Total solder points: 150

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


ILLUSTRATED MANUAL H8012P-ED1

INTELLIGENT LEAD ACID BATTERY CHARGER
K8012

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
Simply connect and forget

Specifications :
Charge current : 0.3 or 1A selectable
Power supply : 2x9V/25VA (our type 2090250MST)
Dimensions (wxdxh): 97 x 140 x40mm / 3.8x 5.5x1.6
Not suitable for non-rechargeable or NiCd/NiMH batteries
modifications reserved

Options :
Transformer prim. 230V - sec. 2x9V/25VA: 2090250MST
Enclosure: TKAUS22G
Power cord: NETSNOER








5%
4K7= ( 4 - 7 - 2 - B )

1%
4K7= ( 4 - 7 - 0 - 1 - 1 )

COLOR= 2 5

I P E SF S DK N D GB F NL
C
O
D
E

CODICE
COLORE
CODIGO
DE
CORES
CODIGO
DE COL-
ORES
VRI
KOODI
FRG
SCHEMA
FARVE
KODE
FARGE
KODE
FARB
KODE
COLOUR
CODE
CODIFI-
CATION
DES
COU-
LEURS
KLEUR
KODE
C
O
D
E
0 Nero Preto Negro Musta Svart Sort Sort Schwarz Black Noir Zwart 0
1 Marrone Castanho Marrn Ruskea Brun Brun Brun Braun Brown Brun Bruin 1
2 Rosso Encarnado Rojo Punainen Rd Rd Rd 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 Vihre Grn Grn Grnn Grn Green Vert Groen 5
6 Blu Azul Azul Sininen Bl Bl Bl Blau Blue Blue Blauw 6
7 Viola Violeta Morado Purppura Lila Violet Violet Violet Purple Violet Paars 7
8 Grigio Cinzento Gris Harmaa Gr Gr Gr Grau Grey Gris Grijs 8
9 Bianco Branco Blanco Valkoinen Vit Hvid Hvidt Weiss White Blanc Wit 9
A Argento Prateado Plata Hopea Silver Slv Slv Silber Silver Argent Zilver A
B Oro Dourado Oro Kulta Guld Guld Guldl Gold Gold Or Goud B

__________________________________________________________________________________________________________________________________________________________

3
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.


For some projects, a basic multi-meter is re-
quired, or might be handy


1.2 Assembly Hints :

Make sure the skill level matches your experience, to avoid disappointments.
Follow the instructions carefully. Read and understand the entire step before
you perform each operation.
Perform the assembly in the correct order as stated in this manual
Position all parts on the PCB (Printed Circuit Board) as shown on the drawings.
Values on the circuit diagram are subject to changes.
Values in this assembly guide are correct*
Use the check-boxes to mark your progress.
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.








0
.
0
0
0


_______________________________________________________________________________________________________________________________________________________


4
1.3 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





__________________________________________________________________________________________________________________________________________________________

5
AXIAL COMPONENTS ARE
TAPED IN THE CORRECT
MOUNTING SEQUENCE !
START

REMOVE THEM FROM THE TAPE
ONE AT A TIME !

1. JUMPER WIRES

q J1
q J2
q J3


2. W RESISTORS

R...

q R1: 47K (4 - 7 - 0 - 2 - 1)

q R2: 27K (2 - 7 - 0 - 2 - 1)
q R3: 120K (1 - 2 - 0 - 3 - 1)
q R4: 180K (1 - 8 - 0 - 3 - 1)
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)
q R16: 10K (1 - 0 - 3 - B)
q R17: 1M (1 - 0 - 5 - B)
q R18: 680 (6 - 8 - 1 - B)
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 R28: 2K2 (2 - 2 - 2 - B)


3. W RESISTORS


q R29: 1.5 (1 - 5 - B - B - 9)
q R30: 1.8 (1 - 8 - B - B - 9)
q R31: 2.2 (2 - 2 - B - B - 9)


_______________________________________________________________________________________________________________________________________________________


6

4. DIODES (Watch the polarity!)

D...
CATHODE

q D1: 1N4148
q D2: 1N4148
q D3: 1N4148
q D4: 1N5400 1N5408
q D5: 1N5400 1N5408
q D6: 1N5400 1N5408
q D7: 1N5400 1N5408
q D8: 1N5400 1N5408



5. IC SOCKET (Watch the posi-
tion of the notch !)

q IC1 : 14P

6. TRANSISTORS

q T1: BC547
q T2: BC547
q T3: BC547
q T4: BC547
q T5: BC547
q T6: BC557

7. VOLTAGE REFERENCE
VR...

q VR1: LM385Z2.5

8. TERMINAL BLOCKS

q SK1: 2P
q SK2: 2P


__________________________________________________________________________________________________________________________________________________________

7
9. SWITCHES
SW...

q SW1: SINGLE POLE (ON-ON)
q SW2: SINGLE POLE (ON-ON)

10. ELECTROLYTIC CAPACI-
TORS (Watch the polarity!)
C...

q C1: 22
q C2: 4700/35V

11. POWER TRANSISTOR
M4 NUT
M4 BOLT
LOCK WASHER
TRANSISTOR
HEATSINK
PCB

q T7: MJ3001, MJ4035, BDX87,
2N6057, 2N6058, 2N6059,
2N6283, 2N6284 or EQ.

12. LEDS (Watch the polarity!)
COLOUR=2...5
LD...
CATHODE
CATHODE



q LD1: 3mm LED RED (2)
q LD2: 3mm LED RED (2)
q LD3: 3mm LED YELLOW (4)
q LD4: 3mm LED GREEN (5)

13. IC (Watch the position of the
notch!)

q IC1: LM324, LM224

_______________________________________________________________________________________________________________________________________________________


8
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.

N - AC
12V
ON
L
AC POWER
AC
Vdc
K8012
ACCU
+
13.6V=

Put SW2 in the 12V position. Measure the voltage across the output termi-
nals. Output voltage should be 13.6V +/- 0.2V.
N - AC
6V
ON
L
AC POWER
AC
Vdc
K8012
ACCU
+
6.8V=


__________________________________________________________________________________________________________________________________________________________

9
Put SW2 in the 6V position. Measure the voltage across the output termi-
nals. Output voltage should be 6.8V +/- 0.2V
N - AC
ON
L
AC POWER
AC
Vdc
K8012
ACCU
+
14.7V=
12V >4Ah
3
3

Put SW2 in the 12V position, put SW1 in the >4Ah position. Connect the
supplied 33/5W resistor to the output terminals. Measure the voltage
across the resistor. It should read 14.7V +/- 0.2V
N - AC
ON
L
AC POWER
AC
Vdc
K8012
ACCU
+
7.3V=
6V >4Ah

3
3

Put SW2 in the 6V position, put SW1 in the >4Ah position. Connect the
supplied 33/5W resistor to the output terminals. Measure the voltage
across the resistor. It should read 7.3V +/- 0.2V

N - AC
ON
L
AC POWER
AC
Adc
K8012
ACCU
+
1A=
10A
12V >4Ah
8.2

Put SW2 in the 12V position, put SW1 in the >4Ah position. Connect the
supplied 8.2 resistor in series with the multi-meter. Switch the multi-meter
to the 10A DC -position. It should read 1A +/- 0.1A.

_______________________________________________________________________________________________________________________________________________________


10
L
N
AC POWER
AC
AC
+
-
ACCU
K8012
ON
0.3A=
Adc
10A
8.2
<4Ah 12V

Put SW2 in the 12V position, put SW1 in the <4Ah position. Connect the
supplied 8.2 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.


__________________________________________________________________________________________________________________________________________________________

11
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

R1823A/B
ON/OFF
0.25A Slow
Fuse
L
N
AC POWER
9V
9V
AC
AC
+
-
ACCU
ACCU
- +
K8012
25VA TRANSFORMER








_______________________________________________________________________________________________________________________________________________________


12
16. ASSEMBLING
R 2 5
A
C
R 8
b
e
c
c
S K 1
R 3
V
R
1
T
3 R 9
R 1 3
R
1
1
R 1 2
T
4
R
2
6
R
2
7
R
2
4
R
2
3
R
1
5
R
2
2
R 7
R
1
9
I
C
1
1
D
5
D
4
C
2
D
7
D
6
S
W
1
S
W
2
R
3
1
R
3
0
R
2
9
L
D
1
L
D
2
L
D
3
L
D
4
C
1
D 1
D 2
D 3
T
1
T
2
R 5
R 4
R 6
R 2
R 1
T
5
T
6
R
1
8
R
1
7
R 2 8
R
2
1
S K 2
-
R 1 4
R 1 0
D 8
6 / 1 2 V
<
/
>
4
A
h
E
N
D

O
F

C
H
A
R
G
E
C
H
A
R
G
E
S
T
A
N
D
B
Y
P
O
L
A
R
I
T
Y
W
R
O
N
G
+
A C C U
V
E
L
L
E
M
A
N

P
8
0
1
2
'
1

L
E
A
D
-
A
C
I
D

B
A
T
T
E
R
Y

C
H
A
R
G
E
R
V
O
L
T
A
G
E
S
E
L
E
C
T
S
E
L
E
C
T
C
A
P
A
C
I
T
Y
B
A
T
T
E
R
Y
J
2
J
3
T
7
C
H
A
R
G
E
R
2
0
R
1
6
J
1
M
3

N
U
T
2
0
m
m

S
P
A
C
E
R
P
C
B
B
O
T
T
O
M
3
0
m
m

M
3

B
O
L
T
S
O
L
D
E
R
R
E
D
B
L
A
C
K
M
3

L
O
C
K

W
A
S
H
E
R
1
0
m
m

M
3

B
O
L
T
M
3

N
U
T
A
C

I
N
L
E
T
T
R
A
N
S
F
O
R
M
E
R
2
x
9
V
/
2
5
V
A
O
N
/
O
F
F

S
W
I
T
C
H
S
T
R
A
I
N

R
E
L
I
E
F

B
U
S
H
I
N
G
M
3

W
A
S
H
E
R
B
O
T
T
O
M
1
0
m
m

M
3

B
O
L
T
M
3

N
U
T


__________________________________________________________________________________________________________________________________________________________

13



17. DRILL PATTERN ENCLOSURE TKAUS22G
CUT

3
,5

3
,5

3
,5

3
,5

3
,5

3
,5

3
,5

3
,
5
1
2
,
5
7
3
3
8
1
3
3
,
5
90
13 24,5
9
BOTTOM

6
,5

6
,5

1
2
20 25,5 10 10 11 17,5 17,5
2
1
,
5
2
7
,
5
3
3

1
1

3
,5

3
,5
20 20 36,5
24,5 27,5
1
7
3
2
3
3
REAR PANEL
FRONT PANEL

All distances are expressed in mm







_______________________________________________________________________________________________________________________________________________________


14
18. PCB LAYOUT
R
2
5
AC
R
8
b
e
c
c
S
K
1
R
3
VR1
T3
R
9
R
1
3
R11
R
1
2
T4
R26
R27
R24
R23
R15
R22
R
7
R19
IC1 1
D5
D4 C2
D7
D6
SW1 SW2
R31
R30
R29
LD1 LD2 LD3 LD4
C1
D
1
D
2
D
3
T1 T2
R
5
R
4
R
6
R
2
R
1
T5
T6
R18
R17
R
2
8
R21
S
K
2
-
R
1
4
R
1
0
D
8
6
/
1
2
V
</>4Ah
END OF CHARGE
CHARGE
FLOAT
POLARITY
WRONG
+
A
C
C
U
VELLEMAN P8012'1 LEAD ACID BATTERY CHARGER
VOLTAGE
SELECT
SELECT
CAPACITY
BATTERY
J2
J3
T7
CHARGE
R20
R16
J1


__________________________________________________________________________________________________________________________________________________________

15
19. DIAGRAM
L
M
3
8
5
-
2
.
5
V
R
1
R
8
1
K
5
1
/
4

L
M
3
2
4
A
1
R
1
1
4
K
7
R
9
1
K
M
J
3
0
0
1
T
7
C
2
4
7
0
0
u
/
3
5
V
D
8
1
N
5
4
0
0
B
C
5
4
7
B
T
3
R
1
4
7
K
R
2
2
7
K
R
6
2
7
0
K
B
C
5
4
7
B
T
2
1
/
4

L
M
3
2
4
A
2
R
7
1
0
K
R
2
6
1
M
R
2
7
1
K
R
3
1
2
.
2
/
0
.
6
W
1
/
4

L
M
3
2
4
A
3
-
+
E
1
6
/
1
2
V
R
1
4
1
0
K
1
4
1
2
1
3
1
/
4

L
M
3
2
4
A
4
R
2
5
1
2
K
R
1
7
1
M
R
1
8
6
8
0
R
1
9
1
5
K
R
2
1
1
0
K
R
1
5
3
3
K
R
2
2
2
2
0
K
A
C
A
C
V
O
L
T
A
G
E

R
E
G
U
L
A
T
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C
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R
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N
T

L
I
M
I
T

(
0
.
1
C
)
I
<
0
.
0
2
C
V
o

7
.
3
5

6
.
8
5
V
o

1
4
.
7

1
3
.
6
I
<
0
.
0
0
7
C
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N
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O
F

C
H
A
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4
1
N
5
4
0
0
D
5
1
N
5
4
0
0
D
7
1
N
5
4
0
0
D
6
1
N
5
4
0
0
0
.
7
V
1
3
0
m
V
5
0
m
V
L
D
4
L
E
D
3
G
R
2
8
2
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2
1
1
4
2 3
1
1
0
9
8 7
5 6
C
1
2
u
2
R
3
1
2
0
K
S
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2
1
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V
6
V
R
3
0
1
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8
/
0
.
6
W
R
2
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1
.
5
/
0
.
6
W
S
W
1
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P
E
N
:

<

4
A
h

(
I
m
a
x
=
0
.
3
A
)
C
L
O
S
E
:

>

4
A
h

(
I
m
a
x
=
1
A
)
R
2
3
2
K
2
L
D
3
L
E
D
3
Y
B
C
5
5
7
B
T
6
B
C
5
4
7
B
T
1
R
4
1
8
0
K
R
5
1
0
K
L
D
2
L
E
D
3
R
R
2
4
2
K
2
B
C
5
4
7
B
T
5
D
1
1
N
4
1
4
8
B
C
5
4
7
B
T
4
R
1
0
1
0
K
R
1
3
1
0
K
D
3
1
N
4
1
4
8
R
1
2
1
K
D
2
1
N
4
1
4
8
L
D
1
L
E
D
3
R
C
H
A
R
G
E
W
R
O
N
G

P
O
L
A
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E
N
D

O
F

C
H
A
R
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E
C
H
A
R
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E
F
L
O
A
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A
D
-
A
C
I
D

B
A
T
T
E
R
Y
A
1
.
.
.
A
4

=

I
C
1
1
8
V
/
1
.
3
A
R
1
6
1
0
K
R
2
0
1
0
K