4/25/2019 12v, 7Ah Smart Battery Charger with PCB Diagram - Engineering Projects

12v, 7Ah Smart Battery Charger with PCB Diagram

September 22, 2016 Engineeering Projects

Here is a 12V, 7Ah smart battery charger circuit which is also referred as smart charger uses three stage of charging i.e.
bulk stage, absorption stage and float stage.

Normal battery charger technology uses single stage battery

charging technology i.e. only charge the battery up to
maximum charging voltage preset by charging circuit. Now
here is a 12V, 7Ah smart battery charging circuit which is also
referred as smart charger uses three stage of charging i.e. bulk
stage, absorption stage and float stage.

You may also like Arduino Controlled 12V battery charger

circuit

80% of the charge is done in bulk stage where current is

constant but voltage is increases. Similarly, rest 20% of charge
is done in absorption stage (14.1VDC to 14.8VDC, depending
upon voltage set for sealed-lead-acid (SLA) 12V, 7Ah battery). Whereas float stage is occurred when charge voltage is
reduced to between 13.0 VDC to 13.6 VDC and current does not drop, also this stage is used to maintain a fully charged
indefinably.

Circuit Description 12v, 7Ah Smart Battery Charger with PCB

Diagram
The circuit diagram of 12V, 7Ah smart battery charger is shown in figure 1. It utilizes a step-down transformer,
adjustable voltage regulator IC (LM317), op-amp comparator, zener diode and few other active and passive
components.

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4/25/2019 12v, 7Ah Smart Battery Charger with PCB Diagram - Engineering Projects

The input 220 Volt AC is step-down to 15V-0-15V using center-tapped transformer. The stepdown voltage is changed to
pulsating DC with the help of full wave rectifier (D1 and D2) and is smoothed by capacitor C1. This voltage is further
given to input pin (pin 3) of adjustable voltage regulator (IC1).

The output voltage obtained from adjustable voltage regulator is determined or controlled by changing resistance at pin
1 of IC1.

Here, we had used dual operation amplifier LM358 (IC2) as comparator which compare output voltage with reference
voltage and control overcharge of battery. The LED1 is used to indicate power where as LED2 and LED3 are used to
indicate charging and full charged of battery respectively.

Calibration of 12v, 7Ah Smart Battery Charger with PCB Diagram

For calibration or setup, remove jumper and reconnect it back after calibration.

1. Adjust potentiometer VR2 to get 13.6V at cathode of diode D5 or at Vcc (pin 8) of IC2.

2. Adjust VR1 to get 0.5V (difference of output i.e. 14.1V-13.6V = 0.5V) at collector of transistor T1.

3. Adjust VR3, so that charging LED (LED2) start to glow.

4. Again adjust VR2 to get 14.1V at cathode of diode D5 or Vcc (IC2) of IC2.

5. The voltage at jumper should be either 14.1 V or 13.6V depends upon voltage at cathode at D5. If voltage at jumper
is 14.1V then the volte at cathode must be 13.6V and vice-versa.

BEP NOTE on 12v, 7Ah Smart Battery Charger with PCB Diagram: –
1. Must use good heat for adjustable voltage regulator IC LM317 (IC1) and it’s must not be connected to ground.

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4/25/2019 12v, 7Ah Smart Battery Charger with PCB Diagram - Engineering Projects

2. Capacitor C4 should be kept near as far as possible to pin 1 of IC2.

3. For calibration jumper JU1 must be removed and put it back after calibration.

4. Battery must be connected with right polarity to the connector CON1.

Click here to download PCB LAYOUT

If you are wish to design your own battery charge indicator there here a circuit for you.

10 Level Battery Charge Indicator Circuit

Check out other various battery charger circuit posted in bestengineeringprojects.com

1. 12 V Battery Charger with overcharge and deep-discharge protecting

2. Ni-Cd Battery Charger

3. Ni-Cd Battery Charger Circuit

4. Automatic battery float charger circuit

PARTS LIST OF 12v, 7Ah Smart Battery Charger with PCB Diagram
Resistors (all ¼-watt, ± 5% Carbon)

R1 = 270 Ω

R2 = 2.2 KΩ

R3, R6 = 10 KΩ

R4, R5 = 22 KΩ

R7 = 0.2Ω, 5W

R8, R9 = 4.7 KΩ

VR1 = 2 KΩ

VR2 = 5 KΩ

VR3 = 20 KΩ

Capacitor

C1 = 2200 µF/40V (Electrolytic Capacitor)

C2, C3 = 10 µF/25V (Electrolytic Capacitor)

C4 = 0.1 µF (Ceramic Disc)

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