DIY Open Source EV Charger

[apowers]

Dwffy
My inductor was something from the forklift parts pile. Its looked like #12 or 14 wire on it . I measured the size of it and tried to count the turns then looked on a chart and guessed it is 25mh. When I plugged that number and the 16 mhz from the cougar control board into that link it suggested 100uf capacitor (Panasonic EEU-EB2E101S 100uf 250 volts). I bought the small LEM (50) and put the neg. output through it 3 times and adjusted the variable resistor on the control board till it interupted at 12 amps. I'm using STW75NFW30 N-channel MOSFET for the switch. 300 volt 60 amp two of them. I'm using one of the STTH600CW diodes. I have a 20 amp fuse on the dc pos. output , a 15 amp breaker and ground fault breaker on the ac input.
I use a pot. to adjust the amps and the volts rise as it charges the batteries.
It is still working fine. But if not connected to battery when you start the switching with the pot. it will burn a mosfet and flip the breaker. Guess how I found that out.

Alvin

[jackbauer]

I actually ended up using a half controlled 3 phase rectifier. Much simpler and works well.

[Weisheimer]

Originally Posted by jackbauer

I actually ended up using a half controlled 3 phase rectifier. Much simpler and works well.

So, are the three modules SCR's?
Curious if you used one of the circuits from an old welder/plasma cutter or if you have done it as an embedded project...

Details?

[Dwffy]

Originally Posted by jackbauer

I actually ended up using a half controlled 3 phase rectifier. Much simpler and works well.

So how did you wire it up Jack? Do you have a diagram I can take a look at?
-Doug

[Dwffy]

Hi Alvin,
Without a diagram I have difficulty trying to visualise how it is all connected up. Can you help me with some more info?
-Doug

[adamj12b]

Originally Posted by Dwffy

Hi there
I am interested in you circuit sounds like it could work for me too. What I need to know is how to instal a buck boost to go higher in voltage. Do you have a diagram for this circuit, it would be appreciated?
Thanks. Doug

Hello Doug,

The design that is currently being worked on is a Boost type PFC power supply. It takes 90-260VAC and while power factor correcting it, boosts the voltage to 400VDC and stores it in the bus.

I will try and get the schematics posted this week.

-Adam

[apowers]

Doug
I don't have any diagrams. The link to the boost converter that I posted has a diagram. http://www.evdl.org/docs/bonn_charger.pdf And this has a diagram. The boost comes after the Bonn. I did not put any taps on the Bonn inductor.
Alvin


I added a small 12 volt transformer to power the control board.

[MaputoMan]

Originally Posted by jackbauer

I actually ended up using a half controlled 3 phase rectifier. Much simpler and works well.

Jack, are you using 3 SCRs, one on each phase, and tying the battery negative to the line neutral? Do you still use an IGBT before the inductor, or is that functionality handled by the SCRs?
I ask b/c I want to do something similar, as my pack is 240v (20x12v) and it charges slowly with single phase 240ac.

[jackbauer]

The charger actaully runs on 415v ac 3 phase and can charge upto 500v at 200amps if the service can handle it. Now this design is very simple and robust but has its disadvantages in terms of imput power requirements and power factor but its coming along nicely.

I've been working on some upgrades and improvements to the buck design :

http://www.youtube.com/watch?v=fR-UEFbLDQI

[sawickm]

Originally Posted by adamj12b

The design that is currently being worked on is a Boost type PFC power supply. I will try and get the schematics posted this week.

Hi Adam,

Were you able to work on you PFC power supply project ??? Hope to here from you soon.

-Mark