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LEAD ACID BATTERY
CHARGER KIT
Ramsey Electronics Model No.
An educational kit that will come in handy around the shop and
garage. Build your own charger instead of shelling out big bucks
for a "store bought" unit. You might learn more than you ever
wanted to know about batteries and battery charging. Amaze
your friends with your new found knowledge. Wait . . .is that
Regis on the phone?
•
No more fried gel cells!
•
Extends the life of your 12 volt lead acid batteries.
•
Automatic ambient temperature compensation.
•
Automatically adjusts charge voltage depending on battery status.
•
Bright front panel charge indicator.
•
Saves spending money on costly replacement batteries; pays for
itself in no time!
•
Add our matching case and knob set for a professional appearance.
LABC1 • 1
LABC1
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Table of Contents
Summary of Contents for Ramsey Electronics LABC1
- Page 1 LEAD ACID BATTERY CHARGER KIT Ramsey Electronics Model No. LABC1 An educational kit that will come in handy around the shop and garage. Build your own charger instead of shelling out big bucks for a “store bought” unit. You might learn more than you ever wanted to know about batteries and battery charging.
- Page 2 Ramsey Electronics publication No. MLABC1 Rev 1.2 First printing: November 2001 COPYRIGHT 2001 by Ramsey Electronics, Inc. 590 Fishers Station Drive, Victor, New York 14564. All rights reserved. No portion of this publication may be copied or duplicated without the written permission of Ramsey Electronics, Inc.
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Page 3: Table Of Contents
Schematic Diagram ....8 Parts Layout Diagram ....9 Parts List ........10 Kit Assembly ....... 12 Custom Case Assembly ..... 15 Adjusting your LABC1 ....17 Safety Considerations ....18 Troubleshooting Guide ....19 Warranty ........23 RAMSEY ELECTRONICS, INC. -
Page 4: Quick Battery Theory
To test a lead acid battery’s SOC, the best indicator is a hydrometer. When you test a battery’s SOC with a hydrometer, you are actually measuring the amount of sulfuric acid left in the electrolyte LABC1 • 4... - Page 5 When you recharge the battery, the process is reversed and the sulfur returns to the electrolyte solution. Proper cycling of the battery will ensure a long and functional life. If the battery is abused by allowing sulfation of the electrode LABC1 • 5...
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Page 6: Circuit Description
C1 to reduce the voltage ripple. Using a bridge configuration on the voltage input allows the user more options to power their LABC1. The use of a 14 VAC or 20 VDC (positive tip) power supply will do nicely with any 12 Volt lead acid battery. - Page 7 BUC (not to be confused with your BUT, or Battery Under Test) is discharged and drawing enough current to set the LABC1 in charge mode. After the current drawn by the battery drops below a certain point, the need for ‘high’...
- Page 8 LABC1 • 8...
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Page 9: Parts Layout Diagram
LABC1 PARTS LAYOUT DIAGRAM LABC1 • 9... - Page 10 PARTS SUPPLIED WITH YOUR LABC1 KIT Capacitors 10 µF electrolytic capacitor [C2] 1000 µF electrolytic capacitor [C1] Resistors and Potentiometers 0.47 ohm, 1 watt (yellow-violet-silver) [R6] 270 ohm (red-violet-brown) [R1] 820 ohm (gray-red-brown) [R3,7,9] 10K ohm (brown-black-orange) [R8] 18K ohm (brown-gray-orange) [R4]...
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Page 11: Kit Assembly
RAMSEY "Learn-As-You-Build KIT ASSEMBLY There are numerous solder connections on the LABC1 printed circuit board. Therefore, PLEASE take us seriously when we say that good soldering is essential to the proper operation of your battery charger kit! • Use a 25-watt soldering pencil with a clean, sharp tip. -
Page 12: Parts Layout Diagram
LABC1 BATTERY CHARGER KIT ASSEMBLY Although we know that you are anxious to complete the assembly of your battery charger kit it is best to follow the step-by-step instructions. Try to avoid the urge to jump ahead installing components. Since you may appreciate some warm-up soldering practice as well as a chance to put some landmarks on the PC board, we’ll first install a couple of... - Page 13 7. Install J2, the 2 screw terminal jack. The openings should face the rear of the PC board. This is where the battery you’re charging will be attached to the LABC1. 8. Install R6, 0.47ohm 1 watt resistor (yellow-violet-silver). This part is physically larger than the other resistors in your kit for a reason;...
- Page 14 The pin orientation of Q1, the 2N3906 (221334) transistor, is incorrect on your LABC1 circuit board The larger flat side with no writing is the one pictured on the silkscreen; orient the part using this as the correct flat side.
- Page 15 Front View after Bending CONGRATULATIONS ! Great job! You’ve made it through the circuit board assembly of your LABC1 kit. We know you’re anxious to “fire it up” but take a moment to look over your work now, checking for imperfect solder joints, misplaced components and correct orientation of polarity sensitive parts.
- Page 16 6. Raise the rear portion of the PC board and extend the jacks through the rear plastic plate. Insert the plate into the grooves on the base tray. 7. Secure the PC board to the bottom base tray with 4 short Phillips head screws. LABC1 • 16...
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Page 17: Adjusting Your Labc1
ADJUSTING YOUR LABC1 BATTERY CHARGER Now that you have finished the assembly stage there is only one more step before you start charging your batteries. The necessary alignment is to adjust R2 for the proper ‘Float’ voltage with reference to the current air temperature around diodes D5 to D14. -
Page 18: Safety Considerations
Your safety is your responsibility and the end use of your LABC1 or any other charger is up to you to use responsibly. Always wear safety glasses and protective gloves while working with lead acid batteries. - Page 19 3) Another point to cover is the type of hook-up wire used to connect your LABC1 to your battery. The wire provided with your kit works well for hobbyist type batteries but you may wish to increase the wire gauge if you plan on working with large capacity batteries or longer wire runs.
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Page 20: Troubleshooting Guide
TROUBLESHOOTING GUIDE If your LABC1 does not work correctly after construction, recheck the following: • correct orientation of VR1, and U1 (see PC board layout diagram) • correct polarity of electrolytic capacitors • correct orientation of diodes D1 to D17 •... - Page 21 Attn. Hobby Kit Department 590 Fishers Station Drive Victor, NY 14564 Please feel free to visit our Website at www.ramseyelectronics.com and offer your observations to other kit enthusiasts as well. And once again, thanks from the folks at Ramsey! LABC1 • 21...
- Page 22 This page intentionally left blank. Don’t you hate it when people do this? Why don’t they just admit that they ran out of things to say! LABC1 • 22...
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Page 23: Warranty
But on rare occasions a sour component can slip through. All our kit parts carry the Ramsey Electronics Warranty that they are free from defects for a full ninety (90) days from the date of purchase. Defective parts will be replaced promptly at our expense. If you suspect any part to be defective, please mail it to our factory for testing and replacement. -
Page 24: Victor, New York
LABC1 LEAD ACID BATTERY CHARGER KIT Quick Reference Page Guide Quick Battery Theory ....... 4 Circuit description ......6 Schematic diagram ......8 Parts layout Diagram ....... 9 Parts list ........... 10 Kit Assembly ........12 Troubleshooting guide ..... 19 Warranty ..........