My 1200W Charging Setup

[markz]

Got me four MW HRP-300-24, and a set of two are connected in series to achieve 41.5V charge on 1.6Ah 18650 cans.
From no juice left ~3.00V to 4.00V took 24:03 minutes
... to 4.10V took 30.5 minutes
... to 4.15V took 33 minutes
Audible 1st stage fan slow down @ 36 minutes
Audible 2nd stage fan slow down @ 41 minutes
Audible 3rd stage fan turn off @ Soon After 41.5 minutes


As you can see I got an odd-ball MW HRP, it cant go lower then 43V, so I have to keep a very close eye on it, I disconnect at 41.7V, and wait for the other set to completely finish and disconnect it, and connect other battery, takes another 3-to-5. Its a bit of a pain. The major problem is when I am out and about riding, and I want to sit at a Tim Hortons to have a frozen donut reheated, I got to babysit the one set to make sure it doesnt go above 41.7V. I am thinking I can install some wire making a DIY wire wound power resistor, to see if I can reduce it by 1.5V.


I calculated the total charge time to be ~45min (12Ah/16A=0.75x60=45min) seems to be an accurate calculation to determine charge time.

Dimensions
Size of each set (two stacked) 199 by 105 by 82 (each module is [from specs] 199*105*41mm L*W*H) running off of 120Vac input, and ~4A input.

Its bulky, but I figure I will start saving for brand new 3.5Ah cans and for the same size pack, I get over double the Ah.

Alternatives are HRP-600-48 size is 218*105*63.5mm (L*W*H) $145usd($200cad) can do 10S or 13S
But you see I paid $150-$170usd for 5 HRP-300-24 which can do
A) 20.5V-to-29V
B) 41V-to-58V which is 10S or 13S
C) 61.5V-to-87V

I am happy with everything, except the bulkiness of the charging, takes up too much space in my pannier bags.

Alternatives I've been looking at to reduce the overall size for 1200W charging on 115Vac outlets.
Meanwell RSP
RSP-1000-48 43V-55V @ 21A pulls 12A from the wall on 115Vac
the 1500's pull 17A from the wall.
Meanwell HLG (LED Drivers, fully sealed)

Meanwell Clones off ebay.

 

[Sunder]

For such a small voltage drop, why don't you use a Zener diode with a forward voltage drop of 1.5v? Saves you having to lose the heat of a resistor, which could be quite substantial if the chargers are high amperage.

Simple introduction here:

https://arstechnica.com/civis/viewtopic.php?f=23&t=409244

Edit: Apologies, I'm confusing Schottky diodes with Zener Diodes. Zener Diodes have a reverse breakdown voltage of what you want to shave off the voltage, so if you want 1.5v shaved off, you get a 1.5v Zener, and put the power through in reverse. 1.5v will be used by the diode, and the rest is forwarded on to the battery. Schottky diodes have a fixed forward voltage drop, so you just keep adding them in series until you get the desired voltage drop.

 

[cal3thousand]

Nice charge setup!

Mean Wells are awesome for the ebiker that knows what he's doing.

 

[markz]

cal3thousand - Thanks, yeah I like it a lot. Although for that setup pictured, its really bulky for guerilla charging. I always carry one half of that setup.

Sunder - Its 16A full blast, 30V from bottom, 43V to top, so about 450 Watts. Need lost 1.5V or more, I could set the MW's to a larger voltage if required for Zener Diode value.


So I think I need a 600W Zener, this ones 11V for pennies. I bet I need 41
http://ca.mouser.com/ProductDetail/ON-Semiconductor/BZG03C15G/?qs=%2fha2pyFadugjLwyUT9kOdavrfFBRwwMX2rPyOgVzo1s%3d

 

[999zip999]

I use two sets of meanwell 24v turned up to 29v and a hp 550 power supply at 12.6v for 41v @ 16amps for half of 24s pack. So can charge each pack at the same time on one power strip. About one hour for 18ah .Works great. P.s. have burn up one 1440 and three 1220 rc chargers.

 

[cal3thousand]

I use regular 'chargers' at home, but Mean Well HLGs or CLGs for guerilla mobile charges

 

[markz]

I use two sets of meanwell 24v turned up to 29v and a hp 550 power supply at 12.6v for 41v @ 16amps for half of 24s pack. So can charge each pack at the same time on one power strip. About one hour for 18ah .Works great. P.s. have burn up one 1440 and three 1220 rc chargers.

Oh great thanks, I got me plenty of them Dell 12V 92A units, crank the MW up and rock the Dell with it. I will try that tonight. May find a more compact Dell type unit, I know Cubes57 talked about an HP.

With the HLGs or CLGs dont they offer too few amps, plus need too many of them?

I am making a new account for Google Maps and marking all the charging locations, so when I am in an area and need more juice, I can go straight to the location rather then waste time and juice hunting an outlet. I think it will work great, because I tend to ride the same area's over and over again, but the area's and routes are large.

Which reminds me, I need to buy a wall power outlet tester, one of those small ones the size of a power cord end.

 

[999zip999]

I had to isolate the HP power supply. Or break the connection from power case and ground. Sometimes a jump wire. Plus there is a trick of checking the ground thru the plug unplugged. The meanwell is 10amp and the hp 12.6v 45or 55amp and the combo is 16amp. Get for my A123.

 

[markz]

If I wanted more amps to charge in 10S (36V) then what about (Dell 12V ~90A) x 3 in series = ~36V ~90A then a MW HRP-300-5 (4.3V-5.8V and 60A) to obtain 40.3V-41.8V and 60A in CC/CV.

Then if I wanted 13S (48V) then I'd find a suitable MW CC/CV.

It will be real bulky.

 

[999zip999]

Mark what batteries are you charging ?

 

[timmy66]

Does the manufacturer suggest these can be run in series? I looked on the HRP-300-24 data sheet and didn't see any mention of it.

Thanks