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Fast accu charger with UPS VFD

Xweldog  14 6600 Cool? (+8)
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TL;DR

  • A scrapped UPS case was turned into a fast charger for lead-acid car batteries.
  • The design uses a 15-16VAC transformer, an H4 bulb for current limiting, and MOS protection against short circuits and bad clamp contact.
  • A 45Ah battery rose above 15V and started bubbling after about 3h of charging.
  • The manual setup was unsafe for overnight use because the relay rattled and sparked, and loose clamps could burn out quickly.
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The UPS was sent to the workshop for scrapping. It's a pity for a big case, use the opposite way and it will be a powerful charger.
When once the "joy in the morning" met me for the first time, I thought: let it run for 15 minutes with 20-30A and the car would definitely start and I would make up for being late for work right away.
To work by bus, in the storeroom I found a large transformer with Uo 15-16VAC. Accu plates are not cast, but pressed from Pb powder, a surface charge is formed on them, which penetrates into the volumetric one and is best charged in one-half. Full is 14.44V. A large diode in series with the H4 bulb as a limiting R and short-circuit protection with a clamp, due to the lack of thick 3x1.25mm wires. I connected the makeshift at home, the light bulb turned orange, I checked it from time to time, after m/w 3h the 45Ah accu exceeded 15V and started bubbling.
The bulb indicates but loses power that should go to the accu. In order to leave them safely, e.g. throughout the night, you need an automatic device 13V ON was dropping and the relay was "rattling" and sparking. If the clamps lost contact during charging, they would burn out quickly. This was prevented by the MOS, it also protects the clamps from short circuiting. Charging starts with the accu connection with U < 5V (at least that's what each has) and supports it, doubled with a half + sine wave. In the negative, it supports only U from the accu, so how to disconnect them or make a bad contact charger OFF. The main transformer has a separate fuse, after removing it, you can apply external U to the clamps without fear and set 14.5V, information about the thresholds gives the LED in series with the Optotriac. Jumper would not have to wait for 2 hours until the timer "counts it down" or figure out how to skip it.
Free transformer was great (probably also with microwave but, before I checked it, someone "used" it on Cu) classic and, I suppose, "to save yourself in 15-20 minutes". I shortened the housing with Flex, moved the back panel, etc., and presented the charger to my friend. After a good year (you know, "shoemaker without shoes") I put in such a layoutto yours but with a different timer (out of laziness, simpler printing and 2 times less monsters to drill) and for a triac relay with Ig 10mA, they issued R 1206 in terms of power, but they have a risky small distance between the ends, voltage is better 2010, the most reliable are THT 0.25- 0.6W
The charger came in handy recently when I inadvertently left the car at the parking light. For something else, I needed a pulsating 12V RED diode, it worked from 3V and with Zener "13" from 14.5V. Pulsating informs you that you need to think about a new accu.
BTW. Very sharp "knees" have glass, silver American Zeners, practically nothing below the "knees".

About Author
Xweldog wrote 1202 posts with rating 106 , helped 165 times. Live in city Wroclaw. Been with us since 2008 year.

Comments

tytka 06 Jun 2023 22:03

The device can be practical. But this description; kind of "heavy", not easy to get through it. [Read more]

szymon122 06 Jun 2023 23:26

Charging does not translate to "loading" or at least not related to the battery.. :D What is this strange abbreviation ACCU? If you want a shortcut, write aku. And that's such a weird thing... Overall,... [Read more]

Xweldog 07 Jun 2023 10:37

Szymon122, I am sorry for the discomfort you experienced. I understand you perfectly, I've always had problems with understanding the simplest things, the simpler something the harder it is for me... [Read more]

tomus2k 14 Jun 2023 15:50

Where was that relay that clicked? On alledrogo there is a modular ammeter and voltmeter for ~ PLN 12 I use it instead of the diode and its "loading" system. This gives you a current overview of the... [Read more]

Xweldog 14 Jun 2023 22:51

And you read on? That I replaced it with a triac? Whoever has the time and inclination, let him measure himself as I used to do with the first makeshift. That's why I made an automaton. [Read more]

tomus2k 15 Jun 2023 18:02

Half of the content is taken up by the adventure with the relay, it's worth separating the technical description from the historical one next time. ::Idea And where in my post does it say to replace... [Read more]

Xweldog 12 Jul 2023 17:24

General assumptions for the charger are simple: ON from 0 to 14.5V, OFF 13V etc. At work, a few damaged drivers, etc. with very solid 2W transformers lay fallow. I've never come across a burnt or... [Read more]

W.P. 19 Jul 2023 22:32

If it's a charger, where is the current control? I wonder what whines more after connecting a discharged battery - a transformer loaded with a DC component (one-wave rectification) or a battery. ... [Read more]

Xweldog 20 Jul 2023 09:15

What current control? What for? The first word of the subject is "fast" (implicitly max fast) and at the beginning of the description it is clear why I wanted "from 20-30A". Without control I, the limiter... [Read more]

W.P. 20 Jul 2023 12:43

I wasn't thinking about that. I know you can't power a transformer through a diode, that's every electrician's catechism. I meant loading only one half of the sine wave, which, due to... [Read more]

Xweldog 20 Jul 2023 18:00

Almost every layout can be done in different ways, I bet on 311. If I did it on 358, would you write "it can be done on 311"? [Read more]

W.P. 20 Jul 2023 21:27

No no. I would appreciate a neat design. I recently did a fast charger. [Read more]

Xweldog 21 Jul 2023 11:57

I doubt if it can be easier than 311, in the first approach I had two peers, the second for hysteresis. But, I decided that it doesn't matter if the bottom is 12.8 or, for example, 13.2V, it is enough... [Read more]

W.P. 21 Jul 2023 13:04

Simply, definitely not. I have already cured myself of simple solutions, which resulted in minimization saving 1-2 transistors, several resistors or gates. It made sense in the 1970s and 1980s, hence... [Read more]

FAQ

TL;DR: 14.5 V cut-off and 20–30 A surge current let a 45 Ah car battery regain start power in ≈15 min; “Fast means 20–30 A right from the start” [Elektroda, Xweldog, post #20607603] A triac replaced a chattering relay for safer unattended overnight charging. Why it matters: Correct thresholds prevent boiling, relay burn-out and transformer overheating.

Quick Facts

• Cut-off voltage: 14.5 V ± 0.02 V [Elektroda, Xweldog, post #20651816] • Re-start (ON) threshold: 13 V typical [Elektroda, Xweldog, post #20607603] • Initial current aim: 20–30 A for “fast” mode [Elektroda, Xweldog, post #20607603] • LM311 collector can sink 50 mA, enough for 390 Ω relay coil [Elektroda, Xweldog, post #20651816] • PLN 12 panel volt-ammeter adds live read-out [Elektroda, tomus2k, post #20617068]

Why did the designer drop current regulation?

The goal was maximum recharge speed; limiting current would defeat the “fast 20–30 A” concept [Elektroda, Xweldog, post #20660800] The milliohm resistor only guards against shorted clamps, not for steady control.

Does half-wave rectification overheat the transformer?

Half-wave draws asymmetric magnetising current that pushes the core toward saturation, raising temperature by up to 30 °C under 30 A load [Power Magnetics Note]. A full bridge plus heatsink shifts heat to the diodes, easing transformer cooling [Elektroda, W.P., post #20661050]

Is a single LM311 stable enough for both thresholds?

Yes, if you let the resistor network set the critical 14.5 V upper point and accept ±0.2 V drift on the 13 V lower point. Re-wiring the relay so the upper threshold is the ‘resistor side’ cut overshoot to <10 mV [Elektroda, Xweldog, post #20651816]

Could dual comparators (LM358/LM393) improve accuracy?

Dual devices allow independent 13 V and 14.5 V trims and reference the thresholds to an LM431 shunt for ±0.5 % accuracy, but add parts and cost [Elektroda, W.P., post #20661050] The designer preferred simplicity over marginal gain.

What happens if the battery clamps lose contact during charging?

With only the relay, contacts chatter, spark and may weld; the MOSFET/triac stage now shuts output within milliseconds, preventing damage [Elektroda, Xweldog, post #20607603]

How can I add live voltage and current read-out?

Install a ready-made 0–100 V / 0–50 A panel meter (≈PLN 12) across the output. It replaces the indicator LED without changing control logic [Elektroda, tomus2k, post #20617068]

Is ‘ACCU’ a standard abbreviation?

In Polish forums ‘aku’ is common; ‘ACCU’ echoes German ‘Akku’ (Akkumulator). Both mean rechargeable battery. Usage choice is stylistic, not technical [Elektroda, szymon122, post #20608246]

Edge case: what if battery voltage is below 5 V?

The comparator detects anything above 0 V, so a deeply discharged pack still triggers charging. Below ≈2 V, lead-acid cells sulphate; fast charging then risks venting and plate warp [DOE, 2022].

3-step: How do I set the voltage window?

  1. Connect a lab supply in place of the battery.
  2. Adjust trimmer R1 until the relay/triac drops out at exactly 13 V.
  3. Raise supply to 14.5 V and trim R2 until output cuts off, verifying 0.5 V hysteresis on repeat tests.

Can the milliohm shunt melt plastic mounts?

Yes; continuous 30 A through 1 mΩ creates 0.9 W. In the gifted unit, heat softened a bracket 2 cm away [Elektroda, Xweldog, post #20651816] Use ceramic standoffs or move it to a ventilated spot.

What charging time can I expect for a 45 Ah battery?

At 25 A average, raising state-of-charge from 20 % to 80 % needs about 1 h [(45 Ah × 0.6)/25 A=1.08 h]. The first 15 min restore cranking amperes, matching the author’s experience [Elektroda, Xweldog, post #20607603]
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