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