november 2016 | Electronics For You

J3
JUMPER
TP7

R7
3.3K

J1
JUMPER

LED4
FULL
CHARGE

T1
BC547

VR1
5K
P2

LED1
POWER

C1
4700u
40V
N

CON1
FOR
230V AC
50Hz,
INPUT

X1

R2
3.3K

D2

6A4

GND

TP0

TP1
D1
6A4
S1
ON/OFF
SWITCH

Fig. 1: Circuit of the 12V battery charger-cum-variable power supply

C2
10u,25V

IC1
LM138
3

D6

1N4007

D7
1N4007

R1
270E

D3
6A4
TP2
D9
1N4007
1

D8

IC2
LM138

TP3
1N4007

C4
10u
25V
3
1

IC4
7812

C3
100u,35V

T2
2N2222

N/C 1

RL1
12V,1C/O

N/O 1

N/C 2
RL2
12V,1C/O
D5
6A4

CON2
TP4
FOR
COOLING
FAN

D12
1N4007

R3
0.1E, 5W

N/O 2

USED IN PCB FOR EXTERNAL CONNECTIONS

POINTS 1 THROUGH 6

ARE JUNCTIONS

P1

BUC# = BATTERY UNDER CHARGING

IN2+
GND

LED2
HEALTHY

VR2
5K

VR3
47K R5
3.3K

LED6

DEAD
BATTERY

R6
TP6
3.3K
2

J2
JUMPER

ZD1
4.7V

VR4
5K
5

6
7 OUT2

OUT1

IN2

IC3 IN1+
LM358

2
IN1
8

Vcc

LED3 CHARGING

R4
3.3K

D10
1N4007

D4
6A4

94

1N4007

Circuit of the 12V battery charger-cum-variable power supply is shown in Fig. 1. It is

built around two LM138 variable voltage regulators (IC1 and IC2), dual op-amp LM358
(IC3), 12V voltage regulator 7812 (IC4), two
relays (with normal 12V, 1C/O PCB-mounted
and 12V, 1C/O, 10A contact-current rating)
and a couple of transistors.
LM138 is a 3-pin, 5A positive-voltage
regulator available in TO-220 or TO-3 package. But continuous current flow of 5A
generates a high temperature, which shuts
down output of LM138 automatically due to
its internal thermal protection.

D13

Circuit and working

X1 = 230V AC PRIMARY TO 15V015V,

5A SECONDARY TRANSFORMER

he circuit presented here can charge

a 12V lead-acid battery of 50Ah to
80Ah (even up to 100Ah) capacity and
can even be used as up to 18V DC variable
power supply of maximum 5A capacity,
which is useful for a test bench. The circuit
can automatically detect the presence of a
battery connection and start charging. At
that time, it disconnects the output provided
as variable power supply. It also detects the
wrong/reverse polarity connection of the
battery terminals and raises an alarm. The
charger initially charges the battery at a
higher voltage (about 14.2V), and once it is
fully charged, it maintains the battery charge
at a constant voltage (about 13.4V).

VR5
5K
R8
10K

LED5 REVERSE
POLARITY
D11
1N4007

R9
3.3K
TP5
3

Fayaz Hassan

C5
0.1u

CON4
FOR 12V
BUC#
5
PZ1
PIEZO BUZZER
R10 100E

CON3
FOR
VPS* 4
LED7 R11
3.3K

12V Battery
ChargerCumVariable
Power
Supply

Do-it-yourself

VPS* = VARIABLE POWER SUPPLY

.
S.C di
ive
w
D

www.efymag.com

Fig. 2: Actual-size PCB pattern of the battery charger-cum-variable power supply

Fig. 3: Component layout of the PCB

This circuit simplifies higher current handling of LM138 by using IC1

and IC2 in parallel, but still output
voltage can be regulated by a single
variable resistance. Care should be
taken for handling the lines carrying 5A current. Two separate relays
(RL1 and RL2) are used to reduce
the cost of the project.
Transformer X1 steps down 230V
AC to 15V-0-15V AC that is then
rectified by diodes D1 and D2 and
smoothened by capacitor C1. This
voltage, which is around 20V DC,
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is fed to IC1 and IC2 that are wired

in parallel. Their output voltage is
regulated either by VR1 (in case of
variable power supply) or VR2 (in
case of battery charger), which is
selected by relay RL2. Output so
obtained is available for the variable
power supply or battery charger
through RL1.
Dual op-amp LM358 (IC3) is
used to control the relays and select
the type of output, that is, whether
for battery charger or variable power
supply. When no battery is connect-

ed for charging, no power is given to

IC3. RL1 and RL2 are in non-energised state, and potmeter VR1 can be
used to get variable voltage output
across CON3 fitted on the cabinet.
When a 12V battery under charging (BUC#) is connected properly
to terminal CON4 for charging, IC3
gets power supply from the battery
through diode D10. If battery voltage
is below dead voltage (say, 6-9V
and at least above 6V), pin 7 of IC3
pulls low and LED6 glows. If the battery is healthy (say, more than 9V),
Electronics For You | november 2016

95

Do-it-yourself
pin 7 of IC3 goes high and switches
on LED2 and conducts transistor T2,
and RL1 and RL2 energise.
Output voltages of IC1 and IC2
are regulated by VR2 and are available for charging at CON4. Once the
battery under charging attains its full
charging voltage, pin 1 of IC3 goes
high, as indicated by the glowing
of LED4, and T1 conducts, which
reduces the voltage at pin 1 of IC1
and IC2.
When a 12V battery is connected
in reverse polarity, D11 conducts,
which, in turn, switches on the
piezo buzzer and LED5 glows. This
protection is important while charging batteries externally.

Construction and testing

An actual-size, single-side PCB for
the 12V battery charger-cum-variable
power supply is shown in Fig. 2 and
its component layout in Fig. 3.
After assembling the circuit on
the PCB, place it in a suitable cabinet. Fit CON3 and CON4 on the front
side of the cabinet. CON3 is for variable power supply (VPS*) and CON4
for battery under charging (BUC#).
Connect CON3 between N/C2
terminal of relay RL2 and point 4
given on the PCB. Connect CON4
between points 3 and 5 given on the
PCB. Fix VR1 through VR5 and all
LEDs on front side of the cabinet,
and label these as shown in the
circuit diagram.
Place transformer X1 inside the
cabinet. Fix CON1 and switch S1
on the rear side of the cabinet. Use
proper heat-sinks for IC1, IC2 and
IC4, and connect a 12V cooling fan
at CON2 for fast cooling.
The circuit works off 230V mains
power supply. Refer the test points table for checking the voltages at various points before using the circuit.

Parts List
Semiconductors:
IC1, IC2
- LM138, variable voltage
regulator
IC3
- LM358 dual op-amp
IC4
- 7812, 12V voltage regulator
T1
- BC547 npn transistor
T2
- 2N2222 npn transistor
LED1-LED7 - 5mm LED
D1-D5
- 6A4 rectifier diode
D6-D13
- 1N4007 rectifier diode
ZD1
- 4.7V zener diode
Resistors (all 1/4-watt, 5% carbon, unless stated
otherwise):
R1
- 270-ohm
R2, R4-R7, R9,
R11
- 3.3-kilo-ohm
R3
- 0.1-ohm, 5watt
R8
- 10-kilo-ohm
R10
- 100-ohm
VR1, VR2,
VR4, VR5
- 5-kilo-ohm potmeter
VR3
- 47-kilo-ohm potmeter
Capacitors:
C1
- 4700F, 40V electrolytic
C2, C4
- 10F, 25V electrolytic
C3
- 100F, 35V electrolytic
C5
- 0.1F ceramic disk
Miscellaneous:
X1
- 230V AC primary to
15V-0-15V, 5A secondary
transformer
RL1
- 12V, 1C/O PCB-mounted
relay
RL2
- 12V, 1C/O, 10A contact current rating relay
CON1, CON2 - 2-pin connector
CON3, CON4 - 2-pin connector terminal
for 10A
S1
- On/off switch (6A)
PZ1
- Piezo buzzer
J1-J3
- 2-pin shorting jumper
connector

- Heat-sink for IC1, IC2, IC4

- 12V cooling fan

3.

4.

5.

6.

Initial setup and testing

1. Remove jumper J1 and J3, connect J2 and switch on S1.
2. Adjust VR1 and VR2 to get 9V
DC (as battery dead voltage or as
96

november 2016 | Electronics For You

7.

required) with respect to ground

at TP6.
Adjust VR4 such that you can
turn on and off status LED2 and
LED6 alternately. RL1 and RL2
also change their states (energise/de-energise).
Adjust VR2 to get the full battery voltage (say, 13.4V DC with
respect to ground) at TP6.
Adjust VR5 to turn on LED4,
if TP7 is connected to ground
through J3.
Once LED4 is set, adjust VR2
to get battery charging voltage
(say, 14.2V DC with respect to
ground) at TP6.
Connect J1 (J2 still connected)
and adjust VR3 to get battery
standby voltage (say, 13.4V DC

Test Points
Test point

Details

TP0

0V (GND)

TP1

Around 20V DC when

S1 is closed

TP2

1.2V to 18V

TP3

1.2V to 18V

TP4

0.5V to 18V

TP5

0.5V to 18V

TP6

Around battery voltage

TP7

0 when J3 is grounded or
12V when J1 is not grounded

with respect to ground) at TP6.

8. Once the required voltages are
set, remove J2. The circuit is
ready to use.
9. If no battery is connected at
CON4, variable voltage is obtained at CON3 by using VR1.
Brightness of LED7 is proportional to the output voltage at CON3.
10. If 12V (50Ah) battery is connected at CON4 in reverse polarity,
buzzer PZ1 gives an alarm sound
and LED5 glows.
11. If the same battery is connected
in correct polarity at CON4, status
of the battery is indicated by
LED2 (healthy) or LED6 (dead).
RL1 and RL2 will get energised in
case the battery is healthy and the
battery will get charging voltage.
Once the battery is fully charged,
LED4 glows, which indicates that
the battery is fully charged and
the charger is at standby voltage.
12. Use proper crocodile clips for
connecting the battery terminals.
EFY note. 1. Charging voltage,
standby voltage and battery dead
voltage may vary as per the manufacturer of the battery. The values indicated here are safe voltage values.
2. Heat-sink with mica insulation
must be provided for IC1 and IC2.
Fayaz Hassan is a manager
at Visakhapatnam Steel Plant,
Visakhapatnam, Andhra Pradesh.
He is interested in microcontroller
projects, mechatronics and
robotics
www.efymag.com