Conrad 553893 Operation Manual

( OPERATING INSTRUCTIONS

(Rechargeable Batteries

and Charging Technology

Understanding and Using

Item No. 553893

Version 05/14

Table of Contents

Page

1 Becoming familiar with the components of the learning package ...... 4

1.1 The Experimenting Board ..............................................................5

1.2 USB Connection Cable .................................................................. 6

1.3 Solar Module..................................................................................7

1.4 Diodes ...........................................................................................8

1.5 Light Emitter Diodes ....................................................................10

1.6 Transistors ................................................................................... 11

1.7 Resistors ...................................................................................... 12

1.8 Electrolytic Capacitors ................................................................. 14

1.9 Battery Holder .............................................................................. 15

1.10 Experimenting Cable ...................................................................16

1.11 Jumper Wire ................................................................................16

2 Use of the USB-Cable ............................................................................17

2.1 Connecting the USB Cable to the Plug Board .............................17

3 Storing Energy .......................................................................................19

3.1 Energy Storage with the Electrolytic Capacitor............................20

4 Familiarising Yourself with Battery Types ........................................... 21

5 First Step with the Solar Module .......................................................... 21

6 Charging Rechargeable Batteries with the USB Source .................... 24

(

7 Charging NiMH and NiCd Rechargeable Batteries ............................. 26

8 Constant Current Charging ...................................................................29

9 Impulse Charging ...................................................................................33

Page

10 Charging a Nickel Zinc Cell ................................................................... 36

11 Charging Lithium Rechargeable Batteries ..........................................40

12 Monitoring Charging .............................................................................. 45

12.1 Rechargeable Battery Tank Display ......................................................... 45

13 Testing Rechargeable Batteries ...........................................................48

13.1 Test at Low Current .................................................................................. 49

13.2 Test at High Current .................................................................................51

14 Rechargeable Battery and Solar Module ............................................. 55

14.1 Charging Rechargeable Batteries with Solar Energy ............................... 58

14.2 Solar Charger – What to Observe ............................................................ 60

15 Using a Return-Current Block ............................................................... 62

16 Using the Charge Controller ................................................................. 64

17 Solar Charge Monitoring of the Lithium Rechargeable Battery ........66

18 Combination Chargers, Charging and Maintenance of Charge ......... 69

19 Solar Night Light .................................................................................... 72

20 Maintenance of the Capacity of Rechargeable Batteries ...................76

20.1 Rechargeable Battery Emergency Rescue ..............................................76

20.2 Rechargeable Battery Care...................................................................... 77

1. Becoming familiar with the components of the learning package

Pieces Component Specication

1 Plug board SYB 46, 270 contacts

1 Solar module

1 USB plug with cable and ends

1 Transistor 2N3904

1 Transistor 2N3906

1 Schottky diode, blue BAT 42

2 Silicon diodes 1N4001

1 LED, red 5 mm

1 LED, orange 5 mm

1 Flashing LED, red 5 mm

1 Carbon resistor 1 W

8 Carbon resistors ¼ W

1 Electrolytic capacitor 1,000 µF, 10 V

1 Battery holder with wire Mignon, AA

4 Plug pins

2 Alligator cable, red and black

1 Jumper wire 1.0 m

for the plug board

1.1 The Experimenting Board

The experimenting board, also called a lab plug board or simply plug board, permits setting up the experiments without using a soldering gun. It comprises of contact springs inside that are connected to each other in a row system. The electronic components and connection wires can be plugged into the contacts repeatedly and thus permit circuit setup without soldering or screwing. Connection wires diagonally cut off with a wire cutter can be pushed in most easily.

The plug board enclosed with the learning package has a total of 270 contacts in the 2.54-mm grid. The 230 contacts in the middle area are connected by vertical strips in rows of 5 each.

At the edges of the wide side, there is one row each with 20 contact points that are horizontally connected with a rail. These „upper“ and „lower“ rows are well suitable as power supply rails.

Fig. 001: The plug board – the power supply rails at the top and bottom

1.2 USB Connection Cable

The USB connection cable of the learning package has a USB A plug on one side and a pin plug for the plug board on the other side. This permits connecting the 5 V (Volt) power supply of a USB source (USB mains plug) to the plug board.

Important!

When connecting the pin plug to the plug board, always observe polarity! The red cable to the pin plug is the plus pole, the black is the minus pole.

Fig. 002: USB connection cable, connection assignment of the plug: 1 = GND, 2 = D+, 3 = D-, 4 = +5 V

Important note on use of the USB power supply

It is urgently recommended to use a simple USB mains unit for the following experiments (e.g. for a mobile phone) with 5 V voltage and at least 500 mA (milliampere) power output.

The USB power supply for the experiments could come from the computer‘s USB socket, but this is urgently advised against!

The reason: Basically, high power devices at the computer USB socket may have a current consumption of 500 mA, low power devices one of up to 100 mA. Unfortunately, not all USB sockets (depending on computer type) are short-circuit protected! Often, there is only one fuse soldered in at the socket, sometimes also the corresponding resistor. Some devices have a fuse that will reset on its own, in others it must be replaced after a short circuit.

There are also mobile computer systems where the USB socket emits a reduced voltage and a reduced current.

1.3 Solar Module

The enclosed solar module comprises several polycrystalline solar cells. The silicon material, put together from several crystals, is contaminated by deliberate doping so that there will be a negative and a positive layer.

At the top, the N-layer (negatively doped) is coated dark blue for better light absorption. The lower layer is the P-layer.

Incoming light will put the electrons in motion and there will be a voltage between

the two described layers. We can use this voltage and the owing current.

A single crystalline silicon solar cell will reach approx. 0.5 V per cell. The current depends on the cell size.

Fig. 003: a) Solar module with protective lm, b) Circuit symbol

1.4 Diodes

A diode only permits current to ow in one direction. They are therefore used to

rectify alternating voltages and block undesired polarity in direct voltage. The function of a diode can be imagined as a kind of check valve (as in water installations) in regular operation.

Fig. 004: a) Silicon diode type 1N 4001; the cathode of the diode can be recognised by the printed-on dash.

In passage direction (circuit symbol arrow), considerable current starts owing in

the silicon diode, such as the 1N 4001, only from a voltage of approx. 0.6–0.7 V or 700 mV (millivolt) onwards.

In photovoltaic systems, low-loss Schottky diodes are usually used in two ways: As blocking diodes and as bypass diodes. The blocking diodes prevent the rechargeable battery from discharging through the photovoltaic modules if there is no sunlight. The bypass diodes protect solar cells and the panel from possible damage that may be caused by partial shading.

The other connection wire is the anode. The technical current direction goes from the anode to the cathode. b) Circuit symbol of the diode

Fig. 005: a) Schottky diode, b) its circuit symbol

1.5 Light Emitter Diodes

The LED (light emitting diode) has another property in addition to those of a regular diode: It lights up when voltage is applied. LEDs should usually always be operated with a dropping resistor for current limitation. Red LEDs require the lowest voltage (1.8 V). Then there are yellow, green, blue and last white LEDs with the highest voltage (up to 3.6 V).

a) b)

Fig. 006: a) Connection assignments of the lightemitting diodes: the anode (+) with longer connection wire (left) and the cathode (–), b) additionally marked

In addition to the »normal« LEDs, there are also special versions such as a

ashing LED. The ashing LED can be recognised by the small black drop within

the red housing. This dot contains tiny electronics in the form of an integrated

circuit that makes the LED ash - once the right voltage is applied.

by a attening at the housing. c) The circuit symbol

of the LED

1.6 Transistors

Transistors are active components that are used in electronic applications to switch and amplify current and voltage.

The bipolar transistors contained in the learning package have the type designations 2N 3904 and 2N 3906. These are complementary small-power transistors that are suitable for a maximum operating voltage of 30 V and a current of up to 200 mA. Complementary means that they are a matching transistor pair of an NPN and a PNP transistor. The designations »N« and »P« stand for the negative and positive semi-conductor layers in the transistor. If you are not very familiar with these terms yet, you will understand their functions from the practical experiments later.

Fig. 007: Transistor connections.

E = Emitter, B = Basis, C = Collector

How the transistor works

A small current applied to the basis-emitter section can control a large

current on the collector-emitter section. I.e. if a low basis current is owing

(positive in NPN transistors, negative in PNP transistors), the transistor will conduct the current from the collector to the emitter or vice versa. If no

current is owing through the basis or if the basis connection is with negative

(NPN) or positive potential (PNP), the transistor will block.

Fig. 008: Circuit symbols for NPN and PNP transistors.

1.7 Resistors

A resistor is a passive element in electrical and electronic circuits. Its main task is reduction of the owing current to sensible values (also see chapter »Light-Emitting Diodes«).

The best-known resistor build is the cylindrical ceramics carrier with axial connection wires.

Fig. 009: a) Resistor, b) Circuit symbol

The resistor values are encoded and printed on as coloured rings. The learning package contains carbon layer resistors with the following values and colour rings according to the table:

Amount Resis-

tance

1 1.2 Ω Brown Red Gold Gold

1 1.5 Ω Brown Green Gold Gold

1 10 Ω Brown Black Black Gold

1 100 Ω Brown Black Brown Gold

3 1 kΩ Brown Black Red Gold

1 2.2 kΩ Red Red Red Gold

1 100 kΩ Brown Black Yellow Gold

1st ring

1st number

2nd ring

2nd number

3rd ring

Multiplier

4th ring

Tolerance

1.8 Electrolytic Capacitors

Electrolytic capacitors (elcos) have a high capacity as compared to regular capacitors. Due to the electrolyte, an electrolytic capacitor is polarity-dependent and the connections are marked with a plus and a minus pole. If a component is connected »swapped« for an extended period of time, this will destroy the electrolyte of the capacitor. The printed-on maximum voltage indication should not be exceeded. Else, the insulation layer may be destroyed.

µ always is the millionth part of the basic unit. µF means micro farad.

a) b)

Fig. 010: a) Electrolytic capacitor. The minus pole is marked by a light-coloured dash at the housing. b) The circuit symbol of the electrolytic capacitor

1.9 Battery Holder

The battery holder is used to hold the rechargeable battery in the AA-mignon format. The battery holder can also be used for the AAA-micro format if the spring at the minus pole connection is elongated a little.

Fig. 011: a) Battery holder; b) Circuit symbol of the battery

1.10 Experimenting Cable

Use the red and black experimenting cables at the ends of which alligator terminals are connected to quickly and simply electrically connect parts to the circuit and to each other – without soldering gun and screwdriver. It is sensible to use the red connection cables for the plus pole and the black ones for the minus pole.

Fig. 012: Experimenting cable with alligator clamps

1.11 Jumper Wire

Wire bridges can be made of the enclosed jumper wire. For this, estimate or measure the approximate length of the wire jumper (plus the length for the wire ends that are to be pushed into the plug-in contacts). The ends must be stripped on approx. 8 mm then. Connection wires that were cut off with a wire cutter can be plugged more easily. The wire jumpers produced once can be reused as often as desired.

2. Use of the USB-Cable

The enclosed USB cable should be connected to a 5-V-USB plug-in mains adapter as it is used for charging mobile phones. Generally, connection to the USB output of a PC is possible, but advised against. The reason: At accidental short circuit when setting up the circuit, the current limitation in the computer (usually in the form of a resistor) may be destroyed.

2.1 Connecting the USB Cable to the Plug Board

Test setup: Plug board, cable with USB-A plugs and pins, resistor 1 kΩ, resistor 1.5 Ω, red LED

The USB cable can remain connected to the plug board for the following charging experiments.

Plug the pin plug of the USB cable into the contacts of the plug board. Observe that the plus pole of the pin plug leads to the upper current supply rail. Then connect the pin connected to the red cable to the plus pole strip and the pin of the

black cable to the minus pole strip with the enclosed jumper wire (see gure). The protective resistor at 1.5 Ω serves as a short-circuit protection in any case.

a) b)

Fig. 013: a) and b): Connect pin plugs to the plug board; connect the

1.5Ω protection resistance to the plus pole. c): Add the LED and the 1kΩ resistor.

In the next step, plug in the red LED. Observe that the longer connection wire reaches the plus pole. Additionally push the 1 kΩ resistor into the plug board. If the USB plug is now connected to the USB power source, the LED should light up.

Fig. 014: Circuit diagram with USB connection and red LED

3. Storing Energy

The principle of energy storage with electrical current that cannot be perceived with our senses can be compared and explained with a principle that we can observe in

water: A water container is lled with water from a tap. The water can be taken out

again at a later time.

Fig. 015: Principle of energy storage, illustrated by a water tank

The »energy storage« has different forms in the electronic world. The learning package contains an electrolytic capacitor. The storage effect can be illustrated

well with this. The benet of the capacitor storage is in its very long service life.

As compared to the rechargeable battery, the storage capacity is low, which has

the benet for experiments that the principle of storage happens in a short period that can be observed well. Comparison: The water tap lls only a small jar. That is much faster than to ll a larger pool.

3.1 Energy Storage with the Electrolytic Capacitor

Test setup: Plug board, cable with USB-A plugs and pins, resistor 1 kΩ, red LED,

electrolytic capacitor, 1,000 µF

The preceding setup is expanded by the electrolytic capacitor. The connection wires of the electrolytic capacitor point to the plus pole rail of the plug board with their plus poles. If the electrolytic capacitor is plugged in correctly, plug the USB plug into the USB plug-in mains adapter. The LED lights up. Disconnect the USB plug from the USB source. The red LED will continue to be lit for a short time although the power supply has been interrupted. The power is interim-stored in the electrolytic capacitor.

Fig. 016: Plug board with storage electrolytic capacitor

Fig. 017: Circuit diagram

4. Familiarising Yourself with Battery Types

The most common battery types used in everyday life:

1. Lead batteries (lead acid, lead gel), e.g. starter battery in the car.

2. Nickel cadmium (NiCd; no longer being sold), often used in cordless screwdrivers.

3. Nickel metal hydride (NiMH)

4. Nickel zinc (NiZn; new on the market)

5. Lithium (Li) in very different designs

The lead battery is familiar from cars as „starter battery“. This battery type is cost-

efcient, long-term stable but heavy. Referring to its weight it only has a low energy

content. Lead is a heavy metal. Old rechargeable batteries must be returned and are then recycled.

Battery types 2 to 5 are the object of the following experiments. Although the nickel-cadmium battery is no longer sold, the long service life of this battery type means that there are still many of it in use.

The experiments practically explain the different charging procedures and what to observe during them.

5. First Step with the Solar Module

Experimenting setup: Solar module, alligator clamps, 2 red LEDs

The learning package includes two red LEDs that are hardly distinguishable from

the outside. To nd out which one is the ashing LED and which one the „regular“

one, you can perform the following simple experiment with the alligator cables and the solar module: Connect the alligator cable and clamps to the connection wires of the solar module, red to red and black to black. Then connect the red alligator clamp to the longer connection wire of one of the red LEDs and the black one to the shorter connection wire. If light falls onto the solar module, you can see that

the connected LED either ashes or stays lit.

Fig. 018: Experimenting setup with alligator clamps

Fig. 019: Circuit diagram, on the left the symbol for the solar module

Usually, LEDs should be operated with a dropping resistor. Since the solar module will only deliver a limited current and this is a short-term experiment, you can make

an exception to nd out which one is the permanently lit LED and which one the ashing LED. The ashing LED is then marked with a piece of adhesive tape for

the further experiments.

Fig. 020: Marked ashing LED

6. Charging Rechargeable Batteries with the USB Source

USB is a standard in the computer area and widely distributed. Electronic devices, computer accessories, such as external hard discs, but also small lamps, fans, etc. can be operated with it.

Most mobile phone providers now offer micro USB as the standard device socket for the charging contact.

The USB standard in the computer is set up so that the devices will rst start in

Low Power-Mode (100 mA or 150 mA) and request a higher current before they switch to regular mode.

The different applications mean that mains units with a 5-V-USB current source are very common. The current supplied by the mains unit is usually at 500 to 2,000 mA. This kind of USB mains unit is well suitable for the other charging experiments.

Fig. 021: USB mains unit

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