Velleman K8012 Intelligent Lead Acid Battery Charger Instructions
- June 12, 2024
- Velleman
Table of Contents
Velleman K8012 Intelligent Lead Acid Battery Charger
Features & Specifications
Features:
- Suitable for 6V and 12V sealed and open lead-acid batteries.
- Fully automatic charge and maintenance cycle.
- Status indicators for charge, float and end-of-charge
- Protected against polarity reversal
Specifications:
- Power Supply: 2 x 9V/25VA
- Charge current: 0,3 or 1A selectable
- Dimensions (wxdxh): 97 x 140 x 41mm / 3,8 x 5,5 x 1,6″
Not suitabel for non-rechargeable or NiCd/NiMH batteries!
Options:
- Transformer prim. 230V – sec. 2x9V/25VA: 2090250MST
- Enclosure: TKAUS22G
- Power cord: NETSNOER
Assembly
Assembly (Skipping this can lead to troubles ! )
Ok, so we have your attention. These hints will help you to make this project
successful. Read them carefully.
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 enables 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 cannot 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.
For some projects, a basic multi-meter is required, or might be handy:
Assembly Hints:
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Make sure the skill level matches your experience, to avoid disappointments.
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Follow the instructions carefully. Read and understand the entire step before you perform each operation.
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Perform the assembly in the correct order as stated in this manual
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Position all parts on the PCB (Printed Circuit Board) as shown on the drawings.
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Values on the circuit diagram are subject to changes.
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Values in this assembly guide are correct*
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Use the check-boxes to mark your progress.
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Please read the included information on safety and customer service
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Typographical inaccuracies excluded. Always look for possible last minute manual updates, indicated as ‘NOTE’ on a separate leaflet.
Soldering Hints:
- Mount the component against the PCB surface and carefully solder the leads.
- Make sure the solder joints are cone-shaped and shiny.
- Trim excess leads as close as possible to the solder joint.
REMOVE THEM FROM THE TAPE ONE AT A TIME!
Construction
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 multimeter.
- Put SW2 in the 12V position. Measure the voltage across the output terminals. Output voltage should be 13.6V +/- 0.2V.
- Put SW2 in the 6V position. Measure the voltage across the output terminals. Output voltage should be 6.8V +/- 0.2V.
- Put SW2 in the 12V position, put SW1 in the >4Ah position. Connect the supplied 33Ω/5Ω resistor to the output terminals. Measure the voltage across the resistor. It should read 14.7V +/- 0.1V.
- Put SW2 in the 6V position, put SW1 in the >4Ah position. Connect the supplied 33Ω/5Ω resistor to the output terminals. Measure the voltage across the resistor. It should read 7.3V +/- 0.1V.
- Put SW2 in the 12V position, put SW1 in the >4Ah position. Connect the supplied 8.2Ω resistor in series with the multimeter. Switch the multimeter to the ‘10A DC’ – position. It should read 1A +/- 0.1A.
- Put SW2 in the 12V position, put SW1 in the >4Ah position. Connect the supplied 8.2Ω resistor in series with the multimeter. Switch the multimeter to the ‘10A DC’ – position. It should read 1A +/- 0.1A.
If any of the measurements show a considerable difference with the reference values, please recheck the entire assembly, and pay special attention to resistor values.
Optional enclosure
Building into an optional enclosure
Figure 7 & 8 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 diameter. Make sure all holes are free of burrs.
Degrease the front panel before sticking the label onto it. The label edges
will need to be trimmed with a sharp cutter.
Connection & Use
Connection: The unit can be connected as shown on figure
10.
Make sure your assembly complies with the local safety regulations. For improved safety, use a non-conductive enclosure.
Use: perform the necessary settings before you hook-up the battery to the unit:
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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
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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.
Operation & troubleshooting
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 voltage
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 current 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 defective battery, a too low charge current setting, or a battery
with a too large capacity.
PCB
Schematic diagram
VELLEMAN Components NV
Legen Heirweg 33
9890 Gavere
Belgium Europe
www.velleman.be
www.velleman-kit.com
Modifications and typographical errors reserved
© Velleman Components nv.
H8012IP – 2005 – ED1
References
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>