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One for the grey nomads
50A Battery
Charger Controller
For 12/24V “house” batteries
Are you one of the many thousands doing the grand trek around Oz in an
RV, caravan or campervan? Then you will know the problems with trying
to charge up your “house” batteries during a long trip. This heavy-duty
charger controller will enable you to charge those batteries much more
quickly using your portable generator and a low-cost 40A or 50A charger.
E
ven if your RV, caravan or campervan has a couple of charge in a fraction of the time. Consequently, the generator
solar panels on the roof, getting your “house” batter- would only need to run for a much shorter time.
What a great idea! The portable generator is used much
ies (ie, the one[s] in the aforementioned RV, caravan
or camper, as distinct from your vehicle battery) quickly more efficiently, it uses a lot less fuel and you don’t have to
up to charge can be a real problem, especially if you arrive listen to the generator droning away for hours on end (nor
do the other people who may be camping at the same site).
at the remote campsite late in the day.
However, there is a drawback with the idea (which was
If you want power, there is no alternative to dragging out
noted by the “grey nomad”). If you don’t monitor the batyour portable generator and using it to charge your batteries.
The big problem is that the limited 12V, typically 5A DC tery voltage closely, there is a considerable risk of overoutput from the generator’s inbuilt charger can take forever charging and ultimately, boiling the batteries.
A multi-stage charger won’t necessarily solve this since,
to bring house batteries up to charge.
That means running the generator for many hours – and depending on its design, during the absorption phase it may
hold the battery at a high enough voltage for long enough
that is not desirable at all.
The idea for this project came to us from a “grey nomad” to cause vigorous boiling of the electrolyte.
There is even a danger of a battery explosion with the
some time ago. Instead of trying to charge from his generaemission of hydrogen during over-charging.
tor’s 12V output, he suggested using a cheap
Design by
Our project removes those risks. It monitors
40A charger, powered by the 230VAC from the
generator. That would bring the batteries up to
JOHN CLARKE the battery while it is being charged and when
32 Silicon Chip
siliconchip.com.au
Features
• Suitable for 230VAC ge
nerators
or solar panels
• Switches off charging wh
en
battery charged
• 12V and 24V batteries
catered for
• Adjustable full charge
voltage
• Easy adjustment
• Charge and power LED
indication
• Generator kill switch ou
tput option
A
K
12VAC
240VAC
+
TO BATTERY
CT
–
D2
12VAC
A
K
TRANSFORMER WITH CENTRE TAPPED SECONDARY
240VAC
12VAC
TRANSFORMER
–
+
THERMAL
CUTOUT
+
θ
siliconchip.com.au
THERMAL
CUTOUT
D1
TRANSFORMER
θ
the voltage comes up to a preset value, say 14.4V, it disconnects the charger.
Better still, about five seconds after that, it switches off
the generator to restore the
serenity.
And best of all, it removes
the need to watch the batteries yourself, so you can
get back to the more serious
campsite task . . . of relaxing
and enjoying yourself!
We should note that many
modern switchmode chargers
do incorporate proper 3-state
or multi-state charging and so
they may safely terminate the
charge in a float condition.
However, if you have large
house batteries, say 200Ah
or more, then even with a
40A charger it will take many
hours to bring them up to full
charge. In that case, you might
elect to only bring the batteries up to the “bulk charge”
state, then terminate the
charge and switch off the gen-
TO BATTERY
–
TRANSFORMER WITH UNTAPPED SECONDARY
~17V PEAK
12V RMS
0V
Fig.1: most simple battery chargers are this simple,
with only a transformer, rectifier and thermal cutout.
It’s the peak voltage that actually does the charging.
erator. Our Charger Controller
will allow you to do that.
Of course, this 50A charger
controller can be used if you do
have mains power on the campsite. Then you don’t need to fire
up the generator – just hook up
the high current charger and
our Charger Controller to your
house batteries and you can be
sure that they will be brought
up to full charge while you enjoy your idyllic surroundings.
Naturally, you don’t have to
be a grey nomad on the grand
tour to consider building our
Charger Controller. It can be
used at any time with any basic charger which does not have
“end-of-charge” detection; most
lower-priced ones don’t.
So why don’t basic battery
chargers limit charging when
the battery reaches full charge?
The answer is that most, especially the lower-cost models,
are too simple: all most have
is a transformer and rectifier
diodes.
November 2016 33
CONNECTOR
FOR CABLE
TO GENERATOR
KILL SWITCH
CHARGER
CONTROLLER
50A
BATTERY
CLIPS
SENSE WIRE FROM
CONTROLLER TO
BATTERY NEGATIVE
TO
CHARGER
+
+
–
–
Fig.2: the charger controller is connected in series with the positive lead from the
battery charger to the positive terminal of the battery. The negative lead of the battery
charger connects directly to the negative terminal of the battery. The negative “sense”
wire, wrapped around the negative lead from the charger is needed for the charger to
monitor the battery voltage and subsequently to interrupt the charging of the battery.
Fig.1 shows two typical battery charger circuits, one
using a centre-tapped transformer and two rectifier diodes or a single winding transformer with a four-diode
bridge rectifier.
Both feed rectified but unfiltered DC to the battery.
The batteries are quite happy to be charged with this pulsating DC; the problem occurs when charging is complete.
The charger doesn’t know so keeps on pushing current in.
The battery overcharges and . . .
Similarly, if you have a bank of solar panels to charge
a 12V or 24V battery, there is the same risk of over-charging. Our Charger Controller can also prevent that from
happening.
BATTERY
the relays and drives the charge indicator, LED2.
12V or 24V batteries
This controller works with 12V or 24V chargers and lead
acid batteries. The battery voltage is measured using a voltage divider comprising a 100kΩ resistor from the battery
positive and two series-connected 22kΩ resistors connecting
to 0V. Total resistance is 144kΩ. The 22kΩ resistors provide
a reduced voltage suitable for IC1 to measure battery voltage at its AN1 input. IC1 requires a voltage at its AN1 input
of less than the supply of 5V and the voltage divider caters
for both 12V and 24V batteries by changing over a jumper
link that selects one of two positions in the voltage divider. Diode D4 protects against reverse battery connection.
Circuit concept
In the 12V position, the divider connection with the
In essence, the 50A Charger Controller is connected in se- jumper (JP1) in the 12V position, comprises a 44kΩ resistries with the positive lead of the charger to the battery. The ance (with the two 22kΩ in series) and the 100kΩ resistor
controller has a 60A automotive relay which disconnects the
with a division ratio of 44/144. This reduces 12V down to
charger when the battery comes up to charge, all under the 3.666V. At full charge, the battery is around 14.4V and so
control of a PIC12F675 microcontroller. A second, smaller the divided voltage is 4.4V.
relay shorts a pair of wires from the kill switch on the genFor the 24V position, the jumper selects the lower 22kΩ
erator. So it’s a pretty simple concept, as shown in Fig.2.
resistor and so the division ratio is 22/144. The reduced
Fig.3 shows the full circuit. You can see the red conduc- voltage becomes 3.666V when the battery is at 24V. At full
tor from the charger positive output at the top right-hand charge of 28.8V, the divided voltage is once again 4.4V.
corner of the diagram. It passes through the contacts of the
Note that the reduced voltage that is applied to the AN1
60A relay and then out to the positive terminal of the bat- input of IC1 is the same for both 12V and 24V batteries.
tery being charged. The output to the battery is also fed to This means that IC1 can detect full charge for either a 12V
an LM2940CT-12 3-terminal 12V regulator which produces or 24V battery just by changing the position of link JP1.
12V to power the two relays,
Instead of using a jumper
RLY1 & RLY2.
shunt to select 12V or 24V,
On the left-hand side of
an SPDT toggle switch on
the circuit, the charger outSupply:........................
12V or12V
24Vand
battery
Supply:........................For
24Vcharger
battery chargers the front panel could be
put is fed via diode D3 to an
used in its place.
Charger
.........
Up toto
50A
ChargerCurrent:.
Current:.
.........Up
50A
LM317 adjustable 3-terminal
The battery is deemed to
Charge
..........
Adjustable from
13.87V
to 13.87V to
Chargevoltage:.
voltage:.
..........Adjustable
range
from
regulator, which provides 5V
be
fully charged when the
for 12V
and and
....................................16.36V
16.36V
for battery
12V battery
DC to run the PIC12F675 miAN1 input rises above the
27.74V
to
32.73V
for
24V
battery
....................................27.74V to 32.73V for 24V battery AN0 input. The AN0 input
crocontroller, IC1.
Battery
With charger
off,off,
~10mA
Batterydrain:..............
drain:..............With
charger
~10mA
The PIC monitors the batis connected to a voltage diKill
switch
output:.......
Contacts
close
for
5s,
Kill
switch
output:.......Closed
contacts
for
5s, 5s after
tery voltage to detect the
vider across the 5V supply,
5s after charging is completed
....................................charging
is completed
end-of charge and it controls
comprising a 5kΩ trimpot
SPECIFICATIONS
SPECIFICATIONS
34 Silicon Chip
siliconchip.com.au
D3 1N4004
100Ω 1W
K
TO
CHARGER +
A
ADJ
50V
IN
120Ω
10µF
+12V
OUT
GND
470nF
10µF
A
D1
1N4004
85
K
5V
ADJUST
100kΩ
TP5V
VR1
100Ω
RLY1
Q1
BC337
B
100nF
6
10kΩ
TP2
(24V BAT)
MCLR/GP3
GP2
AN1/GP1
5
IC1
3
PIC12F675
GP4
-I/P
100nF
22kΩ
Vdd
D2
1N4004
4
1
24V
A
240kΩ
7
GP5
AN0/GP0
C
B
Q2
BC337
E
2
LM317T
BC337
Vss
8
1kΩ
9.1kΩ
E
λ LED1
K
12/24V 5 0A CHARGER CONTROLLER
OUT
IN
LM2940CT-12
LEDS
λ LED2
OUT
ADJ
C
CHARGING
POWER
K
B
1kΩ
A
A
9.1kΩ
SC
TO
GENERATOR
‘KILL’ SWITCH
A
1kΩ
TP1
(12V BAT)
2016
CON2
K
VR2
5kΩ
22kΩ
D4
1N4004
RLY2
CHARGE
VOLTAGE
12V
K
GND
E
1kΩ
JP1
TO
BATTERY –
C
220Ω
10µF
TO
BATTERY +
86
A
300Ω
87
470µF
+5V
NO
ZD1
39V
1W
OUT
IN
K
REG2 LM2940CT-12
03
REG1 LM317T
COM
56A
WIRING
K
A
GND
IN
OUT
GND
1N4004
A
K
Fig.3: the microcontroller in this circuit (IC1) primarily acts as a comparator. It compares a sample of the battery
voltage (at its AN1 input, pin 6) with a reference voltage its AN0 input, pin 7. When the voltage at pin 6 rises above
that at pin 7, IC1 switches on transistor Q1, to actuate relay RLY1 and interrupt the charge.
(VR2) and the associated resistors in series to 0V.
VR2 is adjusted to set the required full charge voltage
for the battery. For a 12V battery, VR2 is adjusted to obtain
1.44V, measured between TP1 and GND, resulting in 4.4V
at the AN0 input. For a 24V battery, (with a full charge
voltage of 28.8V) set VR2 for 2.88V between TP2 and GND.
Note that the GND terminal is connected to the negative
terminal of the battery. Without this connection, the Charge
Controller cannot work.
Relay RLY1 is controlled by the GP2 output of IC1 and
this drives the base of transistor Q1 which turns on the relay.
Relay RLY2 is controlled by via the GP4 output and transistor Q2. Diodes D1 & D2 are included to clamp the voltage
spikes which are generated when the relays are turned off.
If the diodes were omitted, there would be a risk that Q1 &
Q2 could be damaged by the high voltage spikes.
Charging sequence
IC1 monitors the battery at the AN1 input and switches
on relay RLY1 if the battery voltage is over 9V (or over 18V
for a 24V battery). The relay contacts then pass the charging current from the charger to the battery.
When the battery reaches full charge, the relay switches
off to disconnect the charger. The battery is then continuously monitored and relay RLY1 will be switched on again
siliconchip.com.au
if the battery voltage drops to 12.5V or below, for a 12V
battery, or below 25V for a 24V battery.
Of course, if the charger is fed by a portable generator
and the kill switch lead is connected, the generator will
have been turned off and will have to be manually restarted for charging to re-commence.
The charging indicator (LED2) flashes once each second
during charging and stays fully on once the battery is fully
charged. LED2 is off when the battery is disconnected (ie,
below 10V or 20V). LED1 is on while ever the charger is on.
Kill switch relay
Relay RLY2 is included to switch off the generator once
the battery charger has been disconnected by the main relay, RLY1. Relay RLY2 is switched on five seconds after
RLY1 switches off, for five seconds. The kill switch lead
is connected to a socket (which needs to be installed) on
the generator, in parallel with the contacts of the generator’s engine (kill) switch.
Construction
All the components of the Charger Controller are assembled onto a PCB coded 11111161 and measuring 122
x 53.5mm. It is housed in a UB3 plastic case measuring
130 x 68 x 44mm.
November 2016 35
Fig.4: the component overlay and external wiring to the PCB.
Note that the heavy duty wires are not shown here – see Fig.5.
Before installing any components on the PCB, place it
in the plastic case and mark out the position for each of the
corner mounting points on the base.
Fig.4 shows the component overlay of the PCB and the
battery negative terminal and the kill switch socket. Fig.5
shows the heavy duty wiring for the connections to the battery and charger.
You can begin assembly by installing the resistors, using a multimeter to check the value of each before inserting
it. (The table also shows the colour codes for each resistor
value). Diodes D1-D4 and the zener diode ZD1 can be installed. These must be oriented as shown and be careful
not to mix the diode types.
(By the way, if you don’t want to use the kill switch facility, you can omit the components associated with it, ie,
connector CON2, the 2-pin socket, relay RLY2, diode D2,
transistor Q2 and its 1kΩ base resistor). On second thoughts,
you probably should install them because after you use it,
you’ll wonder why you didn’t have the auto-kill facility!
PC stakes can then be installed at test points GND, TP5V,
TP1, TP2 and the relay terminal connections labelled 30,
87, 85 and 86 and the four LED connections.
Install the 3-way header for JP1. (Normally a jumper shunt
is placed on the 12V or 24V battery position). If you intend
to use the Charger Controller for 12V and 24V
batteries, you may prefer to install an SPDT
switch instead. Wire the switch directly to the header or via a 3-way plug.
Make sure you orient the socket for
IC1 correctly and then install the capacitors. The electrolytic types must
be oriented with the shown polarity.
The two 3-terminal regulators are
mounted horizontally onto the PCB
with their leads bent to fit into the PCB
holes. REG2 is installed onto a small
heatsink. Both regulators are secured
using an M3 x 6mm screw and M3 nut.
The trimpots can be mounted next.
VR1 is 100Ω (coded 101) and VR2 is
5kΩ (coded 502). Make sure they are oriented with the adjusting screw as shown in Fig.4; that gives
increasing voltages with clockwise rotation of the adjust36 Silicon Chip
ment screws.
Relay RLY2 goes in next but leave the main relay,
RLY1, until the heavy duty wiring is done.
Next, install the two LEDs. We mounted ours so
that the top of the LEDs are 34mm above the PCB,
which makes them visible through holes in the top
lid of the case.
Before installing IC1, we recommend adjusting
trimpot VR1 for a 5V output. To do this, connect a
12V supply between GND and the anode of diode
D3. Then adjust VR1 for a reading of 5.0V between
GND and TP5V.
If you intend to program IC1 yourself, hex file
1111116A.hex can be downloaded from the Silicon
Chip website (PICs for this project purchased from
Silicon Chip will already be programmed). Install
the programmed PIC into its socket, making sure it is oriented correctly.
Before installing RLY1,
the terminals numbered
30 and 87 will
need to be
wired to
the
Compare this photograph
with Fig.5 opposite.
siliconchip.com.au
56A red cable.
Cut two 90mm lengths of the cable and strip back the
ends of insulation by about 5mm. Solder or crimp (or
crimp and solder) one end of each wire to a large eyelet
connector. The other ends of the cable are soldered to terminals 30 and 87.
Note that the soldering to the No.30 relay terminal should
be made on the side that is near to the No.86 terminal to
avoid any possible shorting to the No.87 PC stake on the
PCB. Wire as shown in Fig.6. At the same time, solder short
(30mm) lengths of hookup wire to each of the 30, 85, 86 and
87 terminals ready to solder to the PC stakes on the PCB.
Cover the bare terminals with 10mm diameter heatshrink
tubing and solder the hookup wires to the PC stakes before
securing the relay with an M5 bolt and nut.
The PCB is mounted on four 6.3mm standoffs at each
corner of the PCB. Use the M3 x 5mm pan head screws to
secure to the PCB. If you are wiring the kill switch output,
its socket can be installed on the end of the case now.
Drilling the case
Drill out the four 3mm corner mounting holes in the base
of the case where marked previously. Countersink the holes
if you intend to use countersunk screws. Drill out holes in
the sides for the two M8 screws and the cable gland. You
may need to use a reamer to open out to the required diameter if you do not have a drill large enough.
The centre of the holes need to be near to the top edge
of the box but no closer than 12mm from the top. See Fig.5
for details.
As previously mentioned, the battery charger red (positive) wire for the positive connection on the battery needs
to be cut and each end terminated to a large eyelet. These attach to the Charger Controller, as shown in Fig.2. The sense
wire from negative battery charger clip is passed through
the end of the case via a cable gland. The wire wraps around
the 0V charger wire and is connected to the charger’s 0V
battery clip. You should be able to solder or crimp the sense
wire to the battery clip or connect it via a crimp eyelet that
is attached to the battery clip with a screw and nut.
Panel label
Front panel artwork can be downloaded from www.
siliconchip.com.au We have provided two versions: one
as we show overleaf and the other with provision for a
12V/24V battery switch.
TO
BATTERY +
EYE TERMINAL LUGS (TWO ON EACH SIDE)
87
86
87A
30
M8 x 15mm
HEX BOLT
& NUT
TO
CHARGER +
RLY 1
85
CONTROLLER
PCB
M3 x 6mm TAPPED SPACERS
M8 x 15mm
HEX BOLT
& NUT
NOTE: FIT HEATSHRINK SLEEVES OVER EACH CABLE ENTRY INTO ITS EYELET,
ALSO OVER SOLDER JOINTS TO RELAY LUGS 87 & 30
Fig.5: this diagram shows the heavy-duty cables running
from the relay (RLY1) to the eye terminal lugs, thence to the
charger and the battery.
siliconchip.com.au
Parts list –
50A Charger/Controller
1 PCB coded 11111161, 122 x 53.5mm
1 UB3 plastic case, 130 x 68 x 44mm
1 panel label, 120 x 60mm
1 12V 60A automotive relay (Jaycar SY4074, Altronics
S4339) (RLY1)
1 SPDT 12V 10A relay (Jaycar SY4050, Altronics S4170A)
(RLY2)
1 2-way screw terminal, 5.08mm spacing (CON2)
4 eye terminals with 8mm eyelet hole, for 10mm2 wire
(Jaycar PT-4936)
1 180mm length of 56A red automotive cable
1 2m length of medium duty black hookup wire
1 TO-220 heatsink, 19 x 19 x 9.5mm
1 8-pin DIL IC socket
1 cable gland for 3-6.5mm diameter cable
1 3-way header with 2.54mm spacings (JP1)
1 pin header shunt (for JP1)
1 SPDT toggle switch (S1) (optional – used instead of JP1
shunt)
2 2-pin chassis-mount male microphone sockets (Jaycar
PP-2013 or equivalent)
2 2-pin female microphone plugs (Jaycar PS-2014 or
equivalent)
2 M8 x 16mm bolts and nuts (NB: NOT PASSIVATED)
1 M5 x 10mm bolt and nut (to secure RLY1)
4 M3 tapped 6.3mm standoffs (for PCB mounting)
8 M3 x 5mm pan head screws (or 4 M3 x 5mm countersunk
and 4 M3 x 5mm pan head) (for PCB mounting)
2 M3 x 6mm pan head screws (for REG1 and REG2)
2 M3 nuts (for REG1 and REG2)
12 PC stakes
1 200mm length of red 10mm diameter heatshrink tubing
2m (or more) of double-sheathed 2-core cable (for kill
switch cable from charger to generator)
Semiconductors
1 PIC12F675-I/P microcontroller programmed with
1111116A.hex (IC1)
1 LM317T adjustable regulator (REG1)
1 LM2940CT-12 low dropout 12V regulator (REG2)
2 BC337 NPN transistors (Q1,Q2)
1 39V 1W zener diode (ZD1)
4 1N4004 1A diodes (D1-D4)
1 3mm red LED (LED1)
1 3mm green LED (LED2)
Capacitors
1 470µF 50V PC electrolytic
3 10µF 16V PC electrolytic
1 470nF 63V or 100V MKT polyester (code 473)
2 100nF MKT polyester (code 103)
Resistors (0.5W, 1%)
1 240kΩ 1 100kΩ 2 22kΩ
1 10kΩ
4 1kΩ
1 300Ω
1 220Ω
1 120Ω
1 100Ω multi-turn top adjust trimpot (VR1)
1 5kΩ multi-turn top adjust trimpot (VR2)
2 9.1kΩ
1 100Ω 1W
November 2016 37
The unit housed in the jiffy box complete with the
high-current cabling. Note the thinner negative
sense wire (black) which passes through the cable
gland and thence wraps around the positive and
negative wires and terminates on the negative
battery clip.
Setting the full-charge voltage
As mentioned, you would typically set the voltage at TP1
and TP2 to 1.44 and 2.88V. That’s gives a full-charge voltage of 14.4V for a 12V battery and 28.8V for a 24V battery.
However, the manufacturer of the battery you are us-
Resistor Colour
No.
1
1
2
1
2
3
1
1
1
1
Value
240kΩ
100kΩ
22kΩ
10kΩ
9.1kΩ
1kΩ
300Ω
220Ω
120Ω
100Ω*
*1W
38 Silicon Chip
4-Band Code (1%)
red yellow yellow brown
brown black yellow brown
red red orange brown
brown black orange brown
white brown red brown
brown black red brown
orange black brown brown
red red brown brown
brown red brown brown
brown black brown brown
A = 8mm diameter
B = 12mm diameter
C = 15mm dia.
12mm
12mm
15mm
B
20mm
Fig.6:
drilling detail
for the 8mm
A
bolts on each side
C
(A), along with the
cable gland (B) and
20mm
microphone socket (C)
on the end of the box. We
haven’t shown the four
3.5mm PCB mounting holes in
the bottom of the box – use the
PCB itself as a template for these.
m
A
m
m
20m
20
You have several options for producing a front panel label. One is to print it onto clear overhead projector film,
using film suitable for your type of printer, and as a mirror
image so the printed side is protected against the lid. With
a black lid you need to attach the label with a light coloured silicone sealant, so the printing can be seen against
the silicone.
Alternatively, you can print onto an A4-sized synthetic
“Dataflex” sticky label that is suitable for inkjet printers
or a “Datapol” sticky label for laser printers. (Google “Dataflex” or “Datapol” for more information).
Then affix the label using the sticky back label adhesive
and cut out the required holes with a hobby knife.
INTERNAL
PILLARS NOT
SHOWN FOR
CLARITY
ing may recommend a higher (say 14.8V) or a lower (say
13.9V) voltage for a 12V battery (and twice those figures
for a 24V battery) and it might need to
be reduced for elevated temperatures.
Codes
Check with the manufacturers’ specifications for details on how much re5-Band Code (1%)
duction with temperature is required.
red yellow black orange brown
You can check the charge voltage
brown black black orange brown
by
measuring the battery voltage as it
red red black red brown
reaches full charge and charging stops
brown black black red brown
and the charge LED continuously lights.
white brown black brown brown
If you missed the full charge point,
brown black black brown brown
switch off the charger and then reapply
orange black black black brown
power and measure the battery again
red red black black brown
at the point where charging ceases.
brown red black black brown
Increase the voltage setting for TP1
or TP2 if the battery charge voltage is
brown black black black brown
set too low.
siliconchip.com.au
Fitted into its jiffy box and cables fitted, the Charger Controller is ready to be connected as shown in Fig.2. Note that the
8mm bolts, washers and nuts should be zinc-plated steel or preferably, stainless steel. Don’t use passivated bolts – they’re
usually not good conductors.
Modifying your generator for a controlled kill!
As explained in the text, one of the best features of this
Charger Controller is that it will automatically turn your
generator off when charging is complete.
But to do this, a small “mod” is necessary – you need to
parallel the generator’s “kill” switch with a two-wire cable
back to the charge controller “kill” relay (RLY2).
Exactly how you do this depends to a large extent on
your generator. Basically, you need to find space on the
control panel to mount a two-pin socket – its mating plug
carries the “kill” command from the charger/controller.
Five seconds after the charge is completed, it shorts
out the kill switch for five seconds (to ensure the generator really does turn off!).
We modified a Powertech 1kW AC/DC generator which
we obtained from Jaycar Electronics some time ago. Unfortunately, this model is not stocked any more – but the
basic arrangement is the same for most small generators.
All you need do is find somewhere on the panel to mount
the socket so that it doesn’t foul anything inside when the
panel is replaced on the generator.
We used two-pin microphone sockets on both the charger controller and the generator. They’re about the small-
est we could find but the big advantage is they have captive (screw-in) plugs and so ensure a reliable connection.
It’s then simply a matter of soldering on a short length
of two-wire cable from the socket to the terminals on the
kill switch (which may be labelled as “ENG SW” or similar),
making sure that the kill switch operation is not disturbed.
Make up a cable as long as is required with mating plugs
and you’re ready to rock and roll . . . in silence!
Building it in
Most RVs, caravans, etc, these days have a separate
“battery box”, more often than not accessible from outside. Unless yours is really crammed full of batteries, it
seems like a good idea to mount the charger/controller
inside the same box.
Whatever you do, make sure the mounting is solid –
you don’t want the unit shaking loose halfway up the Oodnadatta track! An extra strap around the box would be a
worthy “belts and braces” approach.
Naturally, you’d run the generator outside the van (watch
those carbon monoxide fumes!) but connecting cables
SC
could stay readily accessible in the battery box.
The modified control panel of the Powertech (Jaycar) 1kW Generator. At left is the two-pin microphone socket we
added (about the only spot possible!). Centre is a close-up of the wiring and right is the panel about to go back in.
siliconchip.com.au
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