Re: [EVDL] Soneil chargers, was Re: Top-up Charger

Re: [EVDL] Soneil chargers, was Re: Top-up Charger

You guys may want to take some temperature readings off one of these
chargers while under load. There may be a particular side that gets
hottest and would indicate where to direct the cooling. A solution may
be as simple as providing airflow to that side.

DAC

On Thu, Feb 17, 2011 at 8:51 AM, bruce parmenter <[email protected]> w=
rote:
> I like Cor's method of removing the thermal insulating properties of
> the case from the problem, and getting down to true cooling of the
> internal heatsink as likely the best way to go. As a former hardware
> guy (hp Customer Engineer for over twenty five years), I know how to
> do what Cor is suggesting. For me this would be the way to go to get
> around the thermal issues of using those sweet Soneil chargers that
> have problems on high temperature ambient air days.
>
> But, then my old-school hp-way training kicked in, paring down to the
> lowest common denominator of EV'r: some people may not be that techie,
> adventure-some, or comfortable tearing into a charger. So, I thought
> of what could be done to cool the all 16 Soneil chargers keeping them
> intact (as is, in their unopened case) just encase Soneil does not
> contact me or offer a fix.
>
> If I had a set of these charging my pack, I would likely want each one
> near the battery it is charging. This would make it easy to see which
> batteries are weaker (that battery's Soneil charger would take longer
> to reach full charged when its built-in indicator led would change
> from yellow:charging to green:charge-cycle-complete). This would help
> to know the health of the pack over time.
>
> My approach then would be to put all the Soneil chargers inside a
> clear see-through air duct
> http://img2.prosperent.com/images/250x250/www.activeforever.com/images/pr=
oduct/medium/C01313.jpg
> which is fed by a fan drawing the cooler air from from underneath the
> EV.
>
> Since there is little to no acid spray from an AGM when charging, and
> the DC current is low, a standard automotive connector could be used
> between the Soneil charger and the battery. This would allow easier
> yanking of the pack. The AC cord would run inside the duct to power
> all the Soneil chargers.
>
> In my case (my aforementioned onboard EV charging wish-list) I would
> dedicate the Soneil chargers to use the 110VAC input coming from
> either a typical level 1 outlet or the one available on the Coulomb
> EVSE being install where I am.
>
> If so, I would use a 110VAC fan wired so when ever the Soneil chargers
> were powered, the fan would be on as well. If someone wanted to use a
> dual AC input voltage Soneil charger model, then a 12VDC fan could be
> used. Though not much, the fan would steal some DC charging amps from
> recharging/balancing the pack.
>
> {brucedp.150m.com}
>
>
>
>> ----- Original Message -----
>> From: "Cor van de Water" <[email protected]>
>> To: "Electric Vehicle Discussion List" <[email protected]>
>> Subject: Re: [EVDL] Soneil chargers, was Re: Top-up Charger
>> Date: Thu, 17 Feb 2011 12:51:25 +0530
>>
>> The plastic case is probably part of their
>> safety, I mean the protection against touching HV.
> [...]
>> For the Soneil - I guess it depends whether there
>> is still warranty on them and whether you can
>> open the case without destroying it
>> (many laptop charger style bricks cannot be
>> opened, it plastic case is glued or more commonly
>> ultrasonic welded shut.
>> If you need to open them anyway to provide the
>> cooling to make them last, then there is less
>> concern for the case of course.
>> Many power supplies I have seen in this form factor
>> have a rather solid alu heatsink following the
>> interior of the brick with the power transistor
>> (and sometimes also the output diode) insulated
>> from it.
>> Opening it and [mounting] it on a flat (non-conducting)
>> surface, preferably with standoffs to avoid stressing
>> the PCB too much - possibly still using the bottom
>> of the case with holes drilled through where there
>> are holes in the PCB to hold it in the enclosure,
>> then if needed adding fan(s) to blow air over the
>> open supplies will greatly reduce the heatsink-to-
>> ambient thermal resistance.
>> Please note that this will not do much for the
>> temp delta between the actual part and heatsink,
>> so at best you can reduce the heatsink temp and
>> make the unit run cooler and last longer, it is
>> not a good way to increase its spec, so do not try
>> to get more current from it or run it at lower than
>> spec input voltage... [...]
>> Regards,
>> Cor van de Water
> -
>
>
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