Charger for car on IR2153. Pulse charger for charging batteries - Chargers (for cars) - Power sources Charger design elements
A good and interesting circuit for a high-quality charger based on the IR2153 chip, a self-clocked half-bridge driver, which is quite often used in electronic ballasts for energy-saving lamps.
The circuit operates on an AC voltage of 220 volts, its output power is about 250 watts, which is about 20 amperes at 14 volts of output voltage, which is quite enough to charge car batteries.
At the input there is a surge protector, and protection against voltage surges and overload of the power supply. The thermistor protects the keys during the initial moment of switching on the circuit to the 220 volt network. Then the mains voltage is rectified by a diode bridge.
Through the limiting resistance of 47 kOhm, the voltage passes to the generator microcircuit. Pulses of a certain frequency follow the gates of high-voltage switches, which, when triggered, pass voltage into the mains winding of the transformer. On the secondary winding, we have the voltage required to charge the batteries.
The output voltage of the charger depends on the number of turns in the secondary winding and the operating frequency of the generator. But the frequency should not be raised above 80 kHz, optimally 50-60 kHz.
High voltage switches IRF740 or IRF840. By changing the capacitance of the capacitors in the input circuit, you can increase or decrease the output power of the charger, if necessary, you can reach 600 watts of power. But we need 680 microfarad capacitors and a powerful diode bridge.
The transformer can be taken ready from computer block nutrition. And you can do it yourself. The primary winding contains 40 turns of wire with a diameter of 0.8 mm, then we apply a layer of insulation, wind the secondary winding - somewhere around 3.5-4 turns from a rather thick wire or use a stranded wire.
After the rectifier, a filter capacitor is installed in the circuit, the capacitance is not more than 2000 microfarads.
At the output, it is necessary to put pulse diodes with a current of at least 10-30A, the usual ones will immediately burn out.
Attention, the memory circuit does not have short circuit protection and will immediately fail if this happens.
Another version of the charger circuit on the IR2153 chip |
The diode bridge consists of any rectifier diodes with a current of at least 2A, it can be more and with a reverse voltage of 400 Volts, you can use a ready-made diode bridge from an old computer power supply in it with a reverse voltage of 600 Volts at a current of 6 A.
To ensure the required power supply parameters of the microcircuit, it is necessary to take a resistance of 45-55 kOhm with a power of 2 watts, if you cannot find these, connect several low-power resistors in series.
The circuit of such a switching power supply on the Internet is quite common, but some of them made mistakes, but I, in turn, slightly modified the circuit. The driving part (pulse generator) is assembled on an IR2153 PWM controller. The circuit is a typical half-bridge inverter with a power of 250 watts.
Pulse charger for charging batteries circuit
The power of the inverter can be increased to 400 watts by replacing the electrolytic capacitors with 470 uF 200 volts.
Power switches with a load of up to 30-50 watts remain cold, but they need to be installed on heat sinks, there may be a need for air cooling.
A ready-made transformer from a computer power supply was used (literally any one will do). They have a 12 volt bus up to 10 amps (depending on the power of the unit in which they were used, in some cases a 20 amp winding). 10 Amperes of current is enough to charge powerful acid batteries with a capacity of up to 200A / h.
Diode rectifier - in my case, a powerful 30 Amp Schottky diode assembly was used. There is only one diode.
ATTENTION!
Do not short the secondary winding of the transformer, this will lead to a sharp increase in current in the primary circuit, to overheating of the transistors, as a result of which they may fail.
Choke - was also removed from a pulse power supply, if desired, it can be excluded from the circuit, it is used here in a surge protector.
A fuse is also not required. Thermistor - any (I took from a non-working computer power supply). The thermistor preserves the power transistors during voltage surges. Half of the components of this power supply can be soldered from non-working computer PSUs, including electrolytic capacitors.
Field-effect transistors - I installed powerful power switches of the IRF740 series with a voltage of 400 volts at a current of up to 10 amperes, but you can use any other similar switches with an operating voltage of at least 400 volts with a current of at least 5 amperes.
It is not advisable to add additional measuring instruments to the power supply, since the current here is not entirely constant, a pointer or electronic voltmeter may not work correctly.
Finished Charger quite compact and light, it works completely silently and does not heat up at idle, it provides a sufficiently large output current. The cost of components is minimal, but on the market such memory costs $ 50-90.
Winter has come, it's time to think about the charger, for car battery. It is possible to make a charger according to the classical scheme, with a thyristor regulator, but the dimensions and weight of such a charger are very large. You can go and buy a charger, as my friend did, it is thanks to him that I have an excellent factory case)))) - He bought a charger on the market, tried to charge the battery, but somehow it didn’t charge, he came to me, they say, take it apart and see what and how , dismantled laughed and he gave it to me))), in short, inside the trans 80 watts, a diode bridge and a fuse, the trans gives out as much as 11 volts, as you understand, it cannot charge in principle! And I decided to make impulse charging in this case, why impulse? but because the modern element base makes it possible to significantly simplify the circuit without losing reliability.
The principle of operation is as follows, we connect the battery, set the desired charging current (10% of the total battery capacity is recommended, for a 55 A / H battery, the current needs 5.5 A) and go about our business, when the battery is charged, the yellow LED lights up, the battery is fully charged, this charger has protection against short circuit and reverse polarity, which will significantly extend its life))).
This charger is assembled on an inexpensive UC3845 microcircuit, according to the standard switching scheme, the microcircuit controls a powerful field effect transistor the load of which is a pulse transformer. Almost all radio elements can be torn out from computer power supplies, including a transformer, although it will have to be rewound, it took me an hour to rewind with smoke breaks, the beauty of impulses is that it only takes a couple of dozen turns to wind.
Here is the power supply schematic.
There are 2 versions of printed circuit boards for this power supply, the main difference in them is in the size of the transformers. choose the one you have.
The boards differ slightly from the circuit in terms of ratings, and a current regulator has been added on the boards, so that the current can be adjusted from 1 to 7.5 amperes, all elements on the printed circuit boards are signed, the circuit may not be useful during assembly.
Until you no longer want to repeat it, here are my photos of the process of winding the worst thing - a pulse transformer, wound on ferrite from a computer power supply.
From the beginning, the first half of the primary winding is wound; I wound 26 turns with a wire of 0.6-0.7 mm. 
Then the insulation layer can be paper tape in 2 layers, or as described 
Next, we wind the power winding of the UC3845 microcircuit with 6 turns of wire 0.3-0.4 mm. 
Again we wind the insulation and the second half of the primary again 26 turns with a wire of 0.6-0.7 mm .. 
We isolate well 
We wind the secondary, pay attention to the direction of winding and to which conclusions to solder the ends of the windings !!!
6 turns in 3 wires with a diameter of 0.8 mm. 
The last layer of insulation and you're done. 
Do not rush to glue the core, for the circuit to work correctly, the inductance of the primary winding should be 370 uH. I had to put pads of cardboard about 1mm thick. between the halves of the core. It is necessary to measure and adjust the inductance !!!
The whole setting comes down to the selection of 2 resistors indicated in the diagram. At the expense of radiators on transistors, a small one is enough for the IRFZ44, it is advisable to put more on the output diodes, they heat up the most, I just didn’t put a radiator on the power transistor, I still need a small radiator, since during operation the circuit is blown by a fan, the heating is not significant .. I put the vole a bit more powerful than the IRFP22N50A, well, the diodes, respectively, my charge current reaches 10 amperes and more (you need high-quality blowing of the board). True, you can’t leave it like that for a long time, I have a small radiator on the output diode, and I can’t keep it with my hand at such a current, it gets very hot, but after replacing the radiator, I think everything will be super ...
PS. I already burned the charger once - when charging a battery with a capacity of 190 A / h, I set the current as it seemed to me 9.99A but did not take into account that the ammeter simply does not show anymore))) in general, the current there was far beyond 10 A - 3 resistors burned out diode 4148 and power transistor, after replacing everything works further as expected, added a radiator to the power transistor and installed a 120 mm cooler, now the cooling has improved there are no problems with charging)))) To power the digital ampervoltmeter and cooler, I put a small transformer at the output of it 12 volts of change, if the cooler is powered by a charging converter, then at low current it has very small revolutions
Here is a photo of what I got, the battery temporarily powers the voltammeter, I will remove it but later)))
