EA Elektro-Automatik BC-512-21RT Battery Charger Schematic

CTRL BOARD

• IC11: AZ431AZ (Voltage Reference)
• IC9A, IC9B: LM358 / LM358N (Dual Operational Amplifier)
• Q7: BC817 (Transistor)
• R39: 2.7KΩ
• R40: 15KΩ
• R65: 2.7KΩ
• R76: 7.5KΩ
• R77: 1KΩ
• R78: 4.7KΩ
• R79: 1MΩ
• R80: 1KΩ
• R81: 10KΩ
• R82: 10KΩ
• D25: 0R (Resistor/Jumper)
• D32: 0R (Resistor/Jumper)
• RJ7: Connection point
• Connections to V12 (12V Supply), points A, B, C, D.

LED BOARD

• IC3: HEF4541B (Programmable Timer/Oscillator)
• Q8, Q14, Q15: BC817 (Transistor)
• R66: 1MΩ
• R67: 2.2MΩ
• R68: 100nF (Capacitor)
• R70: 2.7KΩ
• R100: 47R
• R43: 4.7KΩ
• R71: 4.7KΩ
• R72: 4.7KΩ
• R74: 4.7KΩ
• R75: 4.7KΩ
• D18, D19, D20, D21, D36, D37: MM4148 (Signal Diode)
• LED1: RED
• LED2: GREEN
• LED3: YELLOW
• LED4: RED
• C42: 120nF
• C43: 100nF
• Connections to V12 (12V Supply), RTC, VDD14, CTC, RS, VC, AR, PH, MR, VSS.

Main Power Supply and Control Circuitry

This section details the primary power conversion and control systems.

Input and Protection Circuitry

• SW1: Power Switch
• F1: Fuse (T10AL250V)
• D1: 1N5408 (Rectifier Diode)
• VDR14D431K: Varistor (Surge Protection)
• CX1: 0.47uF (Capacitor)
• CY1: 2.2nF (Capacitor)
• CX2: 1uF (Capacitor)
• LF1: 1.5mH (Inductor)
• LF2: 13mH (Inductor)
• R1A, R1B, R1C, R1D: 330KΩ (Inrush Current Limiting Resistors)

Rectification and Main Filtering

• BD1: KBU2506 (Bridge Rectifier)
• C2: 220uF/400V (Main DC Filter Capacitor)
• L1: 1.14mH (Choke)

Power Factor Correction (PFC) and Switching Stage

• IC1: FAN4800IN (PFC Controller IC)
• Q1: IRFP460APBF (Power MOSFET)
• D11, D11A: 40CPQ100 (High-Voltage Switching Diodes)
• Q2: 2SK2611 (Switching MOSFET)
• Associated components include numerous resistors (e.g., R2A/B: 10R, R3: 150R, R4A/B: 560K, R5: 82R, R6: 6.2K, R7: 39K, R9: 100R, R10: 10K, R11: 10K, R12: 10R, R13: 10R, R14: 10R, R16: 10K, R17A/B: 430K, R18: 6.2K, R19: 620K, R20A/B/C: 300K, R22: 22K, R23: 10K, R24: 10R, R25: 68K, R26: 75R, R27: 75K, R28: 4.7R, R30: 4.7R, R31: 1K, R32: 10k, R33: 10k, R34: 4.7R, R35: 4.7R, R36: 220R, R36A: 220R, R38: 4.7K, R42A/B: 0.1R, R43: 4.7K, R44: 10R, R45: 1.8K, R46: 274K, R47: 10K, R48: 1.5K, R49: 10K, R50: 1.5K, R51: 4.7R, R53: 1.5K, R54: 20K, R55: 24K, R56: 2.2K, R57: 10K, R58A/B: 10R, R59: 1K, R60: 1K, R61: 10K, R62: 510R, R63: 510R, R64: 270R, R69: 4.7K, R70: 2.7K, R71: 4.7K, R72: 4.7K, R77: 1K, R78: 4.7K, R79: 1M, R80: 1K, R81: 10K, R82: 10K, R83: 1K, R90: 75R, R97: 10K, R98: 2.7K, R99: 6.2K, R100: 47R, R103: 510R, R104: 510R, R105: 10K, R106: 1K, R107: 2.7K, R108: 4.7K, R109: 39K, R111: 200K, R112: 390k, R113: 12K, R114: 10K, R115: 3.9K) and capacitors (e.g., C3: 1uF/63V, C4: 1uF/63V, C5: VCC, C6: 100nF, C7: 100nF, C9: 2.2nF, C10: 1uF, C11: 470pF, C12: 10nF/250V, C13: 1nF, C14: 1nF, C15: 10nF, C16: 100nF, C17: 100nF, C18: 470nF, C19: 220pF/1KV, C20: 10nF, C21: 10nF/1KV, C22: 220pF, C23: 100nF, C24: 2.2nF, C25: 2.2nF, C28: 470nF, C29: 100nF, C30: 10nF/1KV, C31: 10nF/1KV, C32: 47uF/50V, C33: 100nF, C34: 100uF, C35: 220uF, C36: 100nF, C37: 470nF, C38: 100nF, C40: 470nF, C41: 10nF, C46: 100nF, C48: 10nF/250V, C49: 220pF/1KV, C50: 100nF, C52: 100nF, C53: 100nF) and diodes (e.g., D3: UF102G, D4: UF102G, D5: MM4148, D6: MM4148, D7: 1N4148, D8: MM4148, D9: MM4148, D10: UF5408G, D12: 1N4007, D13: MM4148, D14: UF102G, D15: MM4148, D16: SS14, D24: 1N4148, D25: 0R, D26: SS14, D32: 0R, D36: MM4148, D37: MM4148) and transistors (e.g., Q3: 2SC2655, Q4: 2SA1010, Q5: BC817, Q9: 2SC2655, Q11: BC817, Q12: BC817, Q13: BC817, Q14: BC817, Q15: BC817, Q16: 2SC2655, Q17: BC807, Q18: 2SA1010, Q20: BC817).
• Z1, Z2: 22V (Zener Diodes)
• Z3, Z8, Z9: 5.1V (Zener Diodes)
• Z4: 18V (Zener Diode)
• Z6: 16V (Zener Diode)
• RLYA: 12V MDM3541428SCQ26655 (Relay)
• FAN: 12V/0.17A (Cooling Fan)

Output Filtering

• L2: 33uH (Choke)
• C26, C27: 2200uF/25V (Output Filter Capacitors)

Auxiliary Power and Control ICs

• IC22: L7812CV (12V Voltage Regulator)
• IC4A, IC4B: COSMO1010
• IC5: COSMO1010
• IC6A, IC6B: LM358 (Dual Operational Amplifier)
• IC7: AZ431AZ (Voltage Reference)
• IC8A, IC8B: LM358N (Dual Operational Amplifier)
• IC12: COSMO1010

Key signal and power lines include: HV (High Voltage), VB+ (Positive Bias Voltage), VCC (Positive Voltage Supply), Vref (Reference Voltage), VO+ (Positive Output Voltage), FG (Frame Ground/Chassis Ground), PWM (Pulse Width Modulation), VFN (Fan Voltage), IAC (AC Input Current), VDC (DC Voltage), RS, CTC, VC, AR, PH, MR, VSS, RTC, VDD14.

Revision History