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to the calculated 6.25 ohms. This standard value is close enough to the calculated value for proper operation. The C/30 resistor is R3 on the schematic. Again the standard value of 10 ohms is close enough to the calculated value for proper operation. Later on we will see that it s possible to fast-charge the batteries because of the voltage-sensing capacity of the circuit. V1 is a 5K-ohm potentiometer. It is set to trigger the SCR when the NiCd batteries are fully charged. The SCR, once triggered, allows current to flow through a DPDT relay. When power is applied to the circuit, current flows through the LM317 charging the batteries at a C/10 rate. Resistor R3 is shorted by one-half of the DPDT relay. Current also flows through resistor R1, which is a current-limiting resistor for light-emitting diodes (LEDs) D1 and D2. Upon power-up, the red LED D1 will be lit. The red LED indicates that the circuit is charging. As the batteries charge, the voltage drop across V1 becomes greater. After about 14 h, the voltage drop across V1 is great enough to trigger the SCR. When the SCR is triggered, current flows through the coil of the DPDT relay. The relay switches, causing the red LED to go out and the green LED to turn on. The green LED signals that the batteries are fully charged. The other half of the relay switches, opening up the short on resistor R3. With R3 now in the current path, the current flowing to the NiCd batteries is cut to a C/30 level. Diode D3 prevents any current from the batteries flowing back into the circuit. Determining the trigger voltage from V1 For the circuit to function properly, the SCR must turn on when the NiCd batteries are fully charged. The easiest (best) way to do this is to place depleted batteries in the charger, charge the batteries for 14 h, and then adjust V1. When the batteries are fully charged, slowly turn V1 until the relay clicks and the green LED turns on. Design notes When building a charger for your application, keep these points in mind. The main considerations are choosing the C/10 and C/30 current-limiting resistors. Use the given formulas for selecting these values. Current-limiting resistors should be rated around 2 W. If the charging current is high (greater than 250 mA), heat-sink the LM317. If the charger is switched on without the NiCd batteries being connected, the relay will switch immediately, turning on the green LED and providing a C/30 current.
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When building a charger for higher voltages, increase the value of R1 proportionally to limit the current flowing through the LEDs. For instance, for a 12V unit make R1 680 ohms; for a 24V unit make R1 1.2K ohms. At high voltages you may need a low-ohm-value, current-limiting resistor connected to the DPDT relay. Measure the C/10 and C/30 current flowing to the batteries. These measurements will ensure that the proper current is being supplied to the batteries. Series and parallel charging How the batteries are configured determines the voltage and current of the transformer one should use. If you have eight C battery cells in parallel, you need to multiply the current requirements of each individual cell by 8. If the cell is rated at 1200 mAh, the C/10 requirement per battery is 120 mA. For eight cells in parallel, you need close to 1 A (8 120 mA 960 mA 0.96 A) of current. The voltage required is just 1.5 V. The ideal transformer s output would be 1.5V at 1 A. If the eight cells were held in series, the current requirements would be 120 mA at 12V. Fast charger Many of today s NiCd batteries are capable of accepting a fast charge provided that the circuit can sense when the batteries are fully charged and drop the current to C/30. Typically to fast-charge a battery, you double the current for half the time. So you charge a battery at C/5 for 7 h. Although I haven t tried the above circuit for fast charging, there is no reason why it shouldn t work. You may want to start with a C/10 charging current and adjust V1, and then switch resistor R2 for a resistor with half the value. Parts list U1 LM317 voltage regulator L1 DPDT relay (5V or 12V) D1 Red LED D2 Green LED D3 1N4004 Q1 SCR V1 5K-ohm PC-mounted potentiometer R1 330 ohms, 1 4 W R2 5 ohms, 2 W
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