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Power Charger for ElektorWheelie

Dual battery charger for lead acid gel batteries

Power Charger for ElektorWheelie
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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Gerber file

CAM/CAD data for the PCB referred to in this article is available as a Gerber file. Elektor 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 its business partner Eurocircuits as the company of choice for its own prototypes and volume production in selected cases.

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)
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”)
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
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)

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