24V Battery Charger with SCR

http://www.electroschematics.com/9250/24v-scr-battery-charger/

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24V SCR Battery Charger

This circuit was tested and worked properly! Posted by Jim Keith in Power supply with 4 comments Tagged with: battery chargerstestedTL072

This is an extension of the earlier 12V SCR Battery Charger. It is surprisingly easy to increase the output voltage to 24V, but there are both obvious and subtle differences to consider. The most obvious difference is the transition from full-wave center-tapped to a full-wave bridge configuration. In this case, the full-wave bridge is more specifically a semiconverter bridge that contains two rectifiers and two thyristors (silicon controlled rectifiers or SCRs). This project is not recommended for the novice, as advanced trouble-shooting skills and an oscilloscope may be required to get it up and running.

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24V Battery Charger with SCR

http://www.electroschematics.com/9250/24v-scr-battery-charger/

Schematic

TL072 datasheet Bill of materials, excel file link 24v scr battery charger bom.xls Phase control oscillographs

Note that the transformer secondary voltage has significant voltage distortion due to the high peak charging current. This is to be expected and is a function of the leakage inductance and internal resistance of the transformer. Photos

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24V Battery Charger with SCR

http://www.electroschematics.com/9250/24v-scr-battery-charger/

Transformer and output voltage Initially, I thought that the transformer would be a problem, but then I realized that the only thing that had to change is the rectifier configuration. By going from the full-wave center tapped configuration to a full-wave bridge automatically doubles the voltage from 12 to 24V. Of course the output current rating will be lower, but it will be more than half (about 70%) due to the improved secondary waveform that results in lower RMS current. Another consideration is the load regulation, but it is my opinion that it will be satisfactory if it is already designed for battery charger application. Thermally, the transformer is quite forgiving because its thermal time constant is so long that it can charge at the maximum rate for some time before it gets up to temperatureby that time, the battery terminal voltage has increased sufficiently to reduce the charging current. However, it is a good idea to have a properly rated thermal overload switchthat is what the battery charger manufacturers do and it provides short circuit protection as well, and could prevent a thermal melt-down or fire. My particular transformer was rated for 3Aany size transformer may be selected provided the power semiconductors have sufficient current rating. Semiconverter bridge rectifier A semiconverter bridge consists of (2) SCRs and (2) rectifiers. In this application, the SCRs are located in the lower half of the bridge so that the gates may be driven by a positive current source without the requirement for pulse transformer or optical coupler isolation. I elected to go with discrete TO-220 devices due to low cost, high current rating and availability. Bridge module

In the BOM, I selected a 25A bridge module. While it is functional, it is intended for reference only because it costs $60. Locating the SCRs in the lower section referred to as circuit 2. This is the least common configurationso uncommon that DigiKey offers only one such module and has only two pieces in stock. For reference, here are two other module configurations: Circuit 1 places the SCRs in the top sectionit is the most popular, but cannot be gated via this firing circuit schemeit usually requires gate isolation pulse transformers. Circuit 3 is a full converter that uses four SCRsfull converters are used for regenerative applications rather than simple

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24V Battery Charger with SCR

http://www.electroschematics.com/9250/24v-scr-battery-charger/

battery chargers. Flash function Because the regulator circuit derives its power from the battery, it cannot charge if the battery is totally dead. For this reason, I added a flash push button and two rectifiers (D11 & 12) these rectifiers are in parallel with the SCRs. In the event the battery is completely dead, this pushbutton may be pressed to manually charge the battery for a few secondsthis should be sufficient to get minimal surface charge into the battery so that it can now power the electronics. In the 12V battery charger write up, I indicated that I thought that the flash function was unnecessarywell, in the course of time, I found it to be necessary. Note that the pushbutton in this case is quite special, as it must conduct the maximum charge currentmost pushbuttons cannot perform this function without damage from either the high current or attempting to interrupt the 24VDC circuit when the pushbutton is released. DC current at this voltage can draw quite an arc and such can be destructive. The Cherry pushbutton indicated in the BOM is rated for 10A @ 28VDC, and is still inexpensive. Also note that rectifiers D11 & 12 are rated for 6A and are overloaded temporarily during the momentary flash functionthis is OK because the current is allowed to flow for only a few seconds thus preventing junction over-temperature. For a higher current charger, a series limiting resistor may be required to prevent excessive current. A secondary use of D11 & 12 is for line voltage synchronization for the phase control circuit. Circuit Common Normally circuits use a negative commonthat is just the way the world seems to work, but in this case, it was more convenient to make the positive rail the common pointas a result all visualization must be made with this in mind. The only exception is D7 that was installed to prevent damage should the battery get connected reverse. For visualization, simply short out D7. The conventional ground symbol is used for the negative rail. Op amp selection Due to circuit common being the positive rail, it was necessary to select an op amp with a common mode range that extends to the positive railnote that this capability is uncommon among op ampsmany op amps like the LM324 /LM358 have a common mode input voltage range that accommodates the negative rail, but these will not work here and neither will the LM741 op amp. In the earlier 12V version, I recommended the National Semiconductor LF442 op amp, but this device is falling into disuse and the price & availability have subsequently suffered. Instead, I am now recommending the TI TL072 or TL082 JFET input devicesthey cost less than $1 each. One important op amp detail here is powering it via a battery that charges at 29V. While the op amp is rated for 32 volts between rails, the peak voltage of the 24VAC power transformer is dangerously close to that rating. To reduce this voltage, a 6.2V zener diode (D13) is added in series with the negative rail. Ramp Generator C1 and R4 form a ramp generator that generates a negative going sawtooth voltage (relative to the positive rail). It is reset to the positive rail via Q1 and Q2 at line voltage zero crossing. At zero crossing, there is no voltage at the anodes of D11 & D12 (relative to the positive rail), Q1 is off, Q2 is on and C1 is shorted. At all other points in the AC line cycle, C1 is charging. My line frequency was 60HZ. For 50HZ, increase the value of R4 to 82K. Error Amplifier U1B is the error amplifierit amplifies the difference between the -6.2V zener diode (reference voltage) and the feedback voltage at the arm of the V ADJ pot (R6). It is slowed down by the RC filter (R10 & C2), proportionately amplified by the ratio of R14 /R9, and integrated via C3. Perhaps you have heard of a PID (proportional, integral, derivative) controlthis does just that, but neglects the derivative term as it is generally not required in most applications. If the error amplifier is not satisfied, it continues to integrate its output voltage positive or negative until the feedback voltage equals the reference voltage. The function of the operational amplifier is to make the two input voltages equal. The device selection here is the LF442 (or TL082) J-FET input operational amplifier. This is vital in this circuit because the

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24V Battery Charger with SCR

http://www.electroschematics.com/9250/24v-scr-battery-charger/

common mode voltage range of the differential inputs must extend to the positive rail. Few op amps can do this (many have differential voltages that extend to the negative rail, but those will not work in this application). Phase Comparator U1A is the phase comparator. It compares the ramp voltage with the output of the error amplifier. It is also called the ramp-intercept technique. When the ramp generator voltage exceeds the error voltage signal (in the negative direction), the output of U1A switches negative and turns on Q3 thus providing gate current to the SCR that is forward biased. R13 is the gate current limiting resistor. Gate current is approx 100mA. Because the instantaneous ramp generator voltage is time dependent, the point in time at which the phase comparator output switches is also a function of time. To increase the output voltage (or current), the switching point must advance in phase (relative to line synchronization) in order to apply a greater portion of the half-cycle voltage to the battery. Reverse polarity protection If the battery is connected reverse, D7 prevents current from flowing into the regulator circuitry. Since the SCRs cannot be fired, they will not conduct. However, do not press the flash pushbuttonthis is a problem that I have not dealt with yetobserve the Reverse Battery Connection LED. One potential solution requires the addition of a relay that picks up when the battery is reverseits contacts open the Flash pushbutton circuit.

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24V Battery Charger with SCR

http://www.electroschematics.com/9250/24v-scr-battery-charger/

4 Responses to 24V SCR Battery Charger

1. reply

Jim Keith says: on September 28, 2013 at 2:19 am

One detail not mentioned: For oscillographs, charging voltage was set to 27V. With this transformer, it was adjustable up to 28V.

2. reply

Jim Keith says: on September 28, 2013 at 5:02 pm

Note that insulating hardware is required for the diodes indicated on the BOM (FES16GT-E3/45). I was able to avoid insulating hardware because I used some junk box Teccor D1615L diodes that have internal isolationas a result, I was able to connect all 4 tabs to the same aluminum bar without shorting anythingthe bar was live being connected to the negative output. If you do not want the negative terminal grounded to the battery charger case, you will need insulating hardware for the SCRs also. 3. reply @owner, please kindly post here or links of the thermal overload diagram that can be use. i dont no what type of overload to use. i need your guideline on this diagram of the thermal overload. thks hope to read your reply abu says: on September 28, 2013 at 10:48 pm

Jim Keith says: on September 29, 2013 at 3:19 pm reply This is a valid question, but there seems to be no good answer. In my case, I rebuilt an existing battery charger (12V SCR type) that already had a thermal overload relay. The type of overload relay I otherwise had in mind is known as a Phenolic Motor Protector They are used in virtually all refrigerators and air conditionersthey are required to disconnect a stalled motormotor stalling is a problem in refrigeration compressors in which liquid refrigerant prevents the compressor from restarting after a momentary power outage. However, they do not seem to be available as replacement partsI believe that this is for a number of reasons including high reliability because they never seem to fail and the throw-away nature of consumer appliances. http://www.sensata.com/klixon/motor-protector-phenolics.htm My best recommendation is to pilfer one from a junk air conditioner. Industrial motor overload relays cost from $50 to $200 and required a contactor to interrupt the current so this is not a solution. The cheapest is the use of a PTC thermistor type protectorthey are inexpensive, more easily available and come in many current ratingsthe disadvantage is that they do not completely disconnect the load so that they remain latched until power is removed. One possibility is this one:

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24V Battery Charger with SCR

http://www.electroschematics.com/9250/24v-scr-battery-charger/

http://www.digikey.com/product-detail/en/RF1550-000/RF1550-000-ND/1113464 One limitation is the low voltage rating (20V) for the high current versions. Other than that, a conventional fuse provides inexpensive protection.

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http://www.electroschematics.com/9250/24v-scr-battery-charger/

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