the main Scheme Laboratory Articles Obuchalka Links Directory KotArt about the Forum

project

Seleccionar idioma
RadioKot > Circuits > Power > Chargers >
Con la tecnología de Traductor de Google
Add a link to the discussion of
Article tags: Add a tag
the article on the forum

Effective powerful charging-desulphating device for batteries 10-

100 A / h

The author: Vladislav

Posted on 01/31/2012.
Created using KotoRed .

About chargers and devices for desulphating batteries has been written so much that even experienced
amateurs are lost in the variety of circuit solutions. As a result, the amateur radio amateur collects / buys the
first suitable charger for power and uses it, unaware that the battery on the car will last only 2-3 years,
instead of 5 (this is not the limit), and then comes into complete disrepair.

It has long been known and scientifically proven (there are patents on this subject) that charging a battery
with a pulse current is much more efficient than a constant one. In the case of using asymmetric current
(there is also a patent), the efficiency of the process increases even more, which allows using such a charger
as a “reanimator” for old batteries, significantly extending their service life.

There were two reasons to assemble such a device. The first is the lack of such devices on sale, the second is
the desire to master this technology. An analysis was made of various schemes of their various sources (old
magazines Radio, Za Rulem, Internet) as a result of which it turned out that there are no devices meeting the
given requirements and accessible to the average consumer.

The device must provide:

Yandex.Direct
Charging any 3-6-12 volt acid starter or traction batteries with a capacity of up to 100 A
one. / h with a pulse current, with an average value from 1 to 10A with continuously
adjustable at a given limit.
2 Formation of discharge current with a charge / discharge current ratio of 1:10 with the
possibility of stepwise adjustment - selection of a load resistor.
The stabilization of the charging current during the entire charge process with a
deviation of no worse than 10% of the set, the charging current should not depend on the
3
battery level, supply voltage, temperature. The device must be protected against
overload, short circuit and polarity reversal.
The efficiency of the device should be no worse than 70%, the device should have a small Amalgam UV lamps
four. mass and low cost. A good repeatability of the scheme should be achieved, debugging
simplified. The circuit should not contain expensive components. UV lamps JL32525 from the
manufacturer. In stock. Top
The ability to upgrade the circuit to increase the charge current by replacing only the quality!
five. power elements - a transformer, a thyristor, a diode bridge, a measuring shunt without
modifying the low-power control electronics.
j-uv.ru

As a result, all these wishes were achieved! The device is assembled according to the thyristor pulse width
power regulator (PWM) circuit in the primary circuit of the mains transformer with feedback on the current
sensor in the charge circuit. Due to the use in the OU circuit, a high stabilization of the charge current is
achieved, independent of the charge level of the battery, the supply voltage, and the temperature. To generate
discharge current pulses, “dead time” is used — the moment when the mains voltage passes through “0”
before the opening of the power thyristor. This circuit design is rather not new, but “well forgotten old”. Tested
by time!
Shoveling the mountain material on the operation of lead batteries, the following simple conclusions were
made, which should not raise doubts as to their correctness:

1. The charging current should be 1/10 of the battery capacity, it is allowed to deviate to both sides by 20%
without harm to the battery.
Vill C t Offi i l
 VillaCarte. Official
2. Charging time, however, should be approximately 10-12 hours, depending on the state of the battery. A site
significant increase in charge time is allowed in order to bring the electrolyte density back to normal.
Rent and sale of villas . VIP
3. Over time, the battery loses its capacity due to the sulfation of the electrodes. On average, the battery lasts service. Individual selection.
for 2-3 years, then its capacity drops significantly (without taking special measures). 100% Inspected Objects.

4. DC charging is not able to eliminate the sulfation of the electrodes. The battery will be charged as much as
villacarte.com
its chemical capacity (state of the plates) is kept, taking into account the “age” and operating conditions.

5. When charging with direct current, gas and heat are liberally liberated, especially closer to the end of the
charge, i.e. the energy of the charger is wasted on these processes.

6. The battery charge on a car from a regular generator with a constant voltage of 13.8 - 14.5 V is generally
unable to fully charge the battery; in fact, it is constantly “undercharged”, especially in winter. In such a
battery, the destruction of electrodes, the formation of sulfates and other harmful processes, which reduce its
service life, occur much faster. At least once every 3 months, the battery should be put on “prevention” to fully
charge and bring the level and density of the electrolyte back to normal.

7. Charging by pulse current with steep fronts contributes to the desulfation of the battery. The extraneous
chemical formations on the electrodes are destroyed by the action of current pulses, the plates are “restored”. Buy aerial pipe
If alternating charge / discharge pulses with a charge / discharge current ratio of 1:10, the desulfation process without a franchise
is accelerated.
Delivery and installation
8. When charging with a pulse current, much less gas and heat are released, and less water boils away from around the world. Get a
the electrolyte. In order to speed up the charging process, the charging current, however, can be significantly comparative table of
increased, up to ½ the capacity of the battery, especially at the beginning of the charge. manufacturers of the Russia
Federation
9. The battery can be considered fully charged when the electrolyte density in all banks is at least 1.28 - 1.30
and does not grow during the last 3 hours of the charge. Thus, it is impossible to accurately determine the freeflytechnology.net
actual charge level only by the voltage at the battery terminals.

10. And finally, the batteries can not be charged at home! It is very harmful to the health of people and
animals! This work should only be done in a garage or outdoors.

The distribution of the pulse circuitry in power supply units and chargers (in amateur radio conditions - revision
of the AT and ATX power supply units) does not allow for creating an effective charging and recovery device on
their basis. In such devices it is impossible to get a pulsating current with a frequency of 50-100 Hz at the
output, for the simple reason that the mains voltage immediately rectifies there. The converter operates at a
frequency of about 100 kHz, the pulsations on which will be completely useless for the battery (or rather,
harmful). Attempting to modulate the impulse converter control circuit from an external oscillator leads to the
failure of the transistor's key transistors, since such circuits already have feedback to ensure the stabilization
of the output voltage or current. When trying to supply a modulating signal with a frequency of 25-50 Hz, the Cruises in the
control circuit does not have time to stabilize; the power supply operates on pulses of either the maximum Mediterranean
width or the narrowest, which sooner or later leads to the breakdown of powerful transistors. Also, at the same
time, it is impossible to set the output voltage and current. By reducing the modulation frequency to several Tours on the liner in the
Mediterranean . Direct
Hertz, desulfation efficiency is significantly deteriorated. The power unit, with such control, constantly
booking. Order now!
“whistles”, the circuit is constantly in a transient state, which sooner or later disables it.

Another option for creating a pulsating charging current in high-frequency pulse converters is to install a
powerful key at the output of the power supply. This option is viable, but it should be borne in mind that at a dreamlines.ru
charging current of 10A, a serious transistor with a good radiator will be required. It should also be borne in
mind that a very large capacitor must stand in front of the transistor, which will “smooth out” the pulsations
from such switching of the load. Without a condenser, you get what is written in the paragraph above.

Based on this, it is possible to make a simple conclusion - serial ATU and ATX power supply units for creating
powerful charging currents are not suitable, at least, without serious revision of their circuitry.

Another option of charging devices, not less widespread among radio amateurs, is various schemes of
parametric current stabilizers with a powerful transistor at the output. In such schemes, it is easy to obtain a
pulsed charging current, however, such stabilizers have an extremely low efficiency due to the significant heat
release by the output power transistor, which dissipates “extra” power. According to this scheme, it is realistic
to assemble a device with a charge current of 3A, with a charge current already 5A, a huge radiator is required
(for the entire device case), and it is almost impossible to get 10A. It should be noted that the charger must
operate for many hours continuously, which means that it will take at least 2x power reserve for all its power
elements to prevent their overheating and failure.

Finally, consider the “correct” circuit solutions for chargers that are used in industry because of their efficiency
and high efficiency. In such devices, a powerful thyristor is used to control the charging current, which is
included in the break of the charging circuit of the battery. By controlling the pulse supply time, the thyristor
opens at a certain moment, which provides a powerful current pulse at the output that is equal in duration
from the opening of the thyristor to the passage of the mains voltage (sinusoid) through “0”. It is not difficult
to guess that at the output of such a device there will be powerful pulses of the charging one, and the strength
of the charging current will be determined only by their duration. Turning the load in parallel with the battery
(for example, a small 12V lamp) will result in a charger with an asymmetric current.

However, this scheme has one serious drawback: the voltage drop on the thyristor reaches 2V, to reduce
losses (heat generation) with charge currents of more than 10A, several thyristors will need to be connected in
parallel, a powerful and complex circuit will need to be built to control DC pulses), and also, again, use a large
radiator to cool the thyristors ...

Finally, a solution was found. I cite the scheme in its “original” form, in which it was discovered on the
network.

The basic layout of the two screens below, this one is just a prototype.
The scheme is taken from the ancient magazine "Radio" for 1988 and is fully operational. Here, the semistor
KU208G is in the primary circuit of the transformer and the low-voltage circuit is extremely simplified.
Semistor does exactly the same thing as the thyristor, as described above - by setting the moment of
switching on, a pulse of current of the primary winding is formed. Adjusting the current in the primary winding
of the transformer allows you to adjust the current in the load circuit. In this case, the low-voltage circuit is
extremely simplified, which reduces losses in it and significantly increases the efficiency of the entire device!
Unfortunately, in this scheme it is impossible to ensure the stabilization of the charging current. the signal
from the current sensor is analog and the current sensor itself (shunt) must be placed in the charging circuit,
i.e. in the secondary circuit of a power transformer. To transmit a signal from such a sensor to the current
control circuit, i.e. in the circuit of the primary winding of the transformer by simple means is not possible. For
this reason, it is also impossible to stabilize the output voltage of the charger, which is necessary for charging
weak-wave batteries.
The following is a general view and a complete diagram of the charger, devoid of these shortcomings. The
scheme uses “non-standard” engineering solutions, which makes it more interesting and attractive for
repetition. Characteristically, but in the process of debugging the device, there were no problems - in fact, it
only took to “drive” the charging current to the desired values and configure the protection node against
overloads and short-circuiting of the output. As noted above, the circuit does not contain expensive parts -
most of the components can be obtained from faulty AT and ATX power supplies. The scheme can be
somewhat simplified: the automatic protection against overloads can be removed, the measuring devices in
the charging circuit can be removed. At the same time, the quality of the device circuit operation will not
deteriorate. Also, if you plan to charge only 12V batteries, output voltage control channel may not be used. To
increase the power of the device, you only need to install a more powerful power transformer, a rectifier
bridge, and pick up a measuring shunt. All parts in the primary circuit can easily withstand power up to 1 kW,
which is enough for any charger ...
General view of the charger:

Circuit diagram:
Description of the scheme
At the time of power-up (pressing the button S1), the mains voltage is supplied to the transformer TP2,
rectified by a diode bridge and fed to all nodes of low-power electronics. Chip K561LE5 contains four logical
elements "Exclusive or (XOR)", of which only one is used. According to the truth table for this logic, at the
output of the element at this moment there is a log. 1. A high logic level of the output element, through the
limiting resistor, is fed to the base of the composite transistor KT315 - KT815, which leads to the opening of
both transistors and the operation of the relay K1. This relay, by its contacts, shunts the button S1.1 and
closes the charging circuit. When the S1 button is released (after 0.5 - 1 s after pressing), the device remains
connected to the network, since relay contacts K1 remain closed. Lamp L1 shows the device is connected to
the network. In this state, if at least one of the inputs of an element of the K561LE5 chip displays a log. 1, at
the output of the microcircuit, 0 will immediately appear, the transistors of the relay control key will close, the
relay contacts will open and the device will be disconnected from the network. This property of this type of
logic is used for current protection of the device and forced shutdown. Indeed, if you repeatedly press and hold
button S1, the capacitor at pin 2 of the K561LA7 chip will begin to charge gradually and sooner or later (for
about 2 seconds) log 1 will be installed at input 2 and the device will turn off. Exactly also happen when a log
appears. 1 at the input 1 of the above-mentioned chip, i.e. when the current protection threshold is exceeded.
Such simplest automation will protect the circuit from various emergency situations - output short circuit,
network disconnection. In the case of a temperature sensor, timer, etc. It is possible to disable the device by
signals from these sensors.
The main node of the circuit is the TL494 PWM controller. This "venerable" chip has a highly developed control
and monitoring circuit, which allows it to be used in a non-standard way - as a phase controller, while retaining
all the functionality! The master oscillator of the microcircuit, in this case, instead of 80-100 kHz, as in the AT
switching power supply, operates at twice the frequency of the mains supply. At the same time, the CT
terminal generates a synchronization signal (log. 0) through the sinusoid of the mains voltage through 0. Let's
take a closer look at how the synchronizer works. It is known that the ripple frequency of a full-wave rectifier
is 2f, where f is the mains frequency. Thus, after straightening by the bridge, the signal takes the following
form:

We are interested only in voltage drops - the lower parts of the signal. They correspond to the passage of the
mains voltage through the "0". To eliminate the effect of a smoothing capacitor with a capacity of 2000
microfarads, it is “decoupled” from the rectifier bridge by a diode. Pulsations of the mains voltage, through a
limiting resistor of 1 kΩ are fed to the LED of the optocoupler 4N35. At the output of the optocoupler, in this
case, pulses appear that are close to rectangular in shape and coincide in time with the input signal. Transistor
CT 315 in the output circuit of the optocoupler is turned on so that when the pulses fall off the optocoupler
(i.e., when the sinusode passes through 0), it opens and shunts the output CT of the microcircuit. In this case,
the signal on the collector of this transistor has the following form:

The lower horizontal sections of the signal - the passage of the sinusoid of the supply voltage through 0.
Oblique - the working area of the PWM signal i.e. The output signal of TL494 can be a width not larger than the
width of this oblique pulse, i.e. no more than half the width of the mains voltage period. It is characteristic, but
the time of the beginning of the impulse during its regulation will be from the very top, which will allow such
impulses to “chop” the sinusoid by the thyristor and, as a result, to carry out phase power control.
Another interesting point is the way to turn on error amplifiers to ensure that they work together in linear
mode. On their own, TL494 error amplifiers (with standard power on) work as comparators, not differential
amplifiers. For a pulsed power supply operating at a frequency of several hundred kHz, this is normal, and in
our case completely unacceptable. In pulsed power supply units, stabilization of feedback in the circuit is
achieved by capacitors at the output of the PSU, while only one OU TL494 can operate in a linear mode
(voltage or current channel), and the second - only as a comparator (current protection or over-voltage ). In
our case, both OU channels work linearly, since A reference sawtooth voltage is supplied to both of their
inverting (reference) inputs, as at the synchronization input of the generator! Wherein, a linear change in the
voltage at the non-inverting (measuring) inputs of the amplifiers will result in a linear, again, change in the
duration of the output pulse of the PWM controller! In this case, the stability will be determined only by the
stability of the reference voltage source (ION) built into the TL494. Thus, the greater the value of the constant
voltage on the non-inverting inputs of the op-amp, the narrower the output pulse, which makes it possible to
cover the whole circuit with negative feedback to stabilize the voltage and current. This inclusion of the TL494
chip allows organizing two symmetrical control channels for output voltage and current with a minimum of
mounted elements. The internal logic of the TL494 is built in such a way that it does not distinguish the priority
between the control channels: which channel will be higher - it takes control of the PWM controller to itself,
Other terminals TL494 are included as standard, the case on pin 13 switches the microchip from paraphase to
common mode, i.e. Both output keys work together. At the same time, public keys mean the presence of a
signal at the output of the PWM controller, and closed ones - the absence. The following waveform shows the
output. The pulse width is determined by the duration of the falling pulse, i.e. the signal at the controller
output is inverse.

The next node is the NE555 chip with which the thyristor is controlled. A few words about this, no less, (or
rather, more) “respectable” chip. The microchip developed as early as 1970 is still quite attractive for many
applications. In this scheme, it performs the following functions:
1. Generation of rectangular pulses with a frequency of about 10 kHz with a cycle time ratio of 20-80%.
2. Manipulation of the generator by an external control signal.
3. Amplification of the signal power up to 0.5 watts.
The binding of the chip causes the latter to generate the necessary pulses, and the feed log. 1 to pins 2 and 6
translates the output to the log. 0 and stops generating output signals. The signalgram 3 shows what is fed to
the control of this chip. At the same time, the following signal is present at the chip output (on an enlarged
scale along the X axis):

It can be seen how finely “cut” the upper level of the signal by pulses with a frequency of 10 kHz. Do we eat it?
The point is this. The thyristor located in the primary circuit of a power transformer is under high voltage and
galvanic coupling with it is impossible. We do not want to get an electric shock when working with the device?
There are 2 ways of communication: inductive and capacitive. The latter is simple, but is not suitable for
controlling the thyristor due to extreme insecurity. Through the capacitance we will be able to transmit only
one impulse per cycle, and then the capacitance will charge, and cease to pass a direct current. And if the
thyristor does not open? This happens. Another disadvantage is high sensitivity to impulse noise. Besides, the
separation capacitor must somehow be discharged during the absence of a signal, again the problem. In
general, the method is not ours! Another thing - the inductive method of communication using an isolating
transformer. Sometime in times of shortages, rings and other ferrites could not be reached; now, by digging
up the old power supply, a pile of different rings can be removed. The surge protector from the AT power
supply unit is ideal, there are 2 windings of 25 turns each. Here is the finished transformer!
The Ne555 microcircuit, pumps up the primary winding with powerful pulses of 10 kHz frequency, which are
transmitted to the thyristor almost without loss and open it. Galvanic isolation from low-power electronics,
protection from impulse noise, reliable operation, low current consumption. And there are only five parts ...
This is our way;)
The next node (microcircuit) is LM358, containing 2 OU in the case. It follows from the datasheet that this
microcircuit is intended for sound engineering and automation units. Let it be so, but here it is used as a DC
amplifier as a shunt voltage amplifier and comparator of a short circuit protection circuit and a polarity reversal
of the load. The chip is good because it works correctly with unipolar power and has a high stability.
The first LM 358 op-amp is switched on as an FTE and amplifies the voltage drops on the shunt (about 50 mV)
to an operating level of a few volts. The subscript resistor 50k adjusts the gain of the circuit at the maximum
current to eliminate restrictions from the OU. The diode and the output capacitor is the simplest low-pass filter
for converting the pulse voltage taken from the shunt to a direct current to feed the latter through a divider to
the measuring input TL494 and an overload protection comparator.
The second op-amp is a common comparator. When the input voltage 5 is higher than the input 6, the output
voltage appears close to the supply voltage, and in all other cases - zero. This voltage, through a diode,
charges the capacitor very quickly, but the capacitor will be discharged for a long time - 1-2 seconds, which is
enough to block the circuit and turn off the power of the entire device.
The signal of blocking the circuit is fed to the same terminals of the Ne555 microcircuit, as the signal from the
PWM controller, through the diode. High log. the level at pins 2 and 6 causes the microcircuit to stop
generating pulses, the thyristor closes and the voltage disappears at the device output.
The voltage control channel (pin 1 of the TL 494) is necessary in the case of charging low-voltage batteries (3
- 6 V) or charging 1 can of battery (if possible). Indeed, it does not make sense to apply a voltage greater than
the voltage of a rechargeable battery several times. However, it should be noted that without using this
channel, the current limiting channel will do its job perfectly and will not allow more current to be pumped into
the battery than is necessary. In fact, the voltage control channel did more “for beauty”, just as a useful
option, you can easily do without it, by putting pin 1 TL 494 on the case.
A few words about the charging circuit (in the diagram it is highlighted in bold marker). It's all very simple. A
powerful diode bridge is connected to the secondary winding of the power transformer. Parallel to it is a 24-
ohm wire resistor for generating asymmetric current pulses. When the thyristor is closed, current flows from
the battery through this resistor, creating a small discharge current. A 1000 microfarad capacitor is necessary
for the voltmeter to work properly in the charge circuit with no payload — a rechargeable battery. Without a
capacitor on narrow pulses, the volt review will not show correctly. A chain of resistors at 27 Kom, 15 Kom and
1 Kom, as well as a capacitor, is integrated for supplying a voltage signal to the measuring terminal TL 494. As
noted above, it may not be.
The high-voltage part of the device does not contain anything unusual, it is a classic thyristor phase power
regulator used in dimmers and other similar devices. However, in our case, the regulator load is of a reactive
nature (especially at idle and a weak charge current). It should be remembered EMF self-induction winding of
the transformer, which can parasitically affect the cascade of regulation. To reduce the effect of this EMF, the
primary winding of the transformer should be bridged with a small capacitor of 0.022 microfarads, which will
absorb voltage surges at the time of opening the thyristor especially at the beginning of the control curve A
absorb voltage surges at the time of opening the thyristor, especially at the beginning of the control curve. A
0.5 µF capacitor eliminates interference with radio reception that may occur when operating such phase
regulators.
A few words about the measurement of pulse currents and device stability. The fact is that this device
produces a pulsating current at the output, and, depending on the magnitude of the charging current, not only
the width but also the amplitude of these pulses changes. With acceptable accuracy, such currents can be
measured with conventional magnetoelectric devices (a frame with a current in a magnetic field), however,
using electronic measuring devices (based on microcontrollers from the Master Kit sets, etc.), a very significant
measurement error is possible without taking special measures. Similarly, current and voltage stabilization
circuits use the simplest low-pass filter (resistor, capacitor) and introduce significant measurement errors of
the pulsed signal. Details in the scheme are selected so in order to ensure compliance of the actual (stabilized)
charging current with the reading of the switch ammeter in the range of 1 - 10A. However, when trying to
power other active loads (not batteries) from this circuit, there will be a mismatch between the current to be
stabilized and the current to be measured (and voltage too), and the higher the load resistance, the higher the
measurement and stabilization error. The way out is to use specialized chips RMS - DC converters, which
"calculate" the exact value of the EMF of the pulse signal and produce a constant voltage equivalent to the
measured signal. When using such microcircuits in the channels for measuring current and voltage, the charger
can be used as a laboratory power supply unit. However, such improvements will somewhat complicate the
scheme. In this case, it is not necessary because

The signal at the output of the charger - current 5A:

The signal at the output of the charger - current 10A:

Design and details

Possible layout of the device:
Most of the parts can be extracted from faulty AT and ATX power supplies. Deviations of resistors by 20% will
not affect the operation of the circuit. Electrolytic capacitors in the measurement circuits may differ in capacity
by a factor of 2, as well as filter capacitors.
The NE555, TL494 chips can be replaced with “Soviet” analogs, the K561LE5 chip can be replaced with a
similar one from the 176 or 155 series, powering the last + 5V from the output of the ION TL494. Also, you
can find and apply its import counterpart. The dual op-amp chip LM 358 can be replaced with almost any op-
amp capable of operating from a unipolar power supply. Also, you can apply the "Soviet" op amps from the
K140 series, but then you have to take the voltage of –9V somewhere, which is not very convenient.
KT315 transistors any low-power silicon npn, KT815 also any silicon npn transistor of average power. When
using the original relay REN-34 can be used instead of KT815 - KT315, but the latter will warm up. If another
relay is used, the current consumed by the relay coil should be taken into account.
Diode bridges are selected based on current and voltage. The diode bridge in the circuit of the thyristor
KBU6M (1000V, 6A) is torn out of the burnt ATX power supply. The diode bridge power supply of low-power
KTS405 electronics (200V 4A) can be replaced with individual diodes; a diode (100V 1A) after the bridge in
front of a 2000 mKf capacitor can be used with any suitable one. The diode bridge in the charging circuit must
have a double current margin and a fivefold voltage margin. You can apply the "Soviet" diodes D242B, D231A,
etc. in a metal case, but it should be remembered that without radiators, these diodes will not withstand a
current of more than 8A. All diodes that are not marked on the circuit are used by CD 522, 1N4148, etc. any
low-power silicon diodes will do.
Thyristor KU202N can be replaced by T122-25-5, imported BT138 can also be used, but BT151 is no different,
the main thing is that the operating voltage of the device is at least 400V and the current is at least 5A.
Attention! The use of a triac (dual thyristor) in this scheme is not allowed!
Electrolytic capacitors of any type, normal - also, the main thing is to match the operating voltage and
capacitance indicated in the diagram.
The REN 34 relay was torn out of the "Soviet" low-frequency amplifier - there it was used to protect the
acoustics from overloads. You can use any relay, the main thing is that its winding works from 12V, and the
contacts withstand current up to 15A. You can apply two separate relays - there is no difference. Napimer,
starter relays from VAZ cars will do. In this case, the relay coils should be bridged with a diode to suppress the
self-induction currents when the relay is released.
Transformer TP1 TVK110 torn from the "Soviet" black and white TV (yes, such rarities are still found in the
open spaces of our country), but later replaced by a more compact Chinese adapter from the ancient Zyxel
modem. Transformer requirements: no-load voltage 15 ... 18V load current 0.3A. The choice is very wide.
The TP2 OSM-1-0.16 220-24 transformer is ideally suited for this circuit. Good powerful iron, high-quality
winding, in a word - what you need. Unfortunately, the copy I had at the output gave 42V instead of 24V,
which is obviously a lot. I had to unwind the secondary winding, double the wire and wind the winding with a
smaller number of turns. It turned out that the secondary winding contains 44 turns with two (not twisted!)
Parallel wires with a diameter of 1 mm. As practice has shown, this was not enough. We had to wind three
wires. At a current of 10A, the transformer heats up, however, already at 6A it is slightly warm. Summary: the
transformer must be at least 180-200 W of power, the secondary winding must be wound with a wire with a
diameter of at least 2 mm (better - 2.5 ... 3 mm) and output an open circuit voltage of 24 - 26V. Such a
transformer with a current of 10A will not be heated at all.
Transformer TI can be used ready - suitable choke from the mains filter of the power supply AT. If there is no
such choke - on a suitable ferrite ring with an outer diameter of 18-25mm, with MGTF wiring or the like, two
windings with the number of turns are wound 25. Twisting the wires of the windings with "pigtail" is not
necessary. The ends of the windings are fixed with glue. It is advisable to wrap the transformer with varnished
cloth and glue it with BF glue or varnish. Before installing the transformer in the circuit should be phased -
ipmuls of positive polarity coming to the primary winding should induce in the secondary winding also a pulse
of positive polarity, which should be fed to the control electrode of the thyristor.
Variable resistors 10 - 15 kOhm of any design and power, as long as they were the group "A". Allowed group
"C", but not "B"! The fact is that the characteristic of the phase regulator is non-linear, therefore the resistor of
group “B” will greatly complicate the precise setting of the current close to the maximum value. The device
uses ceramic wire variable resistors SP-B at 15 Kom, but this does not mean that it is necessary to install such
Measuring devices - a voltmeter and an ammeter in the charging circuit - switchboard DC magnetoelectric
devices, for example from the M42 series. The ammeter must have a shunt at 10A.
On / off button of any design with two contact groups, and one of the groups is normally closed. The inclusion
lamp can be combined with the button - so visually and conveniently.
The terminals of the charging circuit, the fuse holders and the fuses themselves of any design. Attention!
Installing fuses in the circuit is required! Operating the device without fuses may cause a fire!
The hull of any design. Be sure to have holes for transformer cooling. It is also a pity to install a cooler, which
can be torn out from the same AT or ATX power supply. Diode bridge charging circuit is pathetic to install on
the radiator. You can use a radiator from an AT or ATX power supply.
Important note. Measuring shunt is desirable to apply the factory design, the use of a homemade shunt is
extremely undesirable because its parameters will be unstable! Instead of a shunt at 20A, you can apply a
shunt at 50A, the gain margin at the op amp is enough. It is unacceptable to use a shunt at 15A and below. at
the maximum charging current, it will warm up.
With regard to installation, the charging circuit should be made of thick stranded copper wire with a diameter
of at least 2.5 mm to reduce losses. With a cable length of 2.5 m, the total chain length is 5 m. When using a
wire with a diameter of 2 mm, the voltage drop at a current of 10A in this circuit was about 2V, which is clearly
a lot! Therefore, the diameter of the wires was increased to 4 mm, the voltage drop at a current of 10A was
only 0.75V, which is quite acceptable.
The installation of the high-voltage part of the device must be carried out in accordance with all the
requirements of the electrical safety rules of power electrical installations, all connections must be carefully
insulated, and high-voltage wires must not pass through the wiring with low-voltage wiring. High-voltage wires
must be the same color, for example - red.
The transformer and the device blocks must be firmly and securely fastened inside the device case to prevent
them from touching each other, pressing the wiring, etc.
Installation of the low-voltage electronics unit should be done carefully. You can dilute and make a printed
circuit board, but it is enough to apply a standard development board of 50x80 mm in size - there are not
many details in the scheme, such a board will be more than enough.

Establishment of the device The

assembled device, in the absence of errors in the installation and serviceability of parts, begins to work
immediately. It is required to “drive” the charging current to the desired values, configure the current
protection node, possibly adjust the divider in the output voltage setting channel.
Before first switching on the device, it is necessary to once again check the correctness of installation, the
absence of short circuits, check the correctness of the connection of transformers, thyristor, measuring
instruments. The engines of all variables and trimming resistors should be set to the average position in the
scheme. Connect the load (battery) is not necessary.
When you press the power button should click the relay and turn on the warning lamp. It is necessary to
immediately check the voltage at the control points of the circuit, watch the oscilloscope signals at the points
"A" - "G", they should be similar to the reduced waveforms. If the output voltage appears - you should see the
signal also at the output.
If the circuit is started and everything works fine (the parts are not heated), you can proceed to the initial
installation of the charging current. Temporarily solder the top output of the variable resistor for adjusting the
charge current from the circuit, and solder it to the + 9V power bus. By rotating the variable resistor engine
we make sure that the width of the control pulses at the output of the PWM controller changes smoothly from
minimum to maximum. The signal at the output of the device will also vary. You can connect a 12V 21W lamp
to the device's output to make sure that the brightness of the lamp changes when the pulse width is adjusted.
The next step is to calibrate the maximum current of the device. Set the variable resistor current adjustment
in a position in which it is possible to obtain the narrowest pulse (minimum power). The conclusions of the
device are short-circuited. We measure the current - it should be about 1A. Then, we connect an oscilloscope
to the output of the LM358.1 and gradually increases the current to 10A. We look at the waveform. At the
maximum current there should be no restrictions on the part of the OS - the pulses should be approximately
the same as they are shown on the waveforms 6 and 7. The amplitude of these pulses should be about 5V. By
setting the trimming resistor to 50 kΩ, we set the required pulse amplitude or achieve no restrictions. The
f
output current of 10A will be the maximum that the device must output.
We return the output of the variable resistor to its place. We install the resistor-adjusting motor of the charge
current to the upper position, leave the output terminals shorted, turn on the power. The current should rise
sharply to 10A and then immediately drop to 0.7 - 1A. If this does not happen, the current remains high. It is
necessary to check the correct installation of the circuit, especially the LM358, check the shunt, and once again
check the operation of the PWM controller. Having achieved the stabilization of the current, the device can
already be used to charge the batteries. In the presence of LATR, it is desirable to check the quality of the
stabilizer. Turn on the device through LATR, set the current 1 - 4 A and change the voltage from 180 to 270V,
the output current will vary by 5 - 10%.
Check and debug the voltage channel is similar to the current channel. The voltage setting channel is simpler -
there is no op-amp, the signal from the output of the device through the RC chain and the divider is
immediately fed to the TL494. Such a simple scheme does not require any debugging.
Debugging of the protection circuit is reduced to installing a variable resistor at a given maximum load current
(in this case, about 10A) at which the charger turns off. You can set both smaller and greater current - it
depends on the power of the power transformer, diode bridge, the maximum current of the ammeter in the
charging circuit. For most batteries, 8A is sufficient. Attention! The protection current must be set when the
charger terminals are short-circuited or when the battery is connected, the appropriate capacity. It is not
allowed to use active load (high-power lamps, wire resistors, etc.). When the current protection 10A battery
should have a capacity of at least 80 - 100A / h. In the absence of a suitable battery, the terminals of the
device can be temporarily short-circuited and set the maximum charging current, and then the protection
current.

All questions in the Forum .

Me gusta 9 Нравится 0

Заказать печатную платy

Размеры платы Количество

Длина x Ширина мм Выбор количества (шт.)

Количество слоев Толщина

2 слоя 1.6мм

Рассчитать сейчас Получите купон на $5.0

How do you like this article? Did this device work for you?

119 3 20 7 one five

 Yandex.Direct Yandex.Direct Yandex.Direct

Konasil K-200, K- Kenshu - Kenshoo

300 Bid management tool. Bid managment
tool.
Pyrogenic silicon dioxide (fumed silica)
Konasil from a warehouse in Moscow

Amalgam UV lamps

To learn more silica.su To learn more kenshoo.com To learn more j-uv.ru

The performance of the site has been tested in browsers:

IE8.0, Opera 9.0, Netscape Navigator 7.0, Mozilla Firefox 5.0
Adapted to work at screen resolutions from 1280x1024 and higher.
At lower resolutions, horizontal scrolling may occur.
For any questions please contact Kota: kot@radiokot.ru
© 2005-2019