Introduction: How to Make a 12V Lead Acid Battery Charger Circuit
Hello everyone!
Today I will show you step by step that how you can make a 12V 1A~7A lead acid battery charger circuit by using some very simple and easily available components. For better understanding, I would like to recommend you to watch this video before you start making.
Brief Introduction:
This circuit consists of a simple Power Transistor and some resistor and diode networks. we can choose a cutoff charging voltage set point for a 12V lead acid by turning the potentiometer and can protect our batteries from over charging. There are some indicators on the circuit board to indicate the battery connection status, charging status and battery full status.
Step 1: List of Components:
Here is the list of components with valid purchasing links. so you can buy easily.
R1,R3 = 1K https://goo.gl/4XW5DR
R4,R5 = 1.5K https://goo.gl/V1jUMS
R6 = 10K https://goo.gl/RVB6fy
R7 = 1.2K https://goo.gl/RVB6fy
R2 = 1R5W https://goo.gl/RVB6fy
PR1 = 50K https://goo.gl/RVB6fy
Q1 = D882 https://goo.gl/RVB6fy
D1 = 1N4732A https://goo.gl/RVB6fy
D2,D3,D4 = 1N4007 https://goo.gl/RVB6fy
Relay = 12V https://goo.gl/RVB6fy
U1 = LM7815
5MM LED = Red,Green,Blue,Yellow
Alligator Clips = 2
Jumper = 1 https://goo.gl/RVB6fy
Step 2: How to Make?
To make this project, you also need a circuit diagram, which you can download from here for free!
https://www.mediafire.com/file/fc9ndo9hnxqk0ff/Sch...
After understanding Circuit diagram, of course, you will need a PCB. But don't worry, you will not need to design it. Here is a solution!
Just go here: https://www.jlcpcb.com/, then upload free PCB Gerber files from the link given below. They are really professional PCB manufacturer and they have the cheapest prices that I have ever found ($2 for 10 pcs of 10 x10 cm boards).
Download Free PCB Gerber Files here: https://www.mediafire.com/file/h63of8mum6zmlta/Ge...
Step 3:
After collecting all material, Simply solder all components to your new printed circuit board according to the circuit diagram.it is easy! then connect some extra piece of wires to connect input with a power supply, and output with a 12V Lead Acid battery. After soldering all components and wires, you will need a little bit calibration.
Step 4: Calibration of Circuit:
To calibrate the circuit, set your DC regulated power supply at 14.5V and connect +ve wire to the CB+ of circuit and -ve wire of power supply with CB- of the circuit. now turn the potentiometer slowly until blue color LED lights up. After that, disconnect power supply, and connect the "Jumper" on circuit board. Now your circuit is ready to use. connect a battery at the output and set your DC power supply at 16VDC to 18VDC and connect it at the input of circuit.
Step 5: Working:
Basically, this circuit is very simple, based on a single transistor, a zener diode, a 12V relay and some resistor and diode networks. we set a tripping voltage level by using a potentiometer and a resistor network. when the charging voltage reaches that certain value(i.e 14.5V), the zener diode conducts and provide a signal to the base of transistor and makes the output of transistor high which causes the relay to activate and cut off the charging input for the battery.
Step 6: IMPORTANT NOTE:
I designed this circuit to charge your battery @ 70% to 75% only due to some safety reasons. If you want to make it for 100% charging, then remove the LM7815 and connect directly 18VDC supply and set tripping point at 15.8 ~ 16V. and always use 5 to 6 times lower charging current from the maximum value of battery current. i.e 1.2A for a 7AH battery.
*This circuit has not any current limiting feature.(except 1R5W Resistor)
**This circuit is not 100% Perfect, but it is still very useful for hobby/DIY projects.
***Make it at your own risk.
