Automatic 12V Lead Acid Battery Charger

This charger will charge any 12V lead acid battery including flooded, gel and AGM. It is fully automatic and will charge at a rate up to about 4A until the battery voltage reaches a preset point at which it will switch to a very low current float charge. If the battery voltage drops again the charger will begin charging until the voltage once again reaches the cut off point. In this way it can be left connected to a battery indefinitely to maintain full charge without causing damage. An LED indicates when the battery is fully charged.

Schematic

Parts
Part R1, R3 R2 R4, R5, R7, R8 R6 R9 C1 D1 D2 D3 D4 2 1 4 1 1 1 1 1 1 1 Total Qty. Description 330 Ohm 1/4W Resistor 100 Ohm 1/4W Pot 82 Ohm 2W Resistor 100 Ohm 1/4W Resistor 1K 1/4W Resistor 220uF 25V Electrolytic Capacitor P600 Diode 1N4004 Diode 5.6V Zener Diode LED (Red, Green or Yellow) Any 50V 5A or greater rectifier diode 1N4002, 1N4007 Substitutions

Q1 Q2 T1 F1 S1 MISC

1 1 1 1 1 1

BT136 TRIAC BRX49 SCR 12V 4A Transformer 3A Fuse SPST Switch, 120VAC 5A Wire, Board, Heatsink For U1, Case, Binding Posts or Alligator Clips For Output, Fuse Holder

See Notes

Notes
1. R2 will have to be adjusted to set the proper finish charge voltage. Flooded and gel batteries are generally charged to 13.8V. If you are cycling the battery (AGM or gel) then 14.5V to 14.9V is generally recommended by battery manufacturers. To set up the charger, set the pot to midway, turn on the charger and then connect a battery to it's output. Monitor the charge with a voltmeter until the battery reaches the proper end voltage and then adjust the pot until the LED glows steadily. The charger has now been set. To charge multiple battery types you can mount the pot on the front of the case and have each position marked for the appropriate voltage. 2. Q1 will need a heatsink. If the circuit is mounted in a case then a small fan might be necessary and can generally be powered right off the output of D1. 3. T1 is a transformer with a primary voltage appropriate to your location (120V, 220V, etc.) and a secondary around 12V. Using a higher voltage secondary (16V18V) will allow you to charge 16V batteries sometimes used in racing applications. 4. If the circuit is powered off, the battery should be disconnected from it's output otherwise the circuit will drain the battery slowly.

Under-Over Voltage Cut off battery Charger

This example describes the utility over , under voltage automatic protection device , can be in the city less than 170V or higher than 250V electricity is cut off automatically Circuit works Power over the city , under voltage protection circuit automatically from the power circuit , over voltage detection control circuit and under voltage detection control circuit , as shown in Figure 5-178 . Power circuit from the starter button and S2, the power transformer T, rectifier diode VDl, VD2 , and filter capacitor Cl form . Overvoltage detection control circuit consists of resistors Rl-R3, potentiometer RPl, regulator diode VSl, diodes VD3, capacitor C2, transistor Vl relay Kl and composition . Under voltage detection control circuit by the resistors R4-R6, potentiometer RP2, regulator diode VS2, diode VD4, capacitor C3, transistor relays K2 and V2 composition . Sl for the PV of the control switch voltage meter . HLl too , under voltage indicator ; HL2 for the output voltage of the normal light . After pressing the S2 , the utility voltage by T Buck , VDl and VD2 Cl rectifier and filtered , as before, under voltage detection control circuit to provide DC power . When a power voltage is normal , then Vl end , V2 conduction , K2 pull , K2-l and K2-2 in the normally open contact connected , normally closed contact is open, the load of the power is turned , while HL2 point Light . After the release S2 , Kl maintain pull state . If the high voltage electricity at 250V, then VSl breakdown conduction , so that Vl saturated conduction , Kl pull , Kl-l and Kl-2 in the normally closed contact is open, normally open contact connected to the load A power supply circuit and T circuit cut off , Vl and V2 has also closed , Kl and K2 release , HLl light , HL2 off . When a power voltage is low at 170V, the VS2 and V2 closed , K2 release , load and T were cut off the power supply circuit , HLl light . Adjustment RPl of resistance , can change the size of high-voltage threshold . Adjusting the resistance of RP2 , can change the size of low-voltage threshold . Components Selection Rl-R6 are selected 1/4W metal film resistors . RPl and RP2 are selected membrane variable resistor . Cl-C3 are selected voltage value of 16V aluminum electrolytic capacitors . VDlVD4 were selected 1N4001 or 1N4007 type silicon rectifier diode . VSl and VS2 use 1/4W or l/2W silicon voltage regulator diodes . Vl and V2 use C8050 or S8050, 3DG8050 silicon NPN transistor . T use 3-5W, the second voltage power transformers for the two- gV . Kl and K2 are selected JRX-l3F type gV DC relays . HLl and shame are all made of neon lights H . S1 and S2 of the contact current load should be more than 5A . PV use 0-300V AC voltmeter .

Charging is accomplished with a constant current of 60 mA for AA cells to a cutoff of 2.4V per cell, at which point the charge must be terminated. The charging system shown is designed for multi-cell battery pack of 2 to 6 series connected cell or series/paralel arrangements. It is essential that all cells assembled in the pack are at an identical stateof-charge (voltage) before charging. the maximum upper cut-off voltage is 15.6V (62.6V). ICL7665 is a voltage monitor with dual over/undervoltage detection.

Here is a simple but powerful, stable and efficient schematic diagram for a 500w modified sine wave inverter circuit. Originally I used a 555 timer and a CD4017 decade counter to produce the modified sine wave, but then I thought a simple PIC micro controller with its internal clock would produce a stable 50Hz frequency without the need for two IC's. As you can see its a very simple circuit. The CD4017 and 555 Timer circuit can be seen here should anyone want to try that. Some information on this circuit. The PIC16F628A is programmed to produce a logic 5v signal for 5ms at pin 17 then 15ms off. Then the same at pin 18, 5ms on then 15ms off (4.17ms for 60Hz). That is one cycle which is then looped. This results in the signals below on the oscilloscope. (2 channel view) You can see the two 5v pulses from pins 17 & 18.

These two pins are then sent to the gates of the STP55NF06L (or STP36NF06L) logic MOSFET's. These are special power MOSFET's that require just 5v to switch on fully. They also have a very low 0.014 Source to Drain resistance when on which means they can switch high currents without wasting power as heat. This keeps the whole system efficient. They do run cool although a heat sink is required. The main losses in power will be within the transformer itself. They are capable of switching loads up to 55A (or 30A for the STP36NF06L) which makes this a powerful inverter if used with a large (~800VA) transformer. Of course you could use a smaller transformer for small loads. The MOSFET's could be in parallel pairs for even more power. Just give each its own 470 gate resistor and a 22k from each gate to source. I get around 240v AC from the 10-0-10 with a 12v battery but as this circuit is so efficient a 12-0-12 should give you no less than 220v AC at 12v. Of course if you live in a country with 120v, you can just use a 10-0-10v to 120v transformer. If you need 50Hz or 60Hz the PIC files ready to be programmed are at the bottom of this page. The transformer is wired up in reverse. We are using the low voltage side as the primary, and the high voltage side as the secondary. The low voltage side must be centre tapped. I might add I have not tried this circuit at 500w as I don't have a large enough transformer at the moment, but the 55A MOSFET's should be fine. I am going to rewind the secondary of a microwave oven transformer with about 11-0-11v and see how that goes, although I don't think they are the most efficient transformer cores around. Still, it could be an easy and cheap way to make a 500w centre tapped transformer for this project. Will need some chunky primary wire! Its certainly not worth buying a large transformer for this project. For the price of that you could buy a commercial inverter or three. That's no fun though is it! Also don't forget that even to run

a 100w load you will need 12v at almost 10A (calculator). Small sealed lead acid batteries are not going to be much help apart from to light your Christmas tree or charge your mobile phone. The image below is the modified sine wave output you will get from this circuit. It is the same as most of the commercial inverters that are out there that aren't pure sine wave. The advantage for the inverter with using a modified sine-wave is that the MOSFET's are either fully on or fully off, never operating in their linear region which would cause heating and poor efficiency.

Here is the finished driver board.

Note the large 1000F capacitor and 47 resistor. These clean up the voltage spikes coming from the transformer centre tap into the positive rail and protect the PIC from them. I learnt the hard way and burnt out 2 PIC's before looking into the problem with the scope. Don't think that the 5v regulator will fix the spikes! It and the PIC got hot and then the PIC died. Twice! The image below shows what the power supply looks like at each end of the 47 resistor Left is power supply end and right is regulator end. This is with no load on the transformer. The spikes and waveform of them changes with load. The simple resistor and cap cleans it up. This works because the 1000F capacitor will be seen as a low impedance to a voltage spike. The 47 resistor limits the current, so the spikes are dissipated in it as can be seen below.

If you wish to build this circuit you will need a PIC programmer to program the microchip with the HEX file below. If you do not have access to a PIC programmer, please contact me and I can send you a pre programmed PIC16F628A for a small paypal payment to cover the chip and postage. I also have some STP55NF06L MOSFET's if you require those too. I would be interested to hear from anyone who has built this circuit and what results you have had so please let me know!
50Hz HEX file for programming the PIC16F628A 60Hz HEX file for programming the PIC16F628A 16F628A_50Hz_Inverter.zip 16F628A_60Hz_Inverter.zip

Good luck!