1

GOVERNMENT POLYTECHNIC
SITAMARHI
(Under state board of technical education, Patna)

A PROJECT REPORT ON FABRICATION OF

BATTERY CHARGER

Submitted to:-
Department of electrical engineering
Government polytechnic Sitamarhi
(Birpur, Malahi, Sursand)
Submitted by:-
1.GAUTAM KUMAR MISHRA (611442017044)
2.TANDAN KUMAR (611442017012)
3.AMIT KUMAR (611442017037)
4.KISHAN KUMAR (611442017039)
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ACKNOWLEDGMENT
I am thankful to Head of department as well as Guide
Prof. Digvijay kumar and our faculties, who gave me
a great guidance regarding project and instructed me the
importance of this in our field.

KISHAN KUMAR
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DECLARATION
I KISHAN KUMAR declare that the project report Fabrication of
battery charger is based on my own work carried out during the
course of our study under the supervision of Prof. Digvijay Kumar.

I assert the statements made and conclusions drawn are an outcome of

my research work. I further certify that

i) The work contained in the report is original and has

been done by me under the general supervision of my supervisor.
ii) The work has not been submitted to any other Institution for any
other degree/diploma/certificate in this institute or any other
institute of India or abroad.
iii) We have followed the guidelines provided by the institute in
writing the report.
iv) Whenever we have used materials (data, theoretical analysis,
and text) from other sources, we have given due credit to them in
the text of the report and giving their details in the references.

Name:-KISHAN KUMAR
Branch:-Electrical
Roll no.:-611442017039
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GOVERNMENT POLYTECHNIC SITAMARHI, BIHAR

(Malahi, Birpur, Sursand - 843331)
[Affiliated to SBTE, Patna, Approved by AICTE, Delhi]

CERTIFICATE
This is to certified that the project work entitled
“FABRICATION OF BATTERY CHARGER” is a bonafide
work carried out by KISHAN KUMAR (611442017039) in
the partial fulfilment for the award of Diploma in Electrical
Engineering at GOVERNMENT POLYTECHNIC
SITAMARHI.
This project has been approved as it certifies the
academic requirements in respect of project work prescribed
for the degree of Diploma in Electrical Engineering.

Signature of the Guide Signature of the HOD Signature of the Principal

(Prof. Digvijay Kumar) (Prof. Digvijay Kumar) (Dr. B.K. Roy)
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ABSTRACT
A circuit for battery charging includes an SCR that is
periodically gated on for a duration corresponding to
the state of charge of the battery, being gated on for a
duration corresponding to the state of charge on the
battery being the gated for only a short interval when
the battery is essentially fully charged to keep it
charged. The conduction angle is determined from the
open circuited battery potential and the previous
charging history of the battery obtained from potential
sensing circuits. A pedestal and cosine modified ramp
circuit triggers the SCR’s through capacitors with a
resistor inter coupling the SCR gate and cathode
electrodes. Circuitry prevents the unipolar junction
transistor in the latter circuit from remaining latched on.
A potential circuit for determining the rate of charge
includes a resistor connected to the output terminal that
is bypassed when the average value of the signal
connected on the collector of the transistor having the
base connected to the output terminal having a
predetermined value. Diodes inter-couple the SCR’s
and the emitter of the latter transistor for providing
operating potential to the circuits and the starting
charging current to the output terminal when a
connected battery is fully discharged.
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CONTENTS
Sr. no. Description Page no.
i. Acknowledgement 2
ii. Declaration 3
iii. Certificate 4
iv. Abstract 5
1. Introduction 7
2. Objectives 7
3. Block diagram 8
4. Circuit diagram 9
5. Component description 11
6. Operation 15
7. Tools to be used 17
8. Types of SCR battery charger 20
9. Applications 28
10. Limitations 28
11. Comparison b/w single phase switch control and SCR 29
control battery charger
12. Conclusion 30
13. References 31
14. Appendix 32
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1) Introduction:-
The battery is charged with small amount of
AC voltage or DC voltage. So if you want to charge
your battery with AC source then should follow these
steps, we need first limit the large AC voltage, need
to filter the AC voltage to remove the noise, regulate
and get the constant voltage and then give the
resulting voltage to the battery for charging. Once
charging is completed the circuit should
automatically turned off.

2) Objectives:- The objectives of this fabrication

of an automatic battery charger using SCR are an
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automatic battery charger with and without using

trickle charging arrangement. The battery charger
control the charging current with the comparison of
the terminal voltage of the battery under charge and
constant reference voltage obtained across zener
diode.

3) Block diagram:-

The AC source is given to the step down transformer

which converts the large AC source into limited AC
source, filter the AC voltage and remove the noise and
then give that voltage to the SCR where it will rectify
the AC and give the resulting voltage to the battery for
charging
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4) Circuit diagram:-
Circuit diagram of the Battery Charger Circuit
using SCR can be seen below:-

Notes:-
 Assemble the circuit on a good quality PCB or
common board.
 The transformer T1 can be 230V primary, 18V /3A
secondary step down transformer.
 The voltage of the battery at which the charging
should stop can be set by the POT R4.
 The battery can be connected to the charger circuit
by using crocodile clips.
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Circuit diagram explanation:-

 The AC main voltage is given to the step down

transformer the voltage should be down to 20V
approx. the step down voltage is given to the SCR
for rectification and SCR rectifies AC main
voltage. This rectified voltage is used to charge
battery.
 When the battery connecter to the charging circuit,
the battery will not be dead completely and it will
get discharged this will give the forward bias
voltage to the transistor through the diode D2 and
resistor R7 which will get turned on. When the
transistor is turned on the SCR will get off.

 When the battery voltage is dropped the forward

bias will be decreased and transistor gets turned
off. When the transistor is turned off automatically
the diode D1 and resistor R3 will get the current to
the gate of the SCR, this will triggers the SCR and
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gets conduct. SCR will rectifies the AC input

voltage and give to the battery through Resistor R6.

 This will charge the battery when the voltage drop

in the battery decreases the forward bias current
also gets increased to the transistor when the
battery is completely charged the Transistor Q1
will be again turned on and turned off the SCR.

5) Component description:-
i) Transformer:-
A transformer is an electrical device that
transfers energy between two or more circuits
through electromagnetic induction.
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A step down transformer: is one whose

secondary voltage is less than its primary voltage.
It is designed to reduce the voltage from the
primary winding to the secondary winding. This
kind of transformer “steps down” the voltage
applied to it.
As a step-down unit, the transformer converts
high-voltage, low-current power into low-voltage,
high-current power.

ii) Diode:-

In electronics, a diode is a two-terminal electronic

component with asymmetric conductance; it has
low (ideally zero) resistance to current in one
direction, and high (ideally infinite) resistance in
the other. Semiconductor diodes were the first
semiconductor electronic devices.
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Today, most diodes are made of silicon, but other

semiconductors such as selenium or germanium are
sometimes used.

iii) BJT:-

A bipolar junction transistor is a type

of transistor that relies on the contact of two types
of semiconductor for its operation. BJTs can be
used as amplifiers, switches, or in oscillators.

Bipolar transistors are so named because their

operation involves both electrons and holes.

These two kinds of charge carriers are

characteristic of the two kinds
of doped semiconductor material; electrons are
majority charge carriers in n-type semiconductors,
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whereas holes are majority charge carriers in p-type

semiconductors.

iv) Resistor:-

A resistor is a passive two-terminal electrical

component that implements electrical resistance as
a circuit element. Resistors act to reduce current

flow, and, at the same time, act to lower voltage

levels within circuits. In electronic circuits resistors
are used to limit current flow, to adjust signal
levels.

v) Fuse:-

In electronics and electrical engineering, a fuse is a

type of low resistance resistor that acts as
a sacrificial device to provide over
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current protection, of either the load or source

circuit. Its essential component is a metal wire or
strip that melts when too much current flows
through it, interrupting the circuit that it
connects. Fuses are an alternative to circuit
breakers.

6) Operation:-

 Initially when the circuit is powered and the battery

level is below the threshold voltage, the circuit
performs the task of charging the battery. The SCR
gets triggered with a voltage at its Gate terminal
through the resistor R1 and diode D1. It then starts
rectifying the AC voltage, though only for the half
cycle. As the DC current starts flowing to the
battery through the resistor R2, the battery gets
charged. The voltage across the potential divider
consisting of the pot RV1 and resistor R4 depends
upon the voltage across the battery.
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 The non-inverting terminal is given a reference

voltage of 5.2V using a Zener diode. For normal
charging operation, this reference voltage is more
than the voltage across the potential divider and the
output of the comparator is less than the threshold
voltage required to trigger the NPN transistor into
conduction. The transistor and the diode D3 thus
remains off and the SCR gate gets triggering
voltage through R1 and D1.

 Now when the battery starts charging and at a

certain point when it is fully charged, the voltage
across the potential divider reaches a value above
the reference voltage. This implies the voltage at
the inverting terminal is less than the voltage at non
inverting terminal and the output of the comparator
is more than the threshold base emitter voltage for
the transistor.

 This causes the transistor to conduct and it is

switched on. At the same time as the diode D3 is
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forward biased, it starts conducting and this blocks

the triggering the SCR gate voltage as it is now
connected to low potential or ground. The SCR
thus gets switched off and the charging operation is
stopped or paused. Again when the battery charge
drops below the threshold level, the charging
operation resumes in the manner described above.
The resistor R7 and diode D4 are to ensure a small
amount of trickle charging takes place in case of
the SCR being in off condition.

7) Tools to be used:-

i) PCB layout wizard software:-

PCB Wizard is a powerful package for designing

single-sided and double-sided printed circuit
boards (PCBs).
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It provides a comprehensive range of tools

covering all the traditional steps in
PCB production, including schematic drawing,
schematic capture, component placement,
automatic routing, Bill of Materials reporting and
file generation for manufacturing. In addition,
PCB Wizard offers a wealth of clever new
features that do away with the steep learning
curve normally associated with PCB packages.

ii) Copper plated PCB:-

A printed circuit board (PCB) mechanically

supports and electrically connects electronic
components using conductive tracks, pads and
other features etched from copper sheets
laminates onto a non-conductive substrate. PCBs
can be single sided (one copper layer), double
sided (two copper layer) or multi-layer.
Conductors on different layers are connected
with plated-through holes called via is an
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electrical connection b/w layers in a physical

electronic circuit that goes through the plane of
one or more adjacent layers. Advanced PCBs
may contain components-Capacitors, Resistors or
active devices-embedded in the substrate.
Printed circuit boards are used in all but the
simplest electronic products.
iii) Drilling machine for PCB:-

A compact table top high speed PCB drilling

machine with a quick change chuck.
 Feature:-
 Drill holding by precision chuck with lapped
jaws
 Mains operated DC motor Direct drive ( no
belt and pulley)
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 3 Step Speed Control and Illumination of

work Area
 Specification:-
 Motor Speed : up to 20,000 R.P.M
 Range : 0.6 to 3.0 mm
 Base : Metal
 Working Area : 280 mm x 170 mm
 Electrical Power : 230/50Hz, 5A Socket
required

8) Types of SCR battery charger:-

i) Ultra Maxx battery charger:-
The Ultra Maxx combines all of the flexibility,
ruggedness, and reliability of a SCR charger with
special design features tailored especially for
opportunity and fast charging. Building upon the
time-tested Ultra Charge foundation, the Ultra
Maxx adds the increased charge rate, special
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programming features, and extensive data

collection necessary for opportunity charging. Its
sophisticated UC2000 control can adapt to any type
of battery using a built-in library of recharge
profiles while the 60+ control parameters enables
tailoring to site requirements of any user site. Data
archiving is an integral part of the control design,
allowing for effective on going monitoring of site
operations.
 Charges 20% charged batteries to 80% in 3 hours
with a standard 25A/100Ah start rate
 Batteries can be charged up to 50A/100 start rate
and a 5A/100 finish rate
 Bridges the performance gap between traditional
and fast chargers
 Lower charger costs
 IEI charge profile for accurate and efficient
charging
 UC2000 control displays output volts, amps, and
amp hours returned during the charge cycle
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 Archive function enables easy review 19 items of

recorded information for each recharge of the last
99 recharges, all of which can be downloaded to
your computer via DataLink2
 Fully compatible with wired and wireless
DataLink2 networking and analysis tools
 Automatically compensates for battery operating
temperatures with AMETEK's battery mounted
data devices
 Compatible with BID, BID with Ah
Accumulator, and WBID
 Easy-to-change AC input voltage
 Multi-cell/multi-ampere capabilities
 Adapts to all battery types with 7 user-selectable
charge curve options
 UL and CUL listed
 Meets BCI standards

ii) Ultra charge battery charger:-

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The Ultra Charge is one of the most flexible

battery chargers on the market. Able to charge
flooded cell and sealed cell lead-acid batteries of
nearly any voltage or ampere-hour size, it is rated
to recharge a 100% discharged battery in 8 hours or
less.

 Charges 100% discharged batteries in 8 hours

 The UC2000 control displays output volts, amps,
and amp hours returned, showing 19 metrics from
the most recent charge cycle
 Compatible with single/multi-shift applications
 Start rate of 16.3A/100Ah
 Archive function enables information from the last
99 cycles to be reviewed easily
 Adapts to all battery types with 7 user-selectable
charge curve options
 Timer Start Mode allows selection of the time and
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rate of charge
 Programming feature assigns battery capacity and
type to voltage
 Automatically compensates for battery operating
temperatures with AMETEK's battery mounted
devices
 Easy-to-change AC input voltage
 Multi-cell/multi-ampere capabilities
 Fully compatible with both wired and wireless Data
Link
 UL and CUL listed
 Meets BCI standards

iii) Power star battery charger:-

The Power Star industrial battery charger sets
the industry standard for accuracy, efficiency,
flexibility and reliability. Designed to recharge any
100% discharged lead-acid battery in its ampere-hour
rating within 8 hours, the Power Star is engineered to
provide the maximum in charging performance. Also
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available in 60% and 80% rated models. The charger

uses SCR power conversion circuitry, which is
virtually maintenance-free, to provide years of
dependable service.
With the Power Star, the industrial battery
determines its own charge cycle rate with its state of
discharge. The Power Star provides a constant
current-constant voltage-constant current (I-E-I)

charge curve to eliminate the possibility of

overcharge, even with line voltage variations, and it
completes the charge at the proper current regardless
of battery age or specific gravity.
 Choice of interchangeable controls, SCR1000 or
SCR2000, for additional features and flexibility
 Fail-safe design protects batteries
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 100% rated to recharge fully discharged batteries in

8 hours; 80% rated models are also available
 Adapts to all battery types with user-selectable
charge curve options
 Automatically compensates for battery operating
temperature using AMETEK's battery mounted
devices
 Compatible with both wired and wireless Data Link
 UL and CUL listed
iv) Power star plus battery charger:-
Power Star Plus delivers dependable charging
together with high efficiency and easy operation.
Equipped with the SCR2000 control as standard, the
Power Star Plus is designed specifically to fill the
requirements of opportunity and fast charge
applications, able to recharge batteries from 20% to
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80% state of charge in 3 hours or less. It's virtually

maintenance-free SCR power conversion circuitry
provides years of dependable service. Power
Star Plus enables the battery to determine its own
charge rate, based on its state of discharge, electrolyte
temperature, and battery age, while providing a IEI
change curve to eliminate overcharge possibilities,
even with line voltage variations.

 Simple solution to opportunity charging

 Charges 20% charged batteries up to 80% in 3 hours
 Charge rates as high as 50A/100
 Fail-Safe design protects batteries
 Automatically compensates for battery operating
temperature using AMETEK's battery mounted
devices
 No gassing feature
 Excellent warranty
 UL and CUL listed
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9) Applications:-

1. It can be used to charge batteries used for toys.

2. It is a portable circuit and can be carried
anywhere.
3. It can be used as an automatic battery charger,
used specially during driving.

10) Limitations:-

1. The AC to DC conversion here uses only the

rectifier and may contain AC ripples as there is
no filter.
2. The half wave rectifier makes the charging and
discharging quite slow.
3. This circuit cannot be used for batteries with
higher Ampere-hour rating.
4. The battery charging may take longer time.
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11) Comparison b/w single phase switch control and SCR control battery charger:-

SPECIFICATION SINGLE PHASE SCR CONTROL /

SWITCH FCBC CHARGER
CONTROL
Input 230 V + 10% 50 HZ 230 C + 10% 50
Single Phase HZ Single Phase
Fixed Voltage(12V
to 240V)
Output Voltage 12 V, to 240 VDC 415 V + 10% Three
Variable Phase
Output DC Current 1A to 200A 1A to 250 Ams
Indication and Control 1. Input On/Off 1. Input On/Off
Switch Switch / MCB
2. Analog Meter to 2. Digital Meter to
Indicate Output DC Indicate Output DC
Volt & Current Volt & Current
3. LED Indication for 3.LED Indications
Charger On, Cut Off for Mains On
4. Voltage Selector Charger On, Float
Switch, Current On, Boost on
Selector Switch. 4.Voltage and
Current Control
Protection meter
Protections 1. AC Input Fuse 1. AC Input
2. DC Output Fuse / MCB /
Fuse / MCB MCCB
3. Over Current 2. DC Output
Trip Switch Fuse/ MCB /MCCB
3. D/C O/V &
U/V Production &
Single Phase
Preventer
4. Electronic
Output DC Current
Limit
5. Cooling Fan
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TYPE OF RECTIFIER DIODE RECTIFIER HALF-

CONTROLLED &
FULL
CONTROLLED
SCR RECTIFIER
Regulation - Output DC 1 to 3%
Ripple - Output DC from 1
to 5 %

12) Conclusion:-

In this project, Battery is a device which we

can use in our daily life in multiple circuits like a
torch lights, toys, mobile and laptop, automobile
starter etc. Rechargeable batteries are inexhaustible,
pollution free and environmental friendly. So we have
chosen “Battery Charger Circuit Using SCR” as a
project topic. Thus we conclude that the circuit works
as per is designment and requirement.
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13) References:-
 For a paper in a Proceedings/Transactions/Journal:-
International Journal of Scientific and Research
Publication, Volume 4, Issue 5,May 2014.ISN-
2250-3153

 For an authored book:-

George A. Sites, BSEET “An Introduction to SCR
Power Controls” published on 1st January 2014.
Allen Mottershed Tata McGraw-Hill Publication
“Electronic Devices and Circuits”, 2nd Edition,
2005.

 For a website:-
http://www.electronicshub.org/battery-charger-
circuit-using-scr/
http://www.eleccircuit.org/battery-charger-circuit-
using-scr/
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14) Appendix:-

 COMPONENT LIST AND PRICE:-

Sr. no. Components Quantity Price(in
required rupees)
1 Step down 1 80
transformer
2 Diodes 4 8
3 5 4
Resistors
4 SCR 1 10
5 1 8
Potentiometer
6 BJT 1 5
7 Fuse 1 5

Total:- Rs.120