Total solder points: 150

Skill level :
Beginner 1o 2o 3þ 4o 5o Advanced

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

ILLUSTRATED MANUAL H8012P-ED1

 5% 1% COLOR= 2… 5

4K7= ( 4 - 7 - 2 - B ) 4K7= ( 4 - 7 - 0 - 1 - 1 )
I P E SF S DK N D GB F NL
C CODICE CODIGO CODIGO VÄRI FÄRG FARVE FARGE FARB COLOUR CODIFI- KLEUR C
SCHEMA KODE KODE CODE CATION KODE
O COLORE DE DE COL- KOODI KODE O
DES
D CORES ORES COU- D
E LEURS E

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
__________________________________________________________________________________________________________________________________________________________

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.

0.0
For some projects, a basic multi-meter is re- 00
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.

3
_______________________________________________________________________________________________________________________________________________________

1.3 Soldering Hints :

Mount the component Make sure the solder Trim excess leads as
against the PCB surface joints are cone-shaped close as possible to the
and carefully solder the and shiny solder joint
leads

4
__________________________________________________________________________________________________________________________________________________________

AXIAL COMPONENTS ARE q R2: 27K (2 - 7 - 0 - 2 - 1)

TAPED IN THE CORRECT q R3: 120K (1 - 2 - 0 - 3 - 1)
MOUNTING SEQUENCE ! q R4: 180K (1 - 8 - 0 - 3 - 1)
START 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)
REMOVE THEM FROM THE TAPE q R16: 10K (1 - 0 - 3 - B)
ONE AT A TIME ! q R17: 1M (1 - 0 - 5 - B)
q R18: 680 (6 - 8 - 1 - B)
1. JUMPER WIRES 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 J1 q R28: 2K2 (2 - 2 - 2 - B)
q J2
q J3
3. ½W RESISTORS
2. ¼W RESISTORS

R...

q R29: 1.5 (1 - 5 - B - B - 9)
q R1: 47K (4 - 7 - 0 - 2 - 1) q R30: 1.8 (1 - 8 - B - B - 9)
q R31: 2.2 (2 - 2 - B - B - 9)

5
_______________________________________________________________________________________________________________________________________________________

6. TRANSISTORS
4. DIODES (Watch the polarity!)

D...
CATHODE

q D1: 1N4148
q D2: 1N4148 q T1: BC547
q D3: 1N4148 q T2: BC547
q D4: 1N5400 …1N5408 q T3: BC547
q D5: 1N5400 …1N5408 q T4: BC547
q D6: 1N5400 …1N5408 q T5: BC547
q D7: 1N5400 …1N5408 q T6: BC557
q D8: 1N5400 …1N5408
7. VOLTAGE REFERENCE

5. IC SOCKET (Watch the posi-

tion of the notch !)

VR...

q IC1 : 14P
q VR1: LM385Z2.5

8. TERMINAL BLOCKS

q SK1: 2P
q SK2: 2P

6
__________________________________________________________________________________________________________________________________________________________

9. SWITCHES 12. LEDS (Watch the polarity!)

SW...

COLOUR=2...5

q SW1: SINGLE POLE (ON-ON)

q SW2: SINGLE POLE (ON-ON)
CATHODE
10. ELECTROLYTIC CAPACI- CATHODE
LD...
TORS (Watch the polarity!)

C...

q LD1: 3mm LED RED (2)

q LD2: 3mm LED RED (2)
q C1: 2µ2 q LD3: 3mm LED YELLOW (4)
q C2: 4700µ/35V q LD4: 3mm LED GREEN (5)

11. POWER TRANSISTOR 13. IC (Watch the position of the

M4 NUT
notch!)
LOCK WASHER

TRANSISTOR

HEATSINK
q IC1: LM324, LM224

PCB

M4 BOLT

q T7: MJ3001, MJ4035, BDX87,

2N6057, 2N6058, 2N6059,
2N6283, 2N6284 or EQ.

7
_______________________________________________________________________________________________________________________________________________________

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.

13.6V=
K8012 Vdc

ON
L AC +

AC POWER ACCU

N AC -

12V

Put SW2 in the 12V position. Measure the voltage across the output termi-
nals. Output voltage should be 13.6V +/- 0.2V.
6.8V=
K8012 Vdc

ON
L AC +

AC POWER ACCU

N AC -

6V

8
__________________________________________________________________________________________________________________________________________________________

Put SW2 in the 6V position. Measure the voltage across the output termi-
nals. Output voltage should be 6.8V +/- 0.2V
14.7V=
K8012 Vdc

ON
L AC +

33 Ω
AC POWER ACCU

N AC -

>4Ah 12V

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
7.3V=
K8012 Vdc

ON
L AC +
Ω

AC POWER ACCU
33

N AC -

>4Ah 6V

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

1A=
K8012 Adc

10A

ON
L AC + 8.2 Ω

AC POWER ACCU

N AC -

>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 1A +/- 0.1A.

9
_______________________________________________________________________________________________________________________________________________________

0.3A=
K8012 Adc

10A

ON
L AC + 8.2 Ω

AC POWER ACCU

N AC -

<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.

10
__________________________________________________________________________________________________________________________________________________________

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

K8012

ON/OFF
Fuse
L AC +
0.25A Slow R1823A/B
9V

AC POWER ACCU
9V
N AC -
25VA TRANSFORMER

- +

ACCU

11
12
STRAIN RELIEF BUSHING

M3 LOCK WASHER
AC INLET M3 NUT
16. ASSEMBLING

10mm M3 BOLT

VELLEMAN P8012'1 LEAD-ACID BATTERY CHARGER

TRANSFORMER
2x9V/25VA

SOLDER
c
10mm M3 BOLT RED
e
M3 NUT
M3 WASHER T7 b

BOTTOM c

BLACK

D7 C1 R15 R21
AC R16

SK1
R8
D6 R17 R20
R18

D8

R9
D5 T4 J2 R19

R10
D4 C2

ACCU
VR1 R11
R29
1 IC1 R26

R28
SK2
R30
R31 R27

D1
30mm M3 BOLT

R12
R13
R14
R22

R7

R1
R2
R3
R4
R5
R6
BATTERY J3 M3 NUT
CAPACITY

R25
T3 T6
SELECT PCB
VOLTAGE R23 T5

D2
D3
SELECT
R24 END OF CHARGE
</>4Ah SW1 SW2
T1 T2 20mm SPACER
J1 WRONG LD1 LD2 LD3 LD4

6/12V
POLARITY CHARGE STANDBY
CHARGE

BOTTOM

ON/OFF SWITCH
_______________________________________________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________________________________________

17. DRILL PATTERN ENCLOSURE ‘TKAUS22G’

38
,5
Ø3
,5
Ø3
,5
Ø3

,5
Ø3

CUT

,5 ,5

133,5
Ø3 Ø3

24,5 13
73

90 9
Ø
,5 3,5
Ø3
12,5

BOTTOM

20 REAR PANEL 36,5 20

1 5
Ø1 Ø
3,
32

,5
Ø3
33

27,5 24,5
17

20 FRONT PANEL 17,5 17,5 11 10 10 25,5

2
Ø1

6,5 ,5
Ø Ø6

Ø3 Ø3 Ø3 Ø3
33

27,5

21,5

All distances are expressed in mm

13
_______________________________________________________________________________________________________________________________________________________

18. PCB LAYOUT

VELLEMAN P8012'1 LEAD ACID BATTERY CHARGER

T7 b

D7 C1 R15 R21
SK1

AC R16
R8

D6 R17 R20
D8

R18
R9

D5 T4 J2 R19
R10

ACCU

D4 C2
+

VR1 R11
R29
SK2
R28

R30 1 IC1 R26

R27
D1

R31
R12
R13
R14

-
R7
R1
R2
R3

R4
R5
R6

R22
R25

BATTERY J3
CAPACITY
T3 T6
SELECT
VOLTAGE R23 T5
D2
D3

SELECT
R24 END OF CHARGE
6/12V

</>4Ah SW1 SW2

T1 T2
J1 WRONG LD1 LD2 LD3 LD4
POLARITY CHARGE FLOAT
CHARGE

14
 19. DIAGRAM

AC
1N5400 1N5400
1N5400 LEAD-ACID BATTERY
D4 D6 T7 D8

+
-
18V/1.3A MJ3001
E1 R20
D5 D7 C1 R10 R1 R3 6/12V 10K
1N5400 1N5400 2u2 10K 47K 120K
LED3Y
AC FLOAT CURRENT LIMIT (0.1C) I<0.007C
R9 T4 CHARGE LD3 R16 END OF
1K 10 10K CHARGE
BC547B 6V 8
SW2 A3 9 R21 R15 R17
R23 10K 33K 1M
1/4 LM324
R8 2K2 0.7V 1/4 LM324
1K5 2 4 R13 R2 12V R4 R6 R14 50mV
R11 10K 27K 180K 270K 10K 12
1
3 A1 T6 R26 R27 A4
13 14
4K7
1/4 LM324
R12 1M 1K OPEN: < 4Ah (Imax=0.3A) 11
D1 1K 1N4148 BC557B
A1...A4 = IC1 T5 5 CLOSE: > 4Ah (Imax=1A)
C2 1N4148 D3 T2 R7
1N4148 BC547B 7
4700u/35V VOLTAGE REGULATOR R22
A2 6 R28
D2 10K SW1
T3 R24 2K2
BC547B 1/4 LM324 220K
BC547B 2K2 R19 R31 R30 R29 R18
T1 R5 130mV R25 15K 2.2/0.6W 1.8/0.6W 1.5/0.6W 680
12K LED3G
LD1 LED3R I<0.02C
10K
VR1 BC547B LD2 Vo→ 7.35 → 6.85 LD4
LM385-2.5 LED3R Vo→14.7 →13.6
END OF CHARGE
WRONG POLARITY CHARGE
__________________________________________________________________________________________________________________________________________________________

15