electronics to convert Meanwell HLG supply into a charger

[heathyoung]

The diodes are across each supply - their purpose is to save the output capacitors in the power supplies if one goes into protection mode (e.g. thermal cut-off) - they stop the entire pack voltage from going across the capacitors of the supply that's 'off'. If you didn't have this, you will blow the caps.

You only need this if you are putting the chargers in series to charge (ie you charge direct to 16S). If you had one charger hooked up to half of one pack, and the other across the other half, you don't need the diodes.

I have an extra diode in series with the output, purely because I leave the chargers hooked up 24/7 (its in a large motorcycle) - if you disconnect, you don't need this.

I prefer to charge in series because I have a CA that's powered all the time, and a battery shunt, and I can see the charge as regeneration.

 

[michaelkramer11]

The diodes are across each supply - their purpose is to save the output capacitors in the power supplies if one goes into protection mode (e.g. thermal cut-off) - they stop the entire pack voltage from going across the capacitors of the supply that's 'off'. If you didn't have this, you will blow the caps.

You only need this if you are putting the chargers in series to charge (ie you charge direct to 16S). If you had one charger hooked up to half of one pack, and the other across the other half, you don't need the diodes.

I have an extra diode in series with the output, purely because I leave the chargers hooked up 24/7 (its in a large motorcycle) - if you disconnect, you don't need this.

I prefer to charge in series because I have a CA that's powered all the time, and a battery shunt, and I can see the charge as regeneration.

Can you supply a link to the diodes you are using? I eventually want to charge with the power supplies in series and run through a cycle analyst as well.

 

[heathyoung]

Across the supplies - I just used 1N4001's - nothing special, they don't have to carry current in normal use.

 

[michaelkramer11]

What diode are you using on the output? I think I may leave the supplies hooked up all the time so i dont have to worry an open connector at pack voltage.

Across the supplies - I just used 1N4001's - nothing special, they don't have to carry current in normal use.

 

[Alan B]

Hi folks. Just wandered across this thread.

The Meanwell LED Supplies make great chargers. The adjustable voltage and current make them a natural. I've been running the 320's for a long time on my at-work charger. Their UL listing is also important for that application. No fans = quiet which is nice as well.

I don't have an automatic cutoff. I watch the current and shut it off when it drops below 0.1A after a couple hours charging. I put a meter on each supply as I don't have them in series. I just connect a 25V supply to each 6S section so there are no issues with relays or diodes. Even after shutting off the supplies the voltage stays the same, so leaving it on longer doesn't make much difference. The reverse current into the supplies is very small. You could program it to cycle on every day or or week if you were going to leave it plugged in, I just unplug it. I use a six pin PowerPole plug to handle all three supplies at once.

Here's an example of end-of-charge conditions. The supplies are matched better than the meters are.

I'm working on an automatic cutoff. I've collected most of the parts, still waiting on a few. I'm going to use a Teensy2 running Arduino type code to monitor the three currents and run some timers, and control the supplies with three separate solid state relays. The Pololu boards have Allegro current sensors which are isolated and put out a 5V analog signal representing the current. The solid state relays are isolated as well and will run on 5V, so it is easy to monitor the currents and control the supplies. The software will turn off the SSR when the current is low enough or the time is exceeded. An LCD display will let me know what the status is.

 

[pomah]

So for me reading 3 pages of discussion I now got confused, to use this type of charger for a single 13s pack, are any modifications needed? What was the conclsion of outcome for when the charger reaches max CV and sets the current to 0? Does it harm your battery?

 

[danielrlee]

So for me reading 3 pages of discussion I now got confused, to use this type of charger for a single 13s pack, are any modifications needed? What was the conclsion of outcome for when the charger reaches max CV and sets the current to 0? Does it harm your battery?

No modification is needed to use the HLG series power supplies as bulk chargers. Set the voltage and current once and then just plug in to the battery. Once the charge is complete, current will have tapered to zero and your battery will be held at the fully charged voltage. No harm will come to your battery at this point.

 

[MrDude_1]

So for me reading 3 pages of discussion I now got confused, to use this type of charger for a single 13s pack, are any modifications needed?

no. no mods are needed. You just need to set the voltage and amperage pots when you take it out of the box.

What was the conclsion of outcome for when the charger reaches max CV and sets the current to 0?

The charger holds the max voltage, and the current drawn by the battery slowly drops until your meter reads zero. truly there is some tiny current flowing always, as the battery is not a perfect device. but for all intents and purposes, nothing is happening. no current is flowing. the battery cannot become "overcharged" in this state.

Does it harm your battery?

This is one of those things people will argue about forever. if you are not at the battery's absolute max charge, then no. it wont harm it. Being fully charged naturally causes some degradation in lithium chemistry batteries, but that is from it being charged, not from the charger.
again, like "whats the best oil" and anything else, people will argue about this forever.

 

[pomah]

Ty guys, some more questions from those of you who have the HLG

From the spec sheet there is a difference between the CLG and HLG:

CLG: http://www.mouser.com/ds/2/260/CLG-150-spec-806004.pdf

HLG: http://www.mouser.com/ds/2/260/HLG-150H-SPEC-806071.pdf

CLG has an working range of 40 ~ 56V while the HLG has a working range of 43 ~ 53V, what is the working range on your samples?

A voltage of 53,95V would be enough for me so the question is if I should maybe try to get the HLG-150H-54A instead