Article

Power Charger for ElektorWheelie

Dual battery charger for lead acid gel batteries

The self-balancing single-axle DIY electrovehicle uses sealed lead acid (SLA) batteries for power. You can of course use the supplied charger to charge them, but it can also be done differently (better). The charger described here is not only suitable for charging the batteries in the ElektorWheelie, but can also be used as a general charger for 12 or 24 volt batteries.

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Materials

090582-PCB.pdf

Gerber file

CAM/CAD data for the PCB referred to in this article is available as a Gerber file. Elektor GREEN and GOLD members can exclusively download these files for free as part of their membership. Gerber files allow a PCB to be produced on an appropriate device available locally, or through an online PCB manufacturing service.

Elektor recommends the Elektor PCB Service service from its business partner Eurocircuits or AISLER as the best services for its own prototypes and volume production.

The use of our Gerber files is provided under a modified Creative Commons license. Creative Commons offers authors, scientists, educators and other creatives the freedom to handle their copyright in a more free way without losing their ownership.

PCB

Download Gerber file: 090582-1-V20

Component list

Resistors
R1,R2,R8,R9,R10,R16 = 10k
R3,R11 = 56k
R4,R12 = 4.7
R5,R13 = 4.7k
R6,R14 = 3.9k
R7,R15 = 0.47
P1,P2 = 2.5kO (2.2kO)
Capacitors
C1,C5 = 2200µF 35V radial, diam. max. 16 mm, lead pitch 7.5mm (0.3”), e.g. Nichicon UPS1V222MHD (Farnell # 8813027)
C2,C3,C6,C7 = 220nF, lead pitch 5mm (0.2”) or 7.5mm (0.3”)
C4,C8 = 10µF 63V radial, diam. max. 6.3mm (0.25”)
Semiconductors
D1,D11,D12,D22 = low current LED 3 mm, green
D2,D13 = low current LED 3 mm, red
D3-D8,D10,D14-D19,D21 = 1N4148
D9,D20,D23-D30 = 1N5401
T1,T2 = BD711
IC1,IC2 = L200CV
Miscellaneous
K1-K7 = spade plug (male), 2-way, PCB mount
PCB, order # 090582-1, see [1]

Not on board
Mains transformer 2x18 V sec, 2x115 V primary. 50 VA, diam. 81 mm (e.g. # Farnell 9530380)
IEC switched /fused AC power inlet, Bulgin type BVA01/Z0000/01 (e.g. Farnell # 3136152)
Fuse 315 mA slow (630 mA slow for 120 VAC)
XLR plug (male) for cable, Neutrik type NC3MXX-BAG (e.g. Farnell # 9991808)
Cablel, 1m, 3-way, 1.5 mm2 , outside diam. 6.7 mm, Lapp type 1119303 (e.g. # Farnell 1491485)
Strain relief, Lapp Kabel type 53111600 (e.g. Farnell 1286049)
Locknut M12 for strain relief, Lapp Kabel type 53119000 (e.g. Farnell # 1178909)
Enclosure, Boss Enclosures type BIM 2006/16/GY (e.g. Farnell # 1171686)
Aluminium sheet, thickness 3mm or 4mm, size 178x178mm
12 spade terminals 6.3x0.8 mm (female)