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ELECTRICIAN - CITS

MODULE 15: Industrial Programmable Systems

EXERCISE 93 : Assemble circuits of battery charger and

Inverter

Objectives

At the end of this exercise you shall be able to
• assemble the battery charging circuit wired on PCB and test it
• construct and test inverter.

Requirements

Tools/Instrument
• Trainees tool kit - 1 Set • Resistors,10∆ 1W - 1 No.
• Pot 1.5∆ /10W
- 1 No.
• soldering iron 35W/250V - 1 No. • Low voltage lamp 6.3V - 1 No.
• De soldering gun 65W/250V - 1 No. • Fuse 250 mA - 3 Nos.
• Star screw driver set (set of 6 Nos) - 1 Set • Neon lamp - 1 No.
• Ammeter 0-10 A M.C - 1 No. • Buzzer 250V - 1 No.
• Voltmeter 0-50V M.C - 1 No. • Soldering flux and 60/40 solder - as reqd.
• Digital multimeter (31/2 digits) - 1 No. • Diode IN 5402 - 3 Nos.
Tools/Instrument • LED : Red and Green - 1 No.
• Auto transformer 0-270 V-5A - 1 No. • Transistor - 2N 3055 - 1 No.
• Step down transformer 240/40V, 300VA - 1 No. • Resistor : 2.2∆ , 22∆ , 50∆ - 1 No each.
• Charger transformer with centre tapping 1K (1 Watt) - 2 Nos.
6V-0-6V,500mA - 1 No. • Electrolytic capacitors
• Sealed maintenance - 1 No. 1000 µfd/25V, 10 µfd, 25V - 2 Nos each.
Free battery 6V/120AH • 2.2 µfd/250V - 1 No.
• Relays double pole - 3 Nos. • Relay NC/No 6V - 1 No.
Materials • Transformer 240V/7.5 - 0 - 75V, 2A - 1 No.
• PCB -115 -General purpose - 2 Nos. • Inverter transformer- iron core
• Push button switches - 2 Nos. laminated 21 SWG - 25 turns,
• Toggle switches 250V/6A - 2 Nos. 29 SWG - 15 turns - Primary
• Diodes 1N4002 - 4 Nos. 36 SWG - 285 turns - Secondary - 1 No.
• Diodes for bridge 1N112 - 4 Nos. • Fuse 2.5A, 0.5A - 1 No Each.
• Capacitors -250mfd /12V - 1 No. • SP Switches (Toggle - 6V) - 2 Nos.

Procedure

TASK 1: Assemble the battery charging circuit

1 Select suiTable PCB (wired PCB)and other components
2 Check all components ie. transformer, relays, battery for their good condition

3 Construct the transformers relays, and other components on PCB. (Fig 1)

4 Connect the charger Transformer (X1)to the auto transformer (X2 ).

5 Connect the secondary of charger transformer (X1) to the full wave bridge rectifier which supplies rectified
voltage to the battery under charge through ammeter, voltmeter and potentiometer.

Note : Step down transformer (X3) keeps the cut off relay in energised condition when the main

AC supply is cut off to the charger circuit. Relay (RL1) is used to cut off the AC main supply to the

charger circuit.

6 Connect the pole (P1) of relay (RL1)to A.C main supply and connect pole (P2) is cut off circuit.

7 Connect the poles (P1 & P2) to normally open (N/O) pin, which will switch ‘OFF’ AC Main supply to the circuit.

8 Connect the test switch (S3) to check battery polarity.

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