Portable lightweight 360W LiFePO4 battery charger

Batteries, Chargers, and Battery Management Systems.
User avatar
avandalen   10 W

10 W
Posts: 90
Joined: Oct 02 2010 10:40am
Location: Maastricht, The Netherlands
Contact:

Portable lightweight 360W LiFePO4 battery charger

Post by avandalen » Apr 10 2011 5:09pm

Because I want to fast recharge the LiFePO batteries during a trip, I need a lightweight mobile charger. Special lightweight battery chargers for ebikes don't exist. So I made one myself. I used the battery charger E-400 from BMSbattery in China. I have done modifications to the housing and the electronics.

See my website here:
http://www.avdweb.nl/solar-bike/electro ... -800g.html

This is the original E-400 battery charger from 1400g:
Image

This is the new lightweight battery charger from 815g:
Image

Advantages of the battery charger
  • The weight, inclusive mains cable, is reduced from 1400g to 815g.
    The charge current is adjustable from 1A to 8A instead of a fixed charge current of 8A.
    Integrated anti spark circuit (coming soon…)
Further weight reducement
In the feature I will reduce the weight to 500g (see website). Who can tell me if my weight reducement assumptions are correct?

User avatar
Icewrench   10 kW

10 kW
Posts: 802
Joined: Sep 07 2008 4:54pm
Location: Seattle Wa USA

Re: Portable lightweight 360W LiFePO4 battery charger

Post by Icewrench » Apr 10 2011 9:14pm

Nice project. I really like the current adjusting feature.

User avatar
auraslip   1.21 GW

1.21 GW
Posts: 3535
Joined: Mar 05 2010 5:19pm

Re: Portable lightweight 360W LiFePO4 battery charger

Post by auraslip » Apr 11 2011 1:38am

Awesome. I'll take one.
THANKS TO EVERYONE HERE WHO TAUGHT ME ABOUT EBIKES. I'M IN YOUR DEBT.

I sell Ebike Brake levers and throttles with custom connectors crimped on! $10 shipped!

ES facebook group

r/ebikes ebikes on reddit

User avatar
Holocene   100 W

100 W
Posts: 122
Joined: Nov 07 2010 6:12pm
Location: Edmonton, Alberta, Canada

Re: Portable lightweight 360W LiFePO4 battery charger

Post by Holocene » Apr 12 2011 4:21pm

Very nice work, excellent design goals. A couple of questions:
1. Will this charge work with North American 110V 60Hz AC;
2. Will the voltage be adjustable for SLA, LiFe, and LiPo chemistry?
Cheers!
2000 ZAP DX electric bike kit on chromoly MTB - retired
2007 Strong GTS-210 electric bike - melted solder in hub
2007 Giant Revive, Crystalyte 405 20" fr, 35A/72V + Cycle-analyst 2.1

User avatar
avandalen   10 W

10 W
Posts: 90
Joined: Oct 02 2010 10:40am
Location: Maastricht, The Netherlands
Contact:

Re: Portable lightweight 360W LiFePO4 battery charger

Post by avandalen » Apr 18 2011 4:15am

Holocene wrote:Very nice work, excellent design goals. A couple of questions:
1. Will this charge work with North American 110V 60Hz AC;
2. Will the voltage be adjustable for SLA, LiFe, and LiPo chemistry?
Cheers!
Hi
The AC Input Voltage is 90Volts~132Volts or 200Volts~264Volts.
Order the E400 charger with the right voltage.
You can adjust any output voltage you need!
So you can use LiFePO4 / Lithium Ion / Lead Acid etc.

Albert

User avatar
Kepler   1 GW

1 GW
Posts: 3116
Joined: Nov 08 2009 9:22pm
Location: Eastern suburbs Melbourne Australia

Re: Portable lightweight 360W LiFePO4 battery charger

Post by Kepler » May 15 2011 10:00pm

I have the 900W version that am going to use for a 30S Lipo bulk charging. I got the 120V version but would like to be able to trim the voltage to better suit. 125V would be preferred. Also like to be able to bulk charge 24S so a voltage of close to 100V would be great also.

There are 7 pots in this charger. Any clue on how I would identify the voltage adjust?

Thanks
Attachments
P1010044-1.JPG
P1010044-1.JPG (124.6 KiB) Viewed 4469 times
Current Rides

Lightest true ebike on the planet: ON ROAD https://endless-sphere.com/forums/viewt ... =6&t=74269
eBoost on facebook: http://www.facebook.com/pages/Eboost/200306283342024/
75 Volt 6 kW FUTR Beta 29'er: OFF ROAD

User avatar
Alan B   100 GW

100 GW
Posts: 7490
Joined: Sep 11 2010 7:43am
Location: San Francisco Bay Area, USA
Contact:

Re: Portable lightweight 360W LiFePO4 battery charger

Post by Alan B » May 15 2011 10:15pm

Nice work. I've been looking at that charger. May have to get one and hack it.

User avatar
avandalen   10 W

10 W
Posts: 90
Joined: Oct 02 2010 10:40am
Location: Maastricht, The Netherlands
Contact:

Re: Portable lightweight 360W LiFePO4 battery charger

Post by avandalen » May 16 2011 9:54am

Kepler wrote:I have the 900W version that am going to use for a 30S Lipo bulk charging. I got the 120V version but would like to be able to trim the voltage to better suit. 125V would be preferred. Also like to be able to bulk charge 24S so a voltage of close to 100V would be great also.

There are 7 pots in this charger. Any clue on how I would identify the voltage adjust?

Thanks
It is a complete different charger. What is the manufacturer? Can you make a larger high resolution image of the whole board? Which SMPS IC is used?
The V pot should be in the Vout feedback loop to the SMPS IC.
Don’t adjust pots when you don’t know what it is.
Albert

silentflight   100 W

100 W
Posts: 119
Joined: May 07 2007 5:42pm
Location: Chicago

Re: Portable lightweight 360W LiFePO4 battery charger

Post by silentflight » May 16 2011 11:29am

Thank you so much for sharing your knowledge in such a clear manner. Your website is also fantastic.

Considering that some recently designed power adapters (for example Apple ipod and Macbook) are so small and light, I imagine we could have small, lightweight, powerful and robust chargers if our market were big enough to justify the engineering and production. Maybe someday! Until then it's highly entertaining to follow along with people like you who are creating better solutions on their own.

User avatar
Kepler   1 GW

1 GW
Posts: 3116
Joined: Nov 08 2009 9:22pm
Location: Eastern suburbs Melbourne Australia

Re: Portable lightweight 360W LiFePO4 battery charger

Post by Kepler » May 16 2011 5:07pm

avandalen wrote:
Kepler wrote:I have the 900W version that am going to use for a 30S Lipo bulk charging. I got the 120V version but would like to be able to trim the voltage to better suit. 125V would be preferred. Also like to be able to bulk charge 24S so a voltage of close to 100V would be great also.

There are 7 pots in this charger. Any clue on how I would identify the voltage adjust?

Thanks
It is a complete different charger. What is the manufacturer? Can you make a larger high resolution image of the whole board? Which SMPS IC is used?
The V pot should be in the Vout feedback loop to the SMPS IC.
Don’t adjust pots when you don’t know what it is.
Albert
Thanks for the reply Albert.

I will take some High res photos of the boards. The manufacturer is http://www.emchargers.com I tried to find a schematic but no luck. I know enough about electronics to dangerous but hopefully with a bit of guidance I can identify the V pot.

I certainly wont adjust any pots until I know what they are :)
Current Rides

Lightest true ebike on the planet: ON ROAD https://endless-sphere.com/forums/viewt ... =6&t=74269
eBoost on facebook: http://www.facebook.com/pages/Eboost/200306283342024/
75 Volt 6 kW FUTR Beta 29'er: OFF ROAD

User avatar
sn0wchyld   1 MW

1 MW
Posts: 1594
Joined: Mar 18 2011 8:27pm
Location: South Aus.

Re: Portable lightweight 360W LiFePO4 battery charger

Post by sn0wchyld » Sep 07 2011 4:47am

hi albert,

Im planning on buying one of these chargers from BMSbattery, I wanted to ask if the Vout is adjustable? Im running 20s lipo now (~82V for 4.1 per cell) but im planning on switching to 24s in the near future. is it possible to adjust to ~98V output?

thanks mate
sc.

User avatar
avandalen   10 W

10 W
Posts: 90
Joined: Oct 02 2010 10:40am
Location: Maastricht, The Netherlands
Contact:

Re: Portable lightweight 360W LiFePO4 battery charger

Post by avandalen » Sep 07 2011 5:44am

sn0wchyld wrote:hi albert,

Im planning on buying one of these chargers from BMSbattery, I wanted to ask if the Vout is adjustable? Im running 20s lipo now (~82V for 4.1 per cell) but im planning on switching to 24s in the near future. is it possible to adjust to ~98V output?

thanks mate
sc.
Yes, you can adjust the voltage too. For Higher voltage, order a charger 84V3A / 84V5A etc.

User avatar
adrian_sm   10 MW

10 MW
Posts: 2404
Joined: Feb 23 2009 12:54am
Location: Melbourne, Australia
Contact:

Re: Portable lightweight 360W LiFePO4 battery charger

Post by adrian_sm » Sep 07 2011 5:58am

Ooops. I made that mistake I orderd a 600w charger but got it initially set to suit my 16s LiFe pack, with the plans to adjust it when I go to a 24s LiFe pack, but it has a 63V cap @ C17 on your schematic. :( Damn.

Can I just swap this cap then make the other mods you outlined? Or am I stuffed?

Regards,
Adrian
Build #1 ~28kg ~ 700w Avanti Hardtail Crystalyte 408, 48V10Ah Headway. ~5500 kms to date. (retired)
Build #2 ~30kg ~2000w Giant AC Dually Crystalyte 408, 48V10Ah Headway + 6s10Ah LiPo = 70V. ~15000 kms to date [SOLD]
Build #3 ~13kg ~2000w Commuter Booster <1kg Friction Drive in Beta testing (www.commuterbooster.com)
Build #??? ~21kg ~1500w Adrian's Bafang BPM Hardtail MTB Bafang BPM code12, 15s LiPo, ~40kph, ~30kms

User avatar
avandalen   10 W

10 W
Posts: 90
Joined: Oct 02 2010 10:40am
Location: Maastricht, The Netherlands
Contact:

Re: Portable lightweight 360W LiFePO4 battery charger

Post by avandalen » Sep 07 2011 6:10am

adrian_sm wrote:Ooops. I made that mistake I orderd a 600w charger but got it initially set to suit my 16s LiFe pack, with the plans to adjust it when I go to a 24s LiFe pack, but it has a 63V cap @ C17 on your schematic. :( Damn.

Can I just swap this cap then make the other mods you outlined? Or am I stuffed?

Regards,
Adrian
I suppose that also the SMPS transformer is different, just order a new one to be sure.

User avatar
adrian_sm   10 MW

10 MW
Posts: 2404
Joined: Feb 23 2009 12:54am
Location: Melbourne, Australia
Contact:

Re: Portable lightweight 360W LiFePO4 battery charger

Post by adrian_sm » Sep 07 2011 6:13am

I was afraid of that. Thanks.
Build #1 ~28kg ~ 700w Avanti Hardtail Crystalyte 408, 48V10Ah Headway. ~5500 kms to date. (retired)
Build #2 ~30kg ~2000w Giant AC Dually Crystalyte 408, 48V10Ah Headway + 6s10Ah LiPo = 70V. ~15000 kms to date [SOLD]
Build #3 ~13kg ~2000w Commuter Booster <1kg Friction Drive in Beta testing (www.commuterbooster.com)
Build #??? ~21kg ~1500w Adrian's Bafang BPM Hardtail MTB Bafang BPM code12, 15s LiPo, ~40kph, ~30kms

User avatar
sn0wchyld   1 MW

1 MW
Posts: 1594
Joined: Mar 18 2011 8:27pm
Location: South Aus.

Re: Portable lightweight 360W LiFePO4 battery charger

Post by sn0wchyld » Sep 07 2011 8:12am

avandalen wrote:
sn0wchyld wrote:hi albert,

Im planning on buying one of these chargers from BMSbattery, I wanted to ask if the Vout is adjustable? Im running 20s lipo now (~82V for 4.1 per cell) but im planning on switching to 24s in the near future. is it possible to adjust to ~98V output?

thanks mate
sc.
Yes, you can adjust the voltage too. For Higher voltage, order a charger 84V3A / 84V5A etc.
should I order a 98V model first and then change the Vout down to 82V, that way I know the internal components will be able to handle the 98V when I do end up switching to 24s? Or should I do it the other way around?

cheers.

User avatar
avandalen   10 W

10 W
Posts: 90
Joined: Oct 02 2010 10:40am
Location: Maastricht, The Netherlands
Contact:

Re: Portable lightweight 360W LiFePO4 battery charger

Post by avandalen » Sep 07 2011 12:46pm

sn0wchyld wrote:
avandalen wrote:
sn0wchyld wrote:hi albert,

Im planning on buying one of these chargers from BMSbattery, I wanted to ask if the Vout is adjustable? Im running 20s lipo now (~82V for 4.1 per cell) but im planning on switching to 24s in the near future. is it possible to adjust to ~98V output?

thanks mate
sc.
Yes, you can adjust the voltage too. For Higher voltage, order a charger 84V3A / 84V5A etc.
should I order a 98V model first and then change the Vout down to 82V, that way I know the internal components will be able to handle the 98V when I do end up switching to 24s? Or should I do it the other way around?

cheers.
Yes, don't order a charger with too low voltage, to be sure. Adjusting the voltage a lower value is always possible.

User avatar
alsmith   100 kW

100 kW
Posts: 1182
Joined: Dec 03 2010 7:25pm
Location: Northumberland, UK

Re: Portable lightweight 360W LiFePO4 battery charger

Post by alsmith » Oct 10 2011 7:27pm

Are VR1 & VR2 linear (or log) pots?
I'm looking at modifying one for 36V LiFePO4 and low capacity 37V LiIon, and then include for 48V LiFePO4 early next year- probably a 600W one used at 3 - 5 Amps most of the time with the possibility of faster charging if needed.

Thanks.

dnmun   100 GW

100 GW
Posts: 16190
Joined: Jun 09 2008 1:32pm
Location: portland, or and loveland, co

Re: Portable lightweight 360W LiFePO4 battery charger

Post by dnmun » Oct 10 2011 11:02pm

@adrian "Can I just swap this cap then make the other mods you outlined?"

i assume the C17 was the output cap so you should be able to swap to 100V but you need to be sure the schottky diode that keeps the charge in the back end will handle the 24S lifepo4. usually the voltage is stamped on the surface of the schottky diode, and the current rating too. the transformer should work with the higher voltage but you need to adjust the current down to keep the power going through the transformer within the transformer spec, and even below it for continuous output. imo

User avatar
adrian_sm   10 MW

10 MW
Posts: 2404
Joined: Feb 23 2009 12:54am
Location: Melbourne, Australia
Contact:

Re: Portable lightweight 360W LiFePO4 battery charger

Post by adrian_sm » Oct 11 2011 12:06am

@dnmum

Thanks a lot. I was pretty annoyed when I realised, and haven't even touched the charger since. Now I will crack it open and have a look see. Cheers.
Build #1 ~28kg ~ 700w Avanti Hardtail Crystalyte 408, 48V10Ah Headway. ~5500 kms to date. (retired)
Build #2 ~30kg ~2000w Giant AC Dually Crystalyte 408, 48V10Ah Headway + 6s10Ah LiPo = 70V. ~15000 kms to date [SOLD]
Build #3 ~13kg ~2000w Commuter Booster <1kg Friction Drive in Beta testing (www.commuterbooster.com)
Build #??? ~21kg ~1500w Adrian's Bafang BPM Hardtail MTB Bafang BPM code12, 15s LiPo, ~40kph, ~30kms

User avatar
adrian_sm   10 MW

10 MW
Posts: 2404
Joined: Feb 23 2009 12:54am
Location: Melbourne, Australia
Contact:

Re: Portable lightweight 360W LiFePO4 battery charger

Post by adrian_sm » Oct 11 2011 7:30am

I have the 600w model and the board is a bit different. It appears to have two caps (C17 & C18) on the output. But I need to remove the board from the case to check properly.

The shottky diode is labelled as 6A10 MIC, so should be fine. So I guess I just have to swap out the caps, and tweak the current/voltage with the POTs.
Attachments
charger_600w_pic1.jpg
charger_600w_pic2.jpg
charger_600w_pic2.jpg (117.2 KiB) Viewed 3700 times
Build #1 ~28kg ~ 700w Avanti Hardtail Crystalyte 408, 48V10Ah Headway. ~5500 kms to date. (retired)
Build #2 ~30kg ~2000w Giant AC Dually Crystalyte 408, 48V10Ah Headway + 6s10Ah LiPo = 70V. ~15000 kms to date [SOLD]
Build #3 ~13kg ~2000w Commuter Booster <1kg Friction Drive in Beta testing (www.commuterbooster.com)
Build #??? ~21kg ~1500w Adrian's Bafang BPM Hardtail MTB Bafang BPM code12, 15s LiPo, ~40kph, ~30kms

dnmun   100 GW

100 GW
Posts: 16190
Joined: Jun 09 2008 1:32pm
Location: portland, or and loveland, co

Re: Portable lightweight 360W LiFePO4 battery charger

Post by dnmun » Oct 11 2011 8:27am

that black diode is a zener on the output to protect it from reverse polarity. it protects the caps on the output.

the schottky diode will be connected to the output of the transformer, usually two outside legs connected to the same trace and the middle leg going to the output, where that cap is. maybe someone else has opened this power supply too and knows.

User avatar
sn0wchyld   1 MW

1 MW
Posts: 1594
Joined: Mar 18 2011 8:27pm
Location: South Aus.

Re: Portable lightweight 360W LiFePO4 battery charger

Post by sn0wchyld » Oct 11 2011 9:06am

Kepler wrote:I have the 900W version that am going to use for a 30S Lipo bulk charging. I got the 120V version but would like to be able to trim the voltage to better suit. 125V would be preferred. Also like to be able to bulk charge 24S so a voltage of close to 100V would be great also.

There are 7 pots in this charger. Any clue on how I would identify the voltage adjust?

Thanks
hey kepler, I just got the exact same one as you, I need to ask though, does yours have a voltage output once everything is turned on? Mine doesn't, even though the display shows 100V, which makes me worried that something is stuffed, and makes finding which wire is + and - near impossible. Im hoping its just some sort of protection circuit, though im not betting on it...

User avatar
adrian_sm   10 MW

10 MW
Posts: 2404
Joined: Feb 23 2009 12:54am
Location: Melbourne, Australia
Contact:

Re: Portable lightweight 360W LiFePO4 battery charger

Post by adrian_sm » Oct 12 2011 5:41am

dnmun wrote:that black diode is a zener on the output to protect it from reverse polarity. it protects the caps on the output.

the schottky diode will be connected to the output of the transformer, usually two outside legs connected to the same trace and the middle leg going to the output, where that cap is. maybe someone else has opened this power supply too and knows.
Okay thanks. Take 2. I found D15 & D16 which are heatsinked directly to the charger shell, appear to be between the transformer, and L2. They are FMG36S's.
Attachments
charger_600w_pic3.jpg
charger_600w_pic3.jpg (89.33 KiB) Viewed 3687 times
charger_600w_pic4.jpg
charger_600w_pic4.jpg (89.97 KiB) Viewed 3687 times
Build #1 ~28kg ~ 700w Avanti Hardtail Crystalyte 408, 48V10Ah Headway. ~5500 kms to date. (retired)
Build #2 ~30kg ~2000w Giant AC Dually Crystalyte 408, 48V10Ah Headway + 6s10Ah LiPo = 70V. ~15000 kms to date [SOLD]
Build #3 ~13kg ~2000w Commuter Booster <1kg Friction Drive in Beta testing (www.commuterbooster.com)
Build #??? ~21kg ~1500w Adrian's Bafang BPM Hardtail MTB Bafang BPM code12, 15s LiPo, ~40kph, ~30kms

dnmun   100 GW

100 GW
Posts: 16190
Joined: Jun 09 2008 1:32pm
Location: portland, or and loveland, co

Re: Portable lightweight 360W LiFePO4 battery charger

Post by dnmun » Oct 12 2011 8:49am

looks good, did you google the specs? those diodes need to be able withstand a higher voltage than your output voltage. and a little bit more, but if they are adequate you can get away with just upping the output caps. they get hot so that's why they get heat sinked to the case. really hot.

Post Reply