555 Contest Entry

NiCd Battery Rejuvenator

David Ashton

v1.1

Disclaimer: NiCd batteries can be dangerous when overcharged and can source large currents if incorrectly connected. Do not attempt to build this circuit unless you have some experience building electronic circuits and can ensure that the circuit is working correctly. I have recently had access to a large number of oldish NiCd batteries. Most of them are good, so I can use them in torches and other projects. However, the odd bad one turns up which shows as shorted and cannot be charged. This is due to whiskers of cadmium which grow across the electrodes and short them out, and happens when batteries are left discharged for long periods. A quick zap at around 10-20 times the usual charge rate will usually burn out these whiskers and restore the battery to normal operation, but often when this is done, the battery rapidly returns to its shorted state. If a NiCd battery has a capacity C, you would usually charge it at 0.1C, or maybe higher up to 0.3 C - if you limit the charge by time or battery temperature rise. Obviously a sustained charge at 1-2 C is not a good idea. What can be done is to zap the battery at around 2 C for a short time say 5 - 10 seconds and then discharge it at a slower rate (around 0.1 0.2 C) until it discharges to about 1.1 volts just under the nominal voltage of 1.2 Volts, and repeat this process many times. There are two requirements here a timed charge and a voltage detection to end discharge. A 555 can do both, and is ideal for a simple Battery rejuvenator design. The battery receives a zap charge at 2 C for 5-10 seconds. It is then discharged at 0.1 C until the voltage reaches 1.1 V, at which point it receives another timed zap, and the process repeats itself. Fig 1 Battery rejuvenator circuit diagram Suggested Values D1 1N4148 / 1N4001 T1 Si NPN 100mA R1 220 470 K For 1-2 AH Battery Rc 1 Ohm 5W Rd 12 Ohms 1W BUT Battery Under Test (NiCd cell) RV1 should be adjusted for 2.2 volts on pin 5. This will make the 555 trigger when Pin 2 goes below 1.1 volts. RLA is normally off and the Battery Under Test (BUT) will discharge through Rd (selected for I = 0.1 0.2 C) until the voltage gets below 1.1 volts. The 555 will then trigger and operate Relay RLA for a period determined by R1 and C1, this should be about 10 seconds. When RLA operates, the BUT will charge at a rate determined by Rc, which should be for a current of about 2C of the battery, at about 3 Volts. When the timer times out, RLA is restored to the discharge position and will remain so until the battery voltage falls below 1.1 again. The 5V supply should be capable of supplying in excess of 3C of the battery if Rc is 1 Ohm this would be at least 3 Amps. Alternatively, a 12V battery may be used, and the top end of Rc should be connected to the 12V positive, and it should be dimensioned to give a current of around 2C of the battery at around 10 volts. The remainder of the circuit should be powered from a 5V 3-terminal regulator (7805). Page 1

Notes: 1. R1 is the timing resistor and should be selected for a charge time of 4-10 seconds. Because the timing comparator voltages have been altered by RV1, the timing values may not be exactly as per the 555 datasheet. 2. Rc should be rated as if it constantly has 5V on it in the case of the suggested 1 Ohm, it should be rated at 5 Watts. This will happen if the battery is completely shorted and unrecoverable. Rc can be calculated as follows:

3. The Hold switch on the reset pin is not strictly necessary, but is useful to stop the charge relay operating while you are changing batteries. When Pin 4 (Reset) of the 555 is held to negative supply, the relay will not operate. The switch and R4 may be omitted. 4. R3 and C2 give a short time constant to the battery voltage into the Trig pin. Without them, false retriggering may take place when the relay releases. 5. The 555 is capable of driving the relay directly, however the 555 at 5V supply will only source around 3.5V, and driving it through a transistor helps prevent retriggering. Dont omit the catch diode D1 it can be a 1N4148 or a 1N4001 it catches the back EMF of the relay which could otherwise destroy the circuit. T1 can be almost any Silicon NPN Transistor, it should be rated for a collector current of at least 100 mA. You may also connect an LED in series with a 1K resistor between 555 pin 3 and the 0V line to show when the circuit is charging the NiCd cell. 6. Initially the discharge period will be very short and on a completely shorted battery the 555 will keep retriggering constantly. However if the battery is recoverable, after a few cycles the discharge time should increase to a few seconds, and eventually to 30-60 seconds. The voltage on charge will usually be above 2 Volts, but will reduce to 1.3 1.4 V as soon as the charge is removed. It will then discharge slowly to 1.1 V at which point the 555 will trigger and give it another zap of charge. Half an hour of this is usually enough to rejuvenate a battery, after which it should be given a full normal charge (14 Hours at 0.1C). 7. NiCd batteries have a memory effect and dont like being partially discharged and then topped up. Once every month or two give them a full discharge and then a full charge. This helps avoid them going short-circuit and keeps them able to hold a full charge. 8. This circuit is intended to work on one cell at a time only. However there is no reason why (with adjustments to the circuit values) it could not work with battery packs. The supply voltage would have to be increased (to above 2.5V x number of cells) and the charge current should be limited to around 1C max. However it is much preferable to work on one cell at a time if several cells are subjected to the same charge they will discharge at different rates and some may end up being reverse charged. If you use crocodile (alligator in the US!) clips you can connect to one cell of a pack at a time.

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Full Parts list R1 R2 R3 R4 Rc Rd C1 C2 D1 RLA1 IC1 T1 Hold 220K to 470 K Select for charge time of +/- 5 Seconds 1Kohm, watt 1Kohm, watt 1Kohm, watt Charge Resistor, 1 Ohm 5 Watts is ok for most AA and C cells, see text. Discharge resistor, 12 Ohms 1 Watt is ok for most AA and C cells, see text. 22 uF, 10 V or more, Tantalum or electrolytic 2.2 uF, 10 V or more, Tantalum or electrolytic 1N4148 or 1N 4001 Silicon diode Relay, 5-10 Amp Single Pole Changeover contacts, 5 V coil 555 Timer Silicon Transistor with Ic (Collector Current) rating of 100 mA min Single pole switch (use Normally open contacts)

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