SC_Universal_Charger_Pt2.pdf

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IllS lHE ONLY SAnERY CHARGER YOU WILL EVER NEED, EVER AGAIN!

- NiCads - NiMHs - SlAS - LiiONs - Bike batteries - car batteries. . .

Part

By JOHN CLARKE

-;,;EIlYCHAIl&11t11

POWER

BATTERV

rtiH~i-~·~~

...

ere's

SlueOI

lIP

the nitty gritty:

t's arguably the only "high cap

acity" fast battery charger you'll

ever need - ever again!

will

easily handle all the batteries you have

in your power tools - it will even

charge your car or motor bike battery!

And while it won't handle low ca

pacity "AA" cells it can charge their

big brothers - 1200mAh and above

along with "C" and "D" types of

1200mAh or more. For a more de

tailed list, see the panel at right or

refer to the full description of opera

tion in last month's

SILICON

CHIP.

Main Features

•

Construction

The

SILICON

CHIP

Universal Fast

Battery Charger is housed in a plastic

instrument case measuring 257 x 190

x 85mm while the components are

mounted on a PC board coded

•

Top-off

at end of fast

•

Voltage chargingcharge for SLA chargdP,us pulsed trickle charge for Nicad & NiMH

•

V I limited

batteries

•

Under

and over-temperature

rise

(dT/d

t-Acid

charge detection for Nicad & NiMH

a tage drop & temperature

)

cuto t f

•

Over

temperature cutout for charger or attery

•

Short circuit battery protection

•

Time-out protection

•

Fuse protection

•

MUlti-LED charge indicators

Fast charges Nicad, NiMH UlaN

Suitable for 1.2V 2 4V 3 6V

' SLA and Lead-AcId batteries

from 1.2Ah to 4.2Ah Plu;

Lii~N8~:66:,

:2'2V,&8.4 V, 9.6V, 12V & 14,4V batteries

Cha

. h

,. V 14 4V

rges elt er 6V or 12V SLA batteries from 1.2·Ah to 4Ah

Ch arges 6V or 12V Lead Ad b

Includes a discharger fa;

N~~ad ~t~~;~~~e~f

any capacity

above

1.2Ah

This photo shows the completed project, giving a good idea of where the various components are located. Probably the

most difficult part is winding the inductor (bottom right) but even this is a snack!

JULY 2001

LEGEND:

PC BOARD PIN

NP • NON-POLARISED (BIPOLAR) CAPACITOR

Figs

1&2

show both sides of the PC board, with the relevant section of the under

side shown below.

I·

•

• 1 •

-f:JD

•

ZDI

- - -

.....

'~. ~0

~[B

fae

-C@

D-

-lJD

lOOk

-[@ •

--c=J-".

-[@Q[j-

14106011 and measuring 121 x

173mm.

If IC1 is the surface mount or .. T"

version, a small satellite PC board,

coded 14302982 and measuring 29 x

16mm is also required.

TransformerT1 is mounted sideways

onto the rear metal panel as shown in

the photographs. Underneath its mount

ing position on the case are several

integral ribs and bushes (mounting pil

lars). These must be removed to allow

the transformer to si t flat.

The easiest way to remove the ribs

is with a sharp chisel (careful!!) while

the bushes are easily cut out with a

large, sharp drill bit.

The main PC board fits over four

integral bushes in the base of the case,

secured with self-tapping screws.

Other bushes (under the board) may

get in the way of the PC board or

components - again, these can be eas

ily removed with a large drill.

Begin construction by checking the

PC board against the published pat

tern. There should not be any shorts

between, or breaks in, the tracks. If

there are, repair these as necessary.

PC stakes are used wherever con

nections need to be made to the PC

board. These are soldered in first, in

the positions indicated. Doing these

first also acts as a guide to the posi

tions of the links and resistors, which

can be soldered in next. Use the ac

companying table as a guide to work

ing out which resistor goes where - or

measure them with a digital multi

meter.

Note that some resistors are mount

ed as a parallel combination: one is

inserted as normal from the compo

nent side of the PC board while the

second (shown in red in Fig. 2 at right)

is soldered between the pigtails of the

first resistor on the underside of the

PC board.

When inserting the smaller diodes

and zeners, take care with their orien

tation and be sure to place each type

in its correct place. Solder in the ICs

and transistors, also taking care to ori

ent them as shown.

As mentioned before, IC1 may be

supplied as a surface-mount type.

so, it must first be soldered onto the

small carrier PC board, which in turn

is connected to the main PC board

with wire links or pin headers.

SILICON CHIP

Parts List - Universal Fast Battery Charger II

1 PC board coded 14106011, 121 x 173mm

1 PC board coded 14302982, 29 x 16mm (required for T

version of IC1)

1 front panel label 244 x 75mm

1 plastic instrument case 250 x 190 x 80mm

1 aluminium rear panel to suit above case

1 heatsink 109 x 75 x 33mm (DSE H-3460 or

equivalent)

1 18V 6A mains transformer (T1) (DSE M-2000 or

equivalent)

1 ETD29/16/10 transformer assembly with 3C85 cores

(L1) (Philips 2 x 4312 020 37502 cores, 1 x 4322 021

34381 bobbin, 2 x 4322021 34371 clips)

1 NTC thermistor (DSE R-1797) (NTC1)

2 3AG panel-mount safety fuse holders (F1,F2)

1 630mA slow-blow 3AG fuse

1 7A fast-blow 3AG fuse

1 SPST Neon illuminated mains rocker switch (S1)

1 SPOT centre-off toggle switch (S2)

1 2-pole, 4-position rotary switch (S3)

1 4-pole, 3-position rotary switch (S4)

1 single pole, 10-position (1 P1 OW) rotary switch (S5)

80 C

thermal cutout (TH1)

1 momentary normally off push button switch (S6)

1 black 4mm heavy duty banana panel socket

1 red 4mm heavy duty banana panel socket

1 black 2mm micro banana panel socket

1 red 2mm micro banana panel socket

1 black 4mm heavy duty banana plug

1 red 4mm heavy duty banana plug

1 black 2mm micro banana plug

1 red 2mm micro banana plug

5 M4 screws x 10mm

6 M4 nuts and star washers

4 M3 screws x 10mm and nuts

1 M3 screw x 25mm and nut

4 self-tapping screws to mount PC board

4 insulating bushes for TO-220 and TO-218 packages

2 TO-218 insulating washers

2 TO-220 insulating washers

31 PC stakes

1 7.5A mains cord with plug

1 mains cord grip grommet

2 1mm spacers 10 x 5mm to gap L1

1 600mm length of red hookup wire

1 600mm length of green hookup wire

1 600mm length of blue hookup wire

1 600mm length of yellow hookup wire

1 600mm length of black hookup wire

1 300mm length of red heavy-duty hookup wire

1 300mm length of black heavy-duty hookup wire

1 150mm length of 0.8mm tinned copper wire

1 2m length of 1mm enamelled copper wire

1 55mm length of 15mm diameter heatshrink tubing

1 50mm length of 25mm diameter heatshrink tubing

10 small cable ties

2 solder lugs for earth terminals

2 10-way single in-line pin headers (if IC1 is surface

mount

'T'

version)

5 5mm LED bezels

Semiconductors

1 TEA1102 or TEA11 02T fast charge IC (IC1)

1 4093 quad Schmitt NAND gate (IC2)

1 4020 binary divider (IC3)

1 TIP147 PNP power Darlington transistor

(01)

1 TIP142 NPN power Darlington transistor

(02)

2 BC337 NPN transistors (03,05)

1 BC548 NPN transistor (04)

2 MUR1550, BYW81 P/200 fast recovery diodes

(01,02)

1 1N4004 1A diode (03)

2 1N914, 1N4148 diodes (04,05)

1 35A 400V bridge rectifier (BR1)

1 12V 1W zener diode (ZD1)

1 11 V 400mW zener diode (ZD2)

5 5mm red LEDs (LED1-LED5)

Capacitors

1 1000llF 63VW PC electrolytic

1 1OOIlF 25VW PC electrolytic

1 100llF 16VW PC electrolytic

2 10llF 16VW PC electrolytic .

2 10llF 100VW MKT polyester (Philips 373 series)

1 3.31lF bipolar electrolytic

1 11lF 16VW PC electrolytic

1 0.181lF MKT polyester

1 0.11lF MKT polyester

1 820pF MKT polyester or ceramic

Resistors

(O.25W 1%)

1 1M.o

1330k.o

1 150k.o

5100k.o

168k.o

433k.o

227k.o

122k.o

218k.Q

115k.o

1 10k.o

1 4.7k.o

1 2.2k.o 0.5W

2 1k.o 1W

1680.0

168.0

20.1.o5W

Miscellaneous

Heatsink compound, solder, etc.

3220k.o

282k.o

130k.o

120k.o

212k.o

1 3.3k.o

1 1k.o

1 10.0

JULY 2001

should be written on each compo

nent. The electrolytic capacitors

must be oriented with the correct

polarity (with the exception of the

2 ---------.- 20

3.3/.lF bipolar type which can be

mounted either way). Now install

the trimpot.

In similar fashion to the power

transistors, the LEOs solder to the

PC board and also emerge through

the front panel. To allow this, the

20 WRNS BIFIIAR WOUND

LEDs are inserted through the

WITH 1

ENAMEllED

()

board with just enough length pok

COPPER WIRE

ing through to allow soldering.

Fig.3: the detail of the inductor winding.

The LEDs are then bent over over

so that they can protrude through

has two windings but both go on as one.

the holes in the panel. We don't

have to remind you to make sure

they're the right way around, do we?

The power transistors and power

diodes solder to the PC board but are

No, we didn't think so ...

The inductor (Ll) is wound with

also secured to the rear panel and

heatsink. They are oriented with the

two lengths of lmm enamelled cop

metal flange towards the edge of the

per wire, wound in "bifilar" mode

PC board and are positioned above

the two lengths are wound as one

the board with sufficient lead length

with each turn of the winding actu

to allow them to reach their mounting

ally being two turns side-by-side, one

holes on the rear of the case.

from each length of wire.

Capacitors can be soldered in next.

Fig.3 explains this method of wind

The accompanying capacitor table

ing. First, if the wire is supplied as a

shows the various codes, one of which

two-metre length (as specified in the

parts list) cut

exactly in half. Now

let's see ... each length will be, uhh,

urn, too hard ...

Next remove the insulation from

one end of each of the two lengths of

wire and terminate (solder) the two

ends onto two pins on the underside

of the transformer bobbin. The actual

pins used doesn't matter since they

are connected together on the PC board

anyway.

Now wind on the two windings of

20 turns by holding both lengths of

wire between your thumb and forefin

ger and winding them on as one (ie,

side-by-side).

Once wound, cut the excess wires

off, strip the insulation from their ends

and terminate the wires onto the pins

on the opposite side of the former.

Again, the actual pins used are not

important.

Insert one core in place and secure

with a clip. Now place the lmm

spacers on the two faces of the in

serted core and place the second core

in position, securing it with the clips

supplied. Insert this inductor assem

bly into the appropriate place on the

PC board and solder in place.

An angled view of the rear of the case, particularly showing the method of mounting the power transistors and diode, the

thermistor (with the red wires), bridge rectifier (block in the middle), transformer and mains wiring. Note that all mains

wiring must be insulated with heatshrink tubing, as shown on the fuseholder at right of picture.

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