This project started here. I had built a high voltage electric vehicle but found the options for charging somewhat limited and very expensive. I wondered how complicated it could possibly be? A couple of minor explosions and the odd electric shock later, here it is - a fully programmable digital charger capable of operating up to 350v and 35A.
I built mine largely from parts salvaged from junk computer UPS's but even if you bought all the parts new, I doubt it would come to much more than $200.
First of all the circuit diagram:
I would strongly recommend you test and tun this using an isolating transformer. While testing, I used and isolating transformer as well a Variac which allowed me to reduce the input voltage to a relatively safe 50v or so.
This is a list of the parts you will probably need to buy. I've not included most of the resistors and capacitors - but they are shown on the circuit above:
High Side Driver - A3120
Encapsulated 12v Power Supply
15v DC/DC Converter (this could do with being higher power than 3W)
5v Zenner Diodes used to protect microcontroller
40A Bridge Rectifier Avoid the Chinese ones from eBay - they say 35A but let the smoke out at about 15A.
Ultra Fast Diodes I'm using 5 salvaged 10A Shottky diodes, but they are no longer available. Something like the ones listed will be fine though. Parallel up enough for 2 x the max charge current.
Microcontroller This is the most expensive part at about $60
Parts you are best off salvaging from something else:
Large Electrolytic Capacitor. Must be rated at >= 2 x your mains input voltage or it will explode (exciting and smelly). I have a 2200uF 500v capacitor - but something a lot smaller will be fine - it's just what I had.
IGBT I've used a big 200A 600v IGBT from a 3 phase UPS - but it only needs to be rated at about double your charge current. There are some nice ones on eBay for about $25 - but you can just parallel up a load of low current ones on a heatsink. Watch out though - often the metal tab on the device is connected to one of the pins. This may cause a problem for other stuff connected to the heatsink - particularly your fingers!
Output smoothing Capacitor I used something similar to this but it's not that critical. It's to get rid of the switching spikes from the output so any low value high voltage (non electrolytic) capacitor will probably do.
It's not shown in the circuit, but I also put a power diode in series with the connection to the batteries. This is just in case the batteries are connected the wrong way round. In this case you will get a loud pop and the smoke will escape.
Relay The microcontroller board includes a relay which it says is rated at 15A. However - it kills itself at a lot less than that. I'm using it to switch a larger 60A relay in the output line (RL1 on the diagram).
Shunt The current is measured using a simple 0.22 Ohm shunt. I would recommend one of these over a wire-wound type as they have very low inductance and can be bolted directly to a heat sink. This particular one is rated at 50W or 14A but bigger are available.
I built mine on stripboard just to try it out - but may get some PCB's made.
Next, I'll cover the software and microcontroller.
I built mine largely from parts salvaged from junk computer UPS's but even if you bought all the parts new, I doubt it would come to much more than $200.
First of all the circuit diagram:
I would strongly recommend you test and tun this using an isolating transformer. While testing, I used and isolating transformer as well a Variac which allowed me to reduce the input voltage to a relatively safe 50v or so.
This is a list of the parts you will probably need to buy. I've not included most of the resistors and capacitors - but they are shown on the circuit above:
High Side Driver - A3120
Encapsulated 12v Power Supply
15v DC/DC Converter (this could do with being higher power than 3W)
5v Zenner Diodes used to protect microcontroller
40A Bridge Rectifier Avoid the Chinese ones from eBay - they say 35A but let the smoke out at about 15A.
Ultra Fast Diodes I'm using 5 salvaged 10A Shottky diodes, but they are no longer available. Something like the ones listed will be fine though. Parallel up enough for 2 x the max charge current.
Microcontroller This is the most expensive part at about $60
Parts you are best off salvaging from something else:
Large Electrolytic Capacitor. Must be rated at >= 2 x your mains input voltage or it will explode (exciting and smelly). I have a 2200uF 500v capacitor - but something a lot smaller will be fine - it's just what I had.
IGBT I've used a big 200A 600v IGBT from a 3 phase UPS - but it only needs to be rated at about double your charge current. There are some nice ones on eBay for about $25 - but you can just parallel up a load of low current ones on a heatsink. Watch out though - often the metal tab on the device is connected to one of the pins. This may cause a problem for other stuff connected to the heatsink - particularly your fingers!
Output smoothing Capacitor I used something similar to this but it's not that critical. It's to get rid of the switching spikes from the output so any low value high voltage (non electrolytic) capacitor will probably do.
It's not shown in the circuit, but I also put a power diode in series with the connection to the batteries. This is just in case the batteries are connected the wrong way round. In this case you will get a loud pop and the smoke will escape.
Relay The microcontroller board includes a relay which it says is rated at 15A. However - it kills itself at a lot less than that. I'm using it to switch a larger 60A relay in the output line (RL1 on the diagram).
Shunt The current is measured using a simple 0.22 Ohm shunt. I would recommend one of these over a wire-wound type as they have very low inductance and can be bolted directly to a heat sink. This particular one is rated at 50W or 14A but bigger are available.
I built mine on stripboard just to try it out - but may get some PCB's made.
Next, I'll cover the software and microcontroller.