[Initial concept of this charger is based on the design originally appearing at http://www.diyelectriccar.com/forums...ger-36627.html
(Simonrafferty's thread). As that thread is now 50+ pages long, I decided to break this one into its own thread. For all the gory technical details leading into this design, please refer to the above thread.]
Over the last few months, my team has developed a 10kW / 60A charger design that exceeds all known chargers available on the market today (that you can put into a vehicle, anyway) - both in power and features. We just hated to pay $4000 to be able to charge our conversions in less than 5 hours...
An incomplete run-down of the capabilities:
* 10kW rated power - tested to 15kW continuous with liquid cooling
* 110 / 220VAC, up to 400VDC input
* up to 350VDC battery voltage (up to 425V with very minor modifications)
* fully PF corrected option available
* 144x144 color screen for controls & readout
* Output power control
* All battery types supported with micro-processor controlled charging regimes
* Integration features - BMS cut-off, End-of-charge signal
* Thermal protection
* Timer shutoff
* Compact design - latest units are packed into a 12x11x8-inch box (air cooled) or 10x8x7" for liquid-cooled
* User-programmable through a USB cable
We have made design fully open-source and available to all at http://www.emotorwerks.com/cgi-bin/VMcharger_V9.pl
. So if you are so inclined, you can make it yourself for ~$900 all-in (including all the heatsinks, enclosure, etc, etc.).
So far (May 2011), we have made and installed 4 complete units and helped ~10 people to make their own builds. Our first unit was installed into the Fiat Conversion described at http://www.diyelectriccar.com/forums...der-51822.html
. It is charging our 110AH 200V LiFePo4 pack at 50A in ~2.5 hours. Max current tested is 65A at lower voltages (tested up to ~100V, I would imagine this would hold up to 144V or so).
Update (August 2012): about 20 complete units installed, ~40 made from kits.
If you like, we can help you with PCBs, parts kits, assembled / tested boards, and fully assembled units. Again, details are at http://www.emotorwerks.com/cgi-bin/VMcharger_V9.pl
I hope that this effort will make EV conversions a bit more affordable to people and we will have a modest contribution to getting more EVs on the roads! Please consider supporting it by letting us help you with building out your units.
As always, we welcome feedback / suggestions / questions.