Vectronics VEC-412K User Manual

IMPORTANT WARRANTY INFORMATION! PLEASE READ

Return Policy on Kits When Not Purchased Directly From Vectronics: Before continuing any further with your VEC kit check with your Dealer about their return policy. If your Dealer allows returns, your kit must be returned before you begin construction.

Return Policy on Kits When Purchased Directly From Vectronics: Your VEC kit may be returned to the factory in its pre-assembled condition only. The reason for this stipulation is, once you begin i nsta lli ng a nd sol deri ng pa rt s, you essenti al ly tak e over the rol e of the devic e's manufacturer . From this point on, neither Vect ronics nor its dea lers can reas onably be held accountab le for the qua lity or the outcome of your work. Because of this, Vectronics cannot accept return of any kit-in-progress or completed work as a warranty item for any reason whatsoever. If you are a new or inexperienced kit b uilder, we urge you to read the manual carefully a nd determine whether or not you're r eady to tak e on the job. If you wish to c hange your mind and return your ki t, you may--b ut you must do i t before you begin c ons tr uc ti on, a nd within ten (10) working days of the time it arrives.

Vectronics Warrants: Your kit contains each item specified in the parts list. Missing Parts: If you determine, during your pre-construction inventory, that any part is

missing, please contact Vectronics and we'll send the missing item to you free of charge. However, before you contact Vect ronic s, please look carefully to c onf ir m you haven't misr ea d the marking on one of the other items provided with the kit. Also, make certain an alternative part hasn't been substituted for the item you're missing. If a specific part is no longer available, or if Engineering has determined that an alternative component is more suitable, Vectronics reserves the right to make substitutions at any time. In most cases, these changes will be clearly noted in an addendum to the manual.

Defective Parts: Today's electronic parts are physically and electrically resilient, and defective components a re r a re. However, if you disc over a n it em duri ng your pr e- c onst r uct i on inventory that's obviously broken or unserviceable, we'll replace it. Just return the part to Vectronics at the address below accompanied with an explanation. Upon receipt, we'll test it. If it's defec tive and appear s unused, we'll ship you a new one right away at no charge.

Missing or Defective Parts After You Begin Assembly: Parts and materials lost or damaged after construction begins are not covered under the terms of this warranty. However, most parts supplied with VEC kits are relatively inexpensive and Vectronics can replace them for a reasonable charge. Simply contact the factory with a complete description. We'll process your order quickly and get you back on trac k.

Factory Repair After You Begin Assembly: Kits-in progress and completed kits are specifically excluded from coverage by the Vectronics warranty. However, as a service to

customers, tec hnicia ns ar e availa ble t o evaluate a nd repai r malf unctioni ng kits for a minimum service fee of $18.00 (½ hour rate) plus $7.00 shipping and handling (prices subject to change). To qualify for repair service, your kit must be fully completed, unmodified, and the printed circuit board assembled using rosin-core solder. In the event your repair will require more than an hour to fi x (or $36.00, subject to change), our technicians will contact you in advance by telephone b efore p erforming t he work. Def ective unit s should b e shipp ed prep aid to:

Vectronics 1007 HWY 25 South Starkville, MS 39759

When shipping, pack your kit well and include the minimum payment plus shipping and handling charges ($25.00 total). No work can be performed without pre-payment. Also, provide a valid UPS return address a nd a day time phone number where you may be reac hed.

VEC-412K Owner's Manual Rapid Battery Charger/Conditioner Kit

INTRODUCTION

Quickly and safely charge all types of NiCad or NiMH batteries; including cell phones, camcorders, lap-top computers, hand-held radios—many in less than a hour! Vectronics’ exclusive

RapidBattery

batteries are fully charged and its top-off feature keeps batteries at full-charge, without overcharging. Simple wall-chargers can fry expensive battery packs if used for weeks at a time. You set how many cells are to be charged, what charge rate to use and for how long, and the discharge rate. The smart integrated circuit chip then takes control—it senses the correct points for discharge and fullcharge. After a full charge, the charger automatically keeps the battery at peak capacity with a periodic top-off charge.

NiCads can develop a memory effect making your batteries appear to be nearly dead or to have a shortened life. Vectronics’s discharge-before-charge feature can recondition NiCads to near new operation by first fully discharging the cells, and then fully recharging the cells. After a few cycles, the memory effect will be reversed, making your expensive battery packs work like new!

technology determines when your

Extend your battery’s useful life. Save valuable time with the Vectronics

RapidBattery

charger kit. No more waiting ho urs for poky trickl e chargers,

and an end to wasting your hard earned dough on new battery pa cks.

TOOLS AND SUPPLIES

Construction Area:

area where you can easily organize and handle small parts without losing them. An inexpensive sheet of white poster board makes an excellent construction surface, while providing protection for the underlying table or desk. Welldiffused overhead lighting is a plus, and a supplemental high-intensity desk lamp will prove especially helpful for close-up work. Safety is an important consideration. Be sure to use a suitable high-temperature stand for your soldering iron, and keep the work area free of combustible clutter.

Universal Kit-building Tools:

additional items to complete, virtually all construction projects require a work area outfitted with the following tools and supplies:

30 to 60 Watt Soldering Iron

High-temperature Iron Holder with Moist Cleaning Sponge

Rosin-core Solder (thin wire-size preferred)

Needle Nose Pliers or Surgical Hemostats

Diagonal Cutters or "Nippy Cutters"

Kit construction requires a clean, smooth, and well-lighted

Although your particular kit may require

VEC-412K Owner's Manual Rapid Battery Charger/Conditioner Kit

Solder Sucker, Vacuum Pump, or Desoldering Braid

Bright Desk Lamp

Magnifying Glass

Phillips screw driver

BEFORE YOU START BUILDING

Experience shows there are four common mistakes builders make. Avoid these, and your kit will probably work on the first try! Here's what they are:

1. Installing the Wrong Part:

and a 10K resistor may look almost the same, but they may act very differently in an electronic circuit! Same for capacitors--a device marked 102 (or .001 uF) may have very different operating characteristics from one marked 103 (or .01uF).

2. Installing Parts Backwards:

capacitors to make sure the positive (+) lead goes in the (+) hole on the circuit board. Transistors have a flat side or emitter tab to help you identify the correct mounting position. ICs have a notch or dot at one end indicating the correct direction of insertion. Diodes have a banded end indicating correct polarity. Always double-check--especially before applying power to the circuit!

3. Faulty Solder Connections:

bridges. Cold solder joints happen when you don't fully heat the connection-or when metallic corrosion and oxide contaminate a component lead or pad. Solder bridges form when a trail of excess solder shorts pads or tracks together (see Solder Tips below).

4. Omitting or Misreading a Part:

Always double-check to make sure you completed each step in an assembly sequence.

Soldering Tips:

professional soldering. Before you install and solder each part, inspect leads or pins for oxidation. If the metal surface is dull, sand with fine emery paper until shiny. Also, clean the oxidation and excess solder from the soldering iron tip to ensure maximum heat transfer. Allow the tip of your iron to contact both the lead and pad for about one second (count "one-thousand-one") before feeding solder to the connection. Surfaces must become hot enough for solder to flow smoothly. Feed solder to the opposite side of the lead from your iron tip--solder will wick around the lead toward the tip, wetting all exposed surfaces. Apply

Cleanliness and good heat distribution are the two secrets of

It always pays to double-check each step. A 1K

Always check the polarity of electrolytic

Inspect for cold solder joints and solder

This is easier to do than you might think!

VEC-412K Owner's Manual Rapid Battery Charger/Conditioner Kit

solder sparingly, and do not touch solder directly to the hot iron tip to promote rapid melting.

Desoldering Tips:

these instructions carefully! First, grasp the component with a pair of hemostats or needle-nose pliers. Heat the pad beneath the lead you intend to extract, and pull gently. The lead should come out. Repeat for the other lead. Solder may fill in behind the lead as you extract it--especially if you are working on a double-sided b o ar d with plat e-thr o ugh hol es. Sho uld this ha pp e n, tr y heat ing the pad again and inserting a common pin into the hole. Solder won't stick to the pin's chromium plating. When the pad cools, remove the pin and insert the correct component. For ICs or multi-pin parts, use desoldering braid to remove excess solder before attempting to extract the part. Alternatively, a low-cost vacuum-bulb or spring-loaded solder sucker may be used. Parts damaged or severely overheated during extraction should be replaced rather than reinstalled.

Work Habits:

instructions and, in many cases, to perform new and unfamiliar tasks. To avoid making needless mistakes, work for short periods when you're fresh and alert. Recreational construction projects are more informative and more fun when you take your time. Enjoy!

Sorting and Reading Resistors:

a color code (shown below). You don't have to memorize this code to work with resistors, but you do need to understand how it works:

If you make a mistake and need to remove a part, follow

Kit construction requires the ability to follow detailed

The electrical value of resistors is indicated by

Resistor Color Code

Blue = 6 Violet = 7 Gray = 8 White = 9 Silver = 10% Gold = 5%

1st Digit 2nd Digit Multiplier

Tolerence

(gold or silver)

Black = 0 (tens) Brown = 1 (hundreds) Red = 2 (K) Orange = 3 (10K) Yellow = 4 (100K) Green = 5 (1Meg)

When you look at a resistor, check its multiplier code first. Any resistor with a black multiplier band falls between 10 and 99 ohms in value. Brown designates a value between 100 and 999 ohms. Red indicates a value from 1000 to 9999 ohms, which is also expressed as 1.0K to 9.9K. An orange multiplier band designates 10K to 99K, etc. To sort and inventory resistors, first separate them into groups by multiplier band (make a pile of 10s, 100s, Ks, 10Ks, etc.). Next, sort each group by specific value (1K, 2.2K, 4.7K, etc.). This procedure makes the inventory easier, and also makes locating specific parts more convenient later

VEC-412K Owner's Manual Rapid Battery Charger/Conditioner Kit

on during construction. Some builders find it especially helpful to arrange resistors in ascending order along a strip of double-sided tape.

Some VEC kits may contain molded chokes which appear, at first glance, similar to resistors in both shape and band marking. However, a closer look will enable you to differentiate between the two--chokes are generally larger in diameter and fatter at the ends than resistors. When doing your inventory, separate out any chokes and consult the parts list for specific color-code information.

Reading Capacitors:

value identification. Instead, the value, or a 3-number code, is printed on the body.

Value Code

10 pF = 100 100 pF = 101 1000 pF = 102

.001 uF = 102*

.01 uF = 103 .1 uF = 104

As with resistors, it's helpful to sort capacitors by type, and then to arrange them in ascending order of value. Small-value capacitors are characterized in pF (or pico-Farads), while larger values are labeled in uF (or micro-Farads). The transition from pF to uF occurs at 1000 pF (or .001 uF)*. Today, most monolithic and disc-ceramic capacitors are marked with a three-number code. The first two digits indicate a numerical value, while the last digit indicates a multiplier (same as resistors).

Electrolytic capacitors are always marked in uF. Electrolytics are polarized devices and must be oriented correctly during installation. If you become confused by markings on the case, remember the uncut negative lead is slightly shorter than the positive lead.

Diodes:

Always look for the banded or cathode end when installing, and follow instructions carefully.

Diodes are also polarized devices that must be installed correctly.

Unlike resistors, capacitors no longer use a color code for

Electrolytic

1 uF

1uF

35V

Multilayer

(270 pF)

271

Ceramic Discs

(.001 uF) (.1 uF)

102

104

Cathode

(shorter Lead)

Diode

LED

VEC-412K Owner's Manual Rapid Battery Charger/Conditioner Kit

Transistors:

power is applied. Transistors in metal cases have a small tab near the emitter lead to identify correct positioning. Semiconductors housed in small plastic cases (TO-92) have an easily-identified flat side to identify mounting orientation. Many specialized diodes and low-current voltage regulators also use this type packaging. Larger plastic transistors and voltage regulators use a case backed with a prominent metal tab to dissipate heat (T-220). Here orientation is indicated by the positioning of the cooling tab.

Emitter

Integrated Circuits:

marking located on one end of the device. A corresponding mark will be silkscreened on the PC board and printed on the kit's parts-placement diagram. To identify specific IC pin numbers for testing purposes, see the diagram below. Pin numbers always start at the keyed end of the case and progress counterclockwise around the device, as shown:

If transistors are installed incorrectly, damage may result when

Metal Can Device Plastic Device Tab-cooled Device

Metal Tab

Flat Side

Proper IC positioning is indicated by a dot or square

8 7 6 5

Installation

Key

1 2 3 4

Pin Numbers

Installation

Key

PARTS LIST

Your package kit should c ontain a ll of the p arts li sted be low. Ple ase go through the parts bag to identify and inventory each item on the checklist before you start building. If any par ts are missing or damaged, r efer to the warranty section of this manual for replacement instructions. If you can't positively identify an unfamiliar item in the bag on the basis of the information given, set it aside until

VEC-412K Owner's Manual Rapid Battery Charger/Conditioner Kit

all other items are checked off. You may then be able to identify it by process of elimination. Finally, your kit will go together more smoothly if parts are organized by type and arranged by value ahead of time. Use this inventory as an opportunity to sort and arrange parts so you can identify and find them quickly.

Ignore the fourth color band when reading resistors, it denotes the

Note

tolerance value and is not needed for parts inventory or assembly directions.

Resistors:

Qty Part Description Designation

6 1.5-ohm 1/4 Watt

(brown-green-gold)

2 18-ohm 1/2 Watt

(brown-gray-black)

1 220-ohm 1/4 Watt

(red-red-brown)

1 820-ohm 2 Watt

(gray-red-brown)

3 1K-ohm 1/4 Watt

(brown-black-red)

1 27K-ohm 1/4Watt

(red-violet-orange)

11 47K-ohm 1/4Watt

(yellow-violet-orange)

2 100K-ohm 1/4 Watt

(brown-black-yellow)

1 270K-ohm 1/4 Watt

(red-violet-yellow)

R16,R22,R23,R24,R25, R26 R21,R28

R20

R3,R12,R17

R2,R4,R6,R7,R8,R9,R10, R11,R14,R15,R18 R19,R27

R13

Capacitors:

Qty Part Description Designation

5 .1-uF disc ceramic (104 or .1) C3,C4,C5,C6,C7

2 100-uF electrolytic C1,C2

Inductors:

Qty Part Description Designation

1 500-uH choke L1

Semiconductors:

Qty Part Description Designation

2 1N4001, diode rectifier D1,D4

VEC-412K Owner's Manual Rapid Battery Charger/Conditioner Kit

1 1N5822, diode Schottky D2

1 1N5223B, 2.7 volt zener diode D3

1 2N3055, power transistor (TO-3) Q1

1 2N3904, transistor Q2

1 IRF9530, power FET Q3

1 BQ2003 IC (16-pin DIP package) U1

1 78L05, +5Vdc voltage regulator U2

1 LED, red CR1

1 LED, yellow CR2

Switches/Jacks/Misc.:

Qty Part Description Designation

1 2.1mm coaxial power jack J1

1 Rotary switch 2 pole, 6 position SW1

3 DPDT push-action switches SW2,SW3,SW4

1 16-pin IC socket For U1

6 3 position header HD1,HD2,HD3,HD4,HD5,

HD6

6 2 position shorting jumper

1 20 AWG red-black cable

3 4-40 phillips x 1/4”screw

3 4-40 phillips hex nut

1 PC board for VEC-412K

1 VEC-412K Owner's Manual

VEC-412K Owner's Manual Rapid Battery Charger/Conditioner Kit

STEP-BY-STEP ASSEMBLY

Before assembling your kit, please take time to read and understand the VEC kit warranty printed on the inside cover of this manual. Also, read through the assembly instructions to make sure the kit does not exceed your skill level. Once you begin construction, your kit will be non-returnable. Finally, if you haven't already done so, please verify that all parts listed in the inventory are included. If anything is missing or broken, refer to the warranty instructions for replacing missing or damaged parts.

Note that part designators, such as R1, C3, etc., appear on a silk-screened legend on the component-mounting side of the printed circuit board. This corresponds with the parts placement page in the manual. All parts will be inserted on the silk-screen side of the board.

If you have last-minute questions about tools and materials needed to build your kit, please refer back to the section titled "Before You Start Building". If you're ready to begin now, let's get started! The directions use two sets of check boxes. Check one when a step is complete and use the other for double-checking your work before operation.

“Install”

and insert the part into its mounting holes on the PC board. T his includes prebending or straightening leads as needed so force is not required to seat the part. Once a component is mounted, bend each lead over to hold it in place. Make sure trimmed leads don’t touch other pads and tracks, or a short circuit may result:

“Solder”

in place, and to inspect both (or all) solder connections for flaws or solder bridges. If no soldering problems are noted, nip off the excess protruding leads with a sharp pair of side cutters.

Notice that the directions use two check boxes. Check one when a step is complete and use the other for double-checking your work before operation.

¼-Watt Resistor Installa tion:

When you are directed to install a part, this means to locate, identify,

Good

When you are directed to solder, this means to solder the part’s leads

Not Good

+ 24 hidden pages