DP2 is a extremely portable battery tester / desulfator / charger. These are the instructions for assembling a DP2 kit. Kits or fully assembled units are available for sale through the Holy Scrap Store. More up to date information is available on the DP2 Page.

Step 1: Open the Enclosure

Step 2: Cut Open the Components Bag

Step 3: Empty Bag Contents

Step 4: ​Place and Solder 28 Pin DIP Socket [U1]

Note:The small impression must be near the right edge of the circuit board.

Step 5: Attach the Fuse Holders to the Fuse

Step 6: Place and Solder the Fuse [F1]

Step 7: Cover the 2-pin Jumper Headers With Their White Covers

Step 8: Place and Solder the Jumpers [J2, J3]

Step 9: Place and Solder 7 Segement Display [D1]

Step 10: Place and Solder DC Barrel Jack [CONN1]

Step 11: Place and Solder AC Power Cord Receptacle [CONN2]

Step 12: Place and Solder Decoupling Capacitors [C4, C5]

Note:Orient the minus sign on capacitors to the bottom of the circuit board

Step 13: Place and Solder the Bridge Rectifier [U3]

Note:Orient the + sign towards the top of the circuit board

Step 14: Place and Solder 300 Ohm Resistors [R1, R2, R3]

Step 15: Place and Solder 25k Ohm Resistor [R4]

Step 16: Place and Solder 470 Ohm Resistor [R5]

Step 17: Squeeze Your Microcontroller Leads to Fit the IC Socket [U1]

Note: I like to hold the chip at a slight angle and gently press the leads in

Step 18: This Is the Amount of Curve You Are Looking for on the Leads.

Step 19: Place the Microcontroller Into the DIP 28 Socket [U1]

Note:The small divot in the chip should be facing the right side of the board

Step 20: Place and Solder the 7805 5v Regulator [U2]

Note:Orient the text side towards the lower circuit board

Step 21: Step 21: Place and Solder the 9v Protection Diode [D2]

Note:Orient the black line on the diode to match the silkscreen (left side)

Step 22: Place and Solder the Slide Switch [S1]

Step 23: Place and Solder Large Charge Capacitors [C1, C2, C3]

Step 24: Place and Solder Large Black Rocker Switch [S2]

Note:Match the 0 / 1 orientation on the silkscreen.

Step 25: Clip Battery Lead to 2" in Length. Twist and Tin the Leads.

Step 26: Solder 9v Battery Cap

Note:Left is negative (black), Right is positive (red) as the silkscreen indicates.

Step 27: Nsert Assembled PCB Into Enclosure

Note:Align cable plug holes then press hard on opposite side of PCB for secure fit. It will be a little uneven as the retailer I've been buying enclosures from has changed models

Step 28: Connect 9v Battery

I ordered da PIMP assembled & when I got it in the lcd display reads 2-3 volts when not connected to anything & when connected to a 12 volt battery it reads 21-26 volts but the battery with a fluke multi meter shows12.16 any idea's on this?
Thank you for your order. I appreciate it. The 9v is either cold or needs to be swapped.
<p>Very detailed and good pictures.</p><p>But to make this easier, always start with the lowest components. That is, diodes (like D2 here) and resistors and work your way up to the taller components. This way, when you turn the PCB around, the components get pressed into the board.</p><p>And please: Leave the IC in its packaging until the very last moment. If there is a socket - until you test the circuit. Don't bend the ICs pins on a plastik surface either (unless it is conductive). Use a metallic surface and ground yourself by touching a grounded object water pipe or ground/earth pin of your mains output. </p><p>ESD (electro static discharge) is a thing. It may even not show up immediately but damage some of the microscopic structures inside. So your circuit works fine for the first time but fails within some weeks/months without an obviuos reason.</p>
<p>hello, I took a look a this design and if I cannot say any about its efficiency, I can tell you that it is pretty dangerous. As there is no galvanic separation between AC mains and battery, the whole thing including the battery to charge should be in an enclosure, where leads of battery as well as the circuit would be un reachable. I read it fast but didn't see any warning about not touching leads of battery. Definitely dangerous!</p>

About This Instructable



Bio: I design and sell two different electronic devices. The first devices desulfates old dying batteries. The second assists people with the fermentation of foods. When ... More »
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