Small capacity voltage regulator charging circuit diagram

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This small-capacity (100VA) voltage regulator and charging device has a load capacity of more than 500 watts during voltage regulation and voltage regulation; it can only load 100 watts during inverter and charging. The working principle and production of the device are described as follows:
Charging the following picture from the power plug CX input 220V mains, press the ZK charging button, the mains via the Xl, ZK band switch TK common arm connected to the Bl high-end tap line X3, X2 directly to the low end of Bl, secondary 12V + The 12V winding and the diodes D2 and D3 form a full-wave rectification circuit. The battery itself acts as a filter, and its output DC is up to about 12V. The battery is charged by the root number 2≈16.9V (FJ is set to prevent the polarity of the battery from being reversed). Adjust the TK to adjust the charging current. The charging current of this device has an adjustment range of 0.5~5A. If the 5A DC meter is connected to the D3 negative electrode ※, it can be read directly. The charging current depends on the battery capacity; the charging time depends on the battery capacity and the charging current.


Two empirical formulas are provided below for reference:
1. Standard charging current I charge = Ah (Ah) × 0.125 (coefficient)
2. Fully charged time h (hours) ≈ Ah (Ah / I charge (A). 0.6 ~ 0.7 (coefficient)

Inverter is connected to a fully charged 12V battery, press the ZK inverter button, the multi-resonant circuit composed of V9, Vl0, Rl, R2, 3, R4, C3, C4 is positively oscillated, V9, Vl0 collector The positive square wave is output in turn, and is integrated by Cl, C2 and R5, R6 (approximate sine wave), V7, V8, and then V5 and V6 are excited respectively, so that Vl~V4 respectively working in parallel obtain sufficient amplitude. The driving power is also turned on and off in turn, the emitter current of Vl ~ V4 flows through the 12V + 12V winding of Bl, the high voltage side of Bl induces the AC high voltage, adjusts TK, and can adjust the output voltage.
WP is the symmetrical balance adjustment resistor of the oscillating circuit. Adjusting it can make up for the difference in characteristics of components such as V9 and V10, so that the positive and negative amplitudes of the output and the waveform are basically symmetrical. Before the test, first adjust to the intermediate resistance position, after power-on inverter (connected 50W ~ 80W load), generally with subjective hearing adjusted to the transformer Bl noise is the smallest (the general ear is not close to hear). If the oscillating differential output is severely asymmetrical, it may cause the V1, V2, V3, and V4 output waveforms to be poor, and the transistor may be heated or damaged.
V5, V6 (D325) should use genuine tube. If you are making a large-capacity device, it is necessary to use DD15D.
The V5 and V6 emitters are respectively connected to the Vl, V2, V3, and V4 bases by the indirect reverse-coupled connection of the 3V windings on Bl, which can improve the saturation and cut-off depth of V1 to V4, which is beneficial to improve the working efficiency of the four transistors. If the phase is wrong, the output voltage is low and the load characteristics (capability) are poor. In the opposite direction, the emitters of V5 and V6 or the bases of Vl, V2, V3 and V4 should have a positive voltage of 0.8V to 1.2V. If it is negative or 0, the phase is wrong.
The length of the inverter time depends on the battery capacity and load. When making, Vl ~ V4 should add 120 square centimeters of heat-dissipating aluminum plate.

The power supply is connected to the listed power, and the ZK voltage regulator button is connected. Then press N, CCJ pull-in, CCJ-2 self-protection, CCJ-1 will connect the mains via ZK and WJ contacts to Bl tap 2 or 6, XZ directly Bl low-end and output, the voltage regulation detection control circuit also has a power supply, and the circuit enters a steady state. The mains is connected to the tap 2 or 6 by the contact of the WJ with the voltage of the city, and the output is always connected to the center X3 of the tap winding. Relatively speaking, the output voltage can be stabilized within a certain range.
The working principle and debugging of the detection control circuit; the main circuit is powered by the voltage regulator +12V, and the base bias is supplied by the unregulated B2 mains secondary +16.5V~22.5V. When the mains rises to a certain value (such as 245V), V12 is positively biased, WJ is connected, WJ contacts e, d are connected to the mains connected to the B6 end (high end), the output is at the middle 4, the output is reduced by about 30V. . While V12 is on, V13 base potential is pressed again by N, and the 1W center arm is slowly adjusted from the b end to the a end, and the V12 is just turned on, WJ is connected; then the 185V mains is input to the device. The 2W center arm is slowly adjusted from the b end to the a end, and the V12 is just cut off and the WJ is released. Although there are D8 and D9 isolation shunts, their mutual involvement still exists. These two adjustments must be repeated at least three times to adjust. Finally, input the 260V mains of the device, press N, WJ to pull in. In this case, slowly adjust the 3W center arm from the b end to the a end, and adjust to V14 just to turn on the CJ, CJ The normally closed contacts A and B are disconnected, the CCJ is de-energized, and the contact CCJ-1 cuts off the mains input to achieve the purpose of overpressure protection. The suppression circuit, the heat dissipation aluminum plate with the power tube fixed and the assembly drawing of the whole machine are shown in the figure below.

When auto-coupling voltage regulation and voltage regulation, the mains does not pass the CCJ-1 through the ZK and TK sliding arms to convert the Bl taps, down to the boost, and vice versa.

Production, option considerations
1. ZK uses a commercially available 5-interlocking double-pole double-throw key switch.
2. The relay CCJ has a high working voltage, and the FJ contact has a large capacity. The selection is strict, and the installation should be away from the circuit board, and each is independently fixed to a suitable safety part, and is well insulated from the casing.
3. Bl is wound with the core of the transformer above 100VA and the skeleton itself. The diameter of the low-voltage winding is relatively thick. It is best to combine the two wires and combine them into a center tap winding. The two 3V windings are also wound in two wires. Interstage insulation should be reliable.
4. Vl ~ V4 is directly mounted on a 160 × l20 square mm, 2mm thick aluminum heat sink, D2, D3 directly soldered on the collector (solder) and emitter feet. The aluminum plate is the collector and is +12V. The aluminum plate should be fixed with insulation support. The electrical negative of this device is not connected to the casing.

5. The connecting wire depends on the current passing through. It is better to use a regular single or multi-strand assembly line with thicker wire diameter, higher insulation and temperature resistance.
6. B2 can be used as a commercially available small transformer. If there is a double 7.5V, it can be used as a 15V winding to switch to bridge rectifier.