Instruction Manual for the Lowest- Cost Solar Battery Regulator Kitset By Martin van Leeuwen

Transcription

1 Instruction Manual for the Lowest- Cost Solar Battery Regulator Kitset By Martin van Leeuwen CONTENT Introduction : 1 Specifications : 1 Safety First : 2 Assembling station : 3 Tools : 3 Soldering : 4 Component identification : 4 Assembling instructions : 7 Assemble the PCB step by step : 8 Appendix 1 : 14 Appendix 2 : 15 Introduction This Solar battery charger controller DIY kitset is suitable for charging and maintaining both open 12V lead-acid batteries. Charging current : 6 or 10A. The battery can be hooked-up to the unit for an indefinite time, and will be kept in optimal condition. Battery type and charge current are selectable, while the charging process is fully automatic. This unit comply to the international STD for Solar regulators. Specifications Easy connection, 6.3 mm Quick connectors suitable for 12V open type lead-acid batteries (Sealed types optional) charge current: 6 A status indicators for charge, float and end-of-charge, error can continuously remain hooked-up to the battery inverse polarity protection provided PCB dimensions: 91 x 87 x 25mm Recommended housing: Low Voltage Disconnect High Voltage Disconnect Overload Protection 1

2 Safety First Please read the safety guide before commencing any work on this kitset. Those who are involved in assembling, checking or faultfinding of this Solar battery charger/conditioner DIY kitset should be made well aware of the difficulties involved. Failure to observe basic wiring rules, simple checking routines and safety handling procedures could end in disaster. A common sense approach and a practical understanding can avoid the pitfalls. The following information is meant as a guide to handling DC powered equipment. Wiring Colour Code The ACTIVE wire is RED. This wire may also be referred to as PLUS or POSITIVE The COMMON, - or EARTH wire is BLACK. It is most important that the wires be correctly terminated. Sloppy connections may reduce the effectiveness of the connection. The following illustration shows how this connection should be made Various means of termination may be applicable to this wiring. Where the wires are screwed into a terminal block, care should be taken to make sure that all strands of the wire are twisted together and secured well under the screw. The wire insulation should enter the block insulation. Firm but not excessive pressure should be applied to the securing screw. Excessive tightening may damage or cut the strands. Wires terminated under screws or similar pressure restraints should not be soldered. Soldering makes the copper wire less resilient and more prone to breakage. Termination of wire into a terminal block Or use Quick Connectors in which the wire is crimped into Preferably, wires soldered to components such as switches, should have the strands of wire fed through the eyelet and twisted around before soldering. A length of firmly fitting spagetti, PVC or heatshrink tubing should be slid over this termination to insulate it and increase the mechanical support. There should always be two methods of wiring restraint employed (such as the soldered termination and a cable tie) so that in the event of one failing, safety is not compromised 2

3 . Construction Competence and Supervision It would be preferable that a second person other than the assembler checks the wiring. Unskilled constructors should be supervised or at least seek advise from experienced or qualified persons before the equipment is powered up. Assembling station Assembling your Solar battery charger/conditioner The best assurance for an easy assembly of your Solar battery charger/conditioner is to make a simple assembly area. Do not allow any surplus components in this area. E.g. Put all components in a separate box or container which enables you to take out the appropriate component you want to place on the PCBoard. The picture below shows a simple and low cost DIY assembling station. All component numbers are put on the label. You will have in each container the amount of components of the same type and value as required. Tools. The tool kit you need can be very basic and consists of: - Solder iron - Sidecutter - Round nose pliers - Wirestripper Wirestripper - PCB vice Solder iron Sidecutter Round nose plier 3

4 Soldering technique Before you start to build your own battery controller and solder components to the PCB you do best to read this carefully. A poorly soldered joint can greatly affect small current flow in the circuit and can cause failure. You can even damage a PC Board Soldering should be smooth and neat. Next, solder to the smaller pads. Be sure that there is no solder bridging. In case you made accidentally a bridge, remove the bridge by lifting the PCB over the solder iron and the iron will draw the solder away from the pads. It is best to wipe the iron tip with a damp cloth to remove the solder. Component identification One of the biggest problem for the assembler is identifying the components correctly. The main trap is in the maze of numbers or colour codes put on the components by manufacturers. Resistors So called because they resist the flow of current. They are normally in the form of small cylinders about 10 mm long. Some high wattage types are rectangular. Resistance is measured in ohms, abbreviated to Ω or R Thousands are indicated by K and called Kilo Ohm, millions by M and often called Megohm. Thus a 12KΩ resistor has a resistance of ohms. The values are marked on the resistors using a colour code. The body has normally 4 rings, in other cases you may find 5 rings. The first three or four rings are grouped a bit closer together and indicate the resistance, the last represents the tolerance in % 4

5 Capacitors Capacitors store a charge. They come in an enormous range of sizes and types with the most confusing identification of all components. The most common types are mylar (green caps), ceramic, electrolytic, polysteren, polyester and tantalum. Electrolytic and tantalum are polarised, that is, have a positive and negative end which must be installed in the correct direction for the circuit to work. Capacitance is measured in Farads. This is too large a unit for most uses so various fractions are used: microfarad (mf) = 10-6 Farad; nanofarad (nf) = 0,001 microfarad picofarad (pf) = 0,001 nanofarad example: 0,01 mf = 10 nf = pf Many ceramic and mylar capacitors are marked using the IEA capacitor code. A system of three numbers and a letter giving the value and tolerance of a capacitor. The first two numbers are the significant figures The third the number of zeros following (value in picofarads). The letter indicates the tolerance: M = 20%; K = 10%; J = 5%; Thus a 123K is 12000pF or 12 nf or 0,012 µf 10% capacitor. Some of the larger value greencaps are marked in µf (usually 0,1µF and larger) Diodes Diodes are used to convert AC current to DC ( rectify), or to detect signals. Most are in the form of a black or clear cylinder 3-10 mm long. Diodes are also polarised, with a cathode (K) and a anode ( A) The cathode is marked with a silver or black stripe or band around the body. In case of power diodes it is clearly indicated on the housing. Light Emitting Diodes (LED) are a special type of diode which lights up red, yellow,green, blue or white when a voltage is applied + anode _ cathode 5

6 Transistors Transistors are the heart of a circuit and have the function to amplify. The transistors and FET type components you are going to use in the Solar battery charger/conditioner are three different types. So we will refrain from further in-depth studies about the transistor in general. In this unit the BC550 and the BC 560 aren used. Both look alike so be careful not to change them around as your gadget will not work. Both transistors have three leads and are called emitter (e), basis (b) and collector (c). Make sure you put these three leads in the right hole. As you can see at the drawing the transistors have a round and a flat side. Make sure you put the transistors in place as is shown on the photograph. MOSFETS Mosfets are the switches of the circuit and have the function to controls the supply of energy too and from the battery. The FET type components you are going to use in the Solar battery charger are identical so no confusion or misplacement is possible. So we will refrain from further in-depth studies about the mosfet in general. But be aware that mosfets are sensitive to electrostatic discharge. So keep these components into a ESD free bag of component box. Make sure you put the mosfets in place as is shown on the photograph. G = Gate D = Drain S = Sources 6

7 Assembling instructions. Below you find a list of components consisting of: 1. Resistors 2. Capacitors 3. Diodes 4. Transistors 5. Large Odd components, FET, Power diode,vdr, LED and QC-jacks Suggestions: Some components of the same value are more often used than others, so put these in the nearest boxes on the assembly station. Put the other components for easy assembly type by type on the same row, e.g. resistors by resistors, capacitors, diodes and odds. Note: A 1200 Ohm resistor could also be written as 1K2 without the Ohm symbol or 47K = 47kOhm or Ohm Bill of materials Qantity Part Type Designator Description Resistors 9 100K R5 R6 R9 R20 R31 R39 R40 R41 R43 Resistor, 0,125 W 6 150K R1 R4 R11 R13 R21 R34 Resistor, 0,125 W 5 47k R12 R14 R28 R30 R33 Resistor, 0,125 W 3 33k R22 R24 R46 Resistor, 0,125 W 3 470k R8 R23 R29 Resistor, 0,125 W 2 4k7 R16 R17 Resistor, 0,125 W 2 6k8 R10 R45 Resistor, 0,125 W 2 27k R7 R35 Resistor, 0,125 W 1 0,01 Ohm R26 Resistor, 2 W 1 1 M Ohm R32 Resistor, 0,125 W 1 1k R38 Resistor, 0,125 W 1 8k2 R27 Resistor, 0,125 W 1 10k R19 Resistor, 0,125 W 1 22k R3 Resistor, 0,125 W 1 39k R18 Resistor, 0,125 W 1 180K R2 Resistor, 0,125 W 1 270k R36 Resistor, 0,125 W 1 390K R15 Resistor, 0,125 W Ohm R25 Resistor, 0,125 W Capacitors 3 10uF/25V C2 C3 C6 C7 Electrolytic Capacitor 2 0.1uF/16V C4 C5 Capacitor 1 1uF/16V C1 Electrolytic Capacitor 7

8 Diodes 5 1N4148 D1 D4 D5 D6 D7 Diode 1 12V D3 Zener Diode 1 BZT03C33 D9 Zener Diode Transistors 7 BC550 Q1 Q2 Q12 Q13 Q16 Q17 Q18 NPN Transistor 9 BC560 Q3 Q4 Q5 Q7 Q8 Q9 Q10 Q11 Q15 PNP Transistor 1 TL431 U1 ref. shuntregulator LARGE Odd Components 2 69N03 / 1RFZ44 Q6 Q14 MOSFET 1 MBR 2045 D8 Diode 1 V 47 VZA1 R44 VDR 1 LED Red 3mm D2 LED 6 QC PCB jacks J1 J6 Assemble the PCB step by step Below we show a simple and safe way of installing components on the PCB. Two types of components are shown which differ in size too. Mark the components of the same type and value in the same way. You may even mark the box where they are in. This way is recommended when going into production or if you are not able to finish the PCB in one time. Work your way out by installing one type of components at the time, following with components of a similar size and solder these first before continue installing the larger components. After having installed a series of component(s), cross them off your list and or drawing. Use an unmarked sheet (see page??) for marking the components. How to ga about to place the components. 1. Bend the component leads with a round nose pliers gently at an angle of approx. 90 degrees. 2. Make sure that the width between de folded leads are approx. the distance between the holes you are going to put the leads in to. 3. After you installed a series of components put some foam rubber on top of the components 4. Clamp the piece of foam rubber in such a way that the components are kept in place. 5. Turn the PCB up side down and cut the leads so that you have approx. 2 mm lead left and solder the leads. Note: When you cut the leads after being soldered the chances are that the solder joint become cracked. In that case the solder joint has a mat surface and lost its shine. 6. Make sure to put the solder iron point on the largest PCB track area as this area needs more heat. A good solder joint looks shiny and slightly curved as shown below in fig.1 Fig. 1 8

9 Placing the resistors. For a start a example is shown how to go about to place the components. There are in total 19 different resistor values in the component assembly kit. On the component layout below and the adjacent photograph there are resistors marked with 5 different values. Each value has its own colour marking. To recognise the resistors even on a black & white copy different patterns are also used. Fig 3 The cut out fig 3 shows how the resistors are marked and recognised. The value of the resistor is printed in the resistor box. The designator is set next to the resistor e.g. R3 = 22KOhm; R18=39kOhm; R39=100KOhm Check the above shown example with your parts list and the unmarked copy so you will understand the way how you can place the remainder of all the resistors correctly on the PCB. Note that resistor R26 is either a large round or a square one. 9

10 Diodes After having placed all the resistors continue with placing the diodes. Fig 4 Fig 5 The diodes are recognised as rectangle boxes with a black line across the box near the end. The black line corresponds with the ring on de diode body. Make sure you put the diode with the ring in the same direction as indicated. D2 = 1N4148 type; D3 = 12Vdc zener diode; D5 = 1N4148 type. Check fig 4 with your parts list and the unmarked copy PCB/layout of components. Fig 6 1. After you installed a series of components put some foam rubber on top of the components 2. Clamp the piece of foam rubber in such a way that the components are kept in place. 3. Turn the PCB up side down and cut the leads so that you have approx. 2 mm lead left and solder the leads. Note: When you cut the leads after being soldered the chances are that the solder joint become cracked. In that case the solder joint has a mat surface and lost its shine. 4. Make sure to put the solder iron point on the largest PCB track area as this area needs more heat. A good solder joint looks shiny and slightly curved as shown in fig.1 10

11 Transistors The resistors and diodes are now installed and you can place the various taller components in. Preferably the transistors first as they are more delicate to handle and place the in the correct way. These types of transistors are easy to be recognised by their flat facing with their type number written on. 1. Bend the transistor leads gently at an angle and the leads fit the holes.. 2. After you installed a series of transistors put in the same as you have done before some foam rubber on top of the components 3. Clamp the piece of foam rubber in such a way that the transistors are kept in place. 4. Turn the PCB up side down and cut the leads so that you have approx. 2 mm lead left and solder the leads. 5. Make sure to put the solder iron point on the largest PCB track area as this area needs more heat Transistors are easily damaged through overheating.. 11

12 Capacitors To economise on the cost of components, electrolytic capacitors are used. This requires more attention in the placing of these components. In case of reversed polarity may not show in the beginning any failure. Though in time it will. 1..After you installed capacitors put in the same way as you have done before some foam rubber on top of the components 2. Clamp the piece of foam rubber in such a way that the transistors are kept in place. 3. Turn the PCB up side down and cut the leads so that you have approx. 2 mm lead left and solder the leads. 4. Make sure to put the solder iron point on the largest PCB track area as this area needs more heat. 12

13 Odd components Last but not least the large Odd components such as the Mosfets, the VDR overvoltage resistor, Power diode D8, QC connectors and Installing the error LED. When using the supplied housing and the LED must be installed like an indicator. A 3 mm hole should be drilled on location where the LED is shown Make sure the distance PCB and top LED must be 3,0 cm. When placing the QCjack connectors, check the that holes are the right size. In case the holes are undersized re-drill before placing the connectors. 1. When placing the mosfets antistatic precautions should be taken. 2. Place the components and do not use the foam. 3. Make sure to put the solder iron point on the largest PCB track area as this area needs more heat. Final check. Inspect the PCB for accidental solder bridges between solder joints. You should have no components left in the boxes assemble the PCB into the housing Mark with labels the output connectors Testing the Low-Cost Solar battery regulator. Instructions to follow 13

14 Appendix 1 Worksheet Layout of components Top view PCB 14

15 Appendix 2 15