 R22
R7
R19
IC1
1
D5 D4 C2
D7
D6
SW1 SW2
R31
R30 R29
LD1 LD2 LD3 LD4
C1
D1
D2
D3
T1 T2
R5
R4
R6
R2
R1
T5 T6
R18
R17
R28
R21
SK2
-
R14 R10
D8
6/12V
</>4Ah END OF CHARGE
CHARGE STANDBY
POLARITY WRONG
+
ACCU
VELLEMAN P8012'1 LEAD-ACID BATTERY CHARGER
VOLTAGE
SELECT
SELECT CAPACITY BATTERY
J2
J3
T7
CHARGE
R20
R16
J1
M3 NUT 20mm SPACER
PCB
BOTTOM
30mm M3 BOLT
SOLDER RED
BLACK
M3 LOCK WASHER
10mm M3 BOLT
M3 NUT
AC INLET
TRANSFORMER
2x9V/25VA
ON/OFF SWITCH
STRAIN RELIEF BUSHING
M3 WASHER
BOTTOM
10mm M3 BOLT
M3 NUT

__________________________________________________________________________________________________________________________________________________________
13
17. DRILL PATTERN ENCLOSURE ‘TKAUS22G’
CUT
Ø3,5
Ø3,5 Ø3,5
Ø3,5
Ø3,5
Ø3,5
Ø3,5
Ø3,5
12,5
73
38
133,5
90
13
24,5
9
BOTTOM
Ø3 Ø3 Ø3 Ø3
Ø6,5 Ø6,5
Ø12
20 25,5 1010
11
17,517,5
21,5
27,5
33
Ø11
Ø3,5
Ø3,5
20 20
36,5
24,527,5
17 32
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
SK1
R3
VR1
T3
R9
R13
R11
R12
T4
R26
R27
R24
R23
R15
R22
R7
R19
IC11
D5
D4 C2
D7
D6
SW1 SW2
R31
R30
R29
LD1 LD2 LD3 LD4
C1
D1
D2 D3
T1 T2
R5 R4 R6
R2
R1
T5 T6
R18
R17
R28
R21
SK2
-
R14 R10
D8
6/12V
</>4Ah END OF CHARGE
CHARGE FLOAT
POLARITY
WRONG
+
ACCU
VELLEMAN P8012'1 LEAD ACID BATTERY CHARGER
VOLTAGE
SELECT
SELECT
CAPACITY
BATTERY
J2
J3
T7
CHARGE
R20
R16
J1

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15
19. DIAGRAM
LM385-2.5
VR1
R8 1K5
1/4 LM324
A1 R11
4K7
R9 1K
MJ3001
T7
C2
4700u/35V
D8
1N5400
BC547B
T3
R1 47K
R2 27K R6
270K
BC547B
T2
1/4 LM324
A2
R7 10K
R26 1M
R27 1K
R31 2.2/0.6W
1/4 LM324
A3
-
+
E1
6/12V
R14 10K
14
12 13
1/4 LM324
A4
R25 12K
R17 1M
R18 680
R19 15K
R21 10K
R15 33K
R22 220K
AC AC
VOLTAGE REGULATOR
CURRENT LIMIT (0.1C)
I<0.02C
Vo→ 7.35 → 6.85 Vo→14.7 →13.6
I<0.007C
END OF
CHARGE
D4
1N5400
D5
1N5400 D7
1N5400
D6
1N5400
0.7V
130mV
50mV
LD4
LED3G
R28 2K2
11
4
2 31
10 9
8 75
6
C1
2u2 R3
120K
SW2
12V
6V
R30 1.8/0.6W R29
1.5/0.6W
SW1
OPEN: < 4Ah (Imax=0.3A) CLOSE: > 4Ah (Imax=1A)
R23 2K2
LD3
LED3Y
BC557B
T6
BC547B
T1
R4 180K
R5 10K LD2
LED3R
R24 2K2
BC547B
T5
D1
1N4148
BC547B
T4
R10 10K R13 10K D3
1N4148
R12
1K
D2
1N4148
LD1
LED3R
CHARGE
WRONG POLARITY
END OF CHARGE
CHARGE
FLOAT
LEAD-ACID BATTERY
A1...A4 = IC1
18V/1.3A
R16
10K
R20
10K