How to build Car Battery 6V or 12V charger

August 4, 2010 - category: Battery charger

Description
Always we needed a charger with which we can charge the car battery. This circuit can charge
automatically, fast and rightly, batteries 6V and 12V. A basic factor in the success in the circuit
operation is the use of transformer [T1] of good quality with very good insulation and resistance in
the short circuits. The Q1 via divider R1-2, the TR1 and the R4, functions as regulated current
source. The current via the R9 drives the power transistors Q5 -6, where is strengthened X2000
times roughly. In a car battery charger the voltage is roughly 6V until 8V. With these conditions the
charge current is roughly 1.2A [is regulated by TR1]. When the battery charge slowly, is increased
her voltage in across. In the 7V it begins conduct the D1. As long as its increased the battery
voltage is decreased the voltage in across the R3 making Q1 conductible. This continued as far the
current reaches the 6A roughly. Then via the fall of tendency in utmost the R10, becomes driver
the Q4. The current that in excess in base of Q5 grounded, confecting the current charge constant.
When the battery charger [14.4V] is completely, activated the parallel to the battery circuit that is
constituted by the R6, D8, and D2 until D6. Simultaneously turns on the D8 that shows that
battery charged completely. Simultaneously Q2 turn on from cause of voltage fall in the R6. The Q3
becomes conductible and grounding some of current in the Q5 base. When the voltage across the
battery reaches roughly in the 15V the current in the Q5 base is very small, so that stops the
battery charging. Diodes D5-6 protect the circuit from error placement of battery or from shortcircuit of big duration. Diode D4 protects the circuit from error placement of poles of battery. Then
Led D9 turns on shows the connection ERROR. Closing switch S2 short the diode D2 [6.8V], now
we can charge a battery 6V.

Adjustment
The inceptive charge current should be adjusted via the TR1 in 1.2A. Adjust can become with a
battery 6V. Connect in cascade with the battery a ampere meter [biggest 10A]. If does not exist
battery 6V, sorted output charger via their ampere meter and we adjust with the TR1 the current in
1.2A. At the regulation switch S2 it should they are in the 12V place, that is to say open. Attention
should be given in the diodes D2 and D3 precision because these protect the battery from
overcharge. If the voltage deviation is up to 100mV we believe to consider as acceptable. If you
meet difficulties in the current adjustment and TR1 is not enough, you can change the resistance
R4 value, until you measure charge current become 1.2A. The two parallel resistors that constitute
the R10, it should they are placed in distance by printed board and Q5-6, because they are heated.
Bridge B1 and Q5-6 should be placed on heatsink after isolate electric from this with suitable
silicone mica. Bridge B1 and the PCB where it will be placed circuit should connected with near and
fat cables, special there that the current are big. Also the lines in PCB should have proportional
width [in the drawing they appear with far line]. The manufacture should become in a good metal
box, suitable dimensions so that exists good ventilation. The all manufacture requires the
proportional experience. The WORK WITH BATTERIES REQUIRES VERY BIG ATTENTION IN the
HANDLING, BECAUSE EXIST ALWAYS the DANGER of EXPLOSION.

Circuit diagram

Part List

R1-11=1K ohm 0.5W 5%

R2=22K ohm 0.5W 5%

R3-5-8=10K ohm 0.5W 5%

R4=2.2K ohm 0.5W 5%

R6=100 ohm 0.5W 5%

R7=100K ohm 0.5W 5%

R9=470 ohm 0.5W 5%

R10=0.08 ohm 10W [2X0.18 ohm parallel] 5W

B1=Bridge Rectifier 25A/40V

D1-2=6.8V 0.4W Zener

D3=4.7V 0.4W Zener

D4-6-7=1N4148

D5=18V 0.4W Zener

D8=LED 5mm Yellow

D9=LED 5mm Red

Q1-2=BC557

Q3-4=BC547

Q5=BD139 [On Heatsink]

Q6=2N3055 [On Heatsink]

TR1=4.7K Trimmer Pot.

C1=4700uF 40V

C2=1uF 25V

T1=230Vac//15V 10A Transf. [See Text]

F1=Fuse 1A Slo Blo [5X20mm]

S1=2X2 Switch 10A per contact

S2=1X2 step mini switch

J1...4=Flat Pin Connector

J5=6pin Connector 2.54mm pin step

A=0-10A Ampere meter

Batt=12V or 6V Battery