DIY Open Source EV Charger

[jackbauer]

Here a few pics of the charger in operation. First pic is running in bulk mode with a 10amp current limit. Second pic in float mode. I had to limit the charge to 10amps due to the poor main service where i work on the car. Was actually causing the lights to dim

[williamson]

Paul: Wheres the new thread, on 14 volt, 90 amp DC-DC converter? Mr Bigh: I live on LI. You can call me, and I'll give you all the info/progress. 631-474-1403. Of course, you'll need my real name: Clyde Smith. Kindest regards to all

[Wonderboy]

I have been lurking around this thread watching the progress with limited understanding of what is going on. Let's just say the extent of my understanding is that I aced my college digital electronics class. I am poised and planning to try out any or all of these open source EV projects on my conversion. Within this year I will either be buying direct or building my own copy of Paul's controller, this charger (when it's finished), and hopefully the DC-DC inverter. I wholeheartedly support what has been going on here, am proud of it, but unfortunately don't have much help to offer but moral and monetary. Keep up the good work guys, I really appreciate it.

-Will

[TheSGC]

Hey JackBauer, does your charger charge at the full 40 AMPs required to charge your PC2150s?

I am looking at building my own 40 AMP charger because I am looking into PC2150 (actually the Sears PM-1 31, but same battery) and it requires a 40 AMP charge at least every 5 cycles to properly live, according to the Odyssey engineers.

I have enough parts to build a 6 AMP prototype over spring break, and if I am successful, I am going to go for the big kahunah, 240v charger with 40 AMP output for a 96 volt pack. I am in the middle of taking AC circuits, so building the charger should not be a problem, except maybe actually getting a 240 volt plug in the house...

[jackbauer]

It so happens that just yesterday I had the chance to run the charger at near 30amps output for the first time as i had access to a 16amp industrial 240v supply. Worked fine albeit for a short time as the batts were not very discharged. The charger is , in theory , capable of 50 amps output. My inductor is oversized for the job if anything. The new software I developed completely eliminates the noise issue on the voltage readings.

Regards the Odyssey batts i cant sing their praises enough. On my short runs thus far they laugh at the demands made by the motor! I had a chance some weeks back to speak to the european sales manager for odyssey and he advised that when connected in series strings of more than 2 units that they be charged to 14.5v during absorption phase not 14.7v. This is to allow for slight imbalance in the pack.

[adamj12b]

Originally Posted by TheSGC

I am looking at building my own 40 AMP charger because I am looking into PC2150 (actually the Sears PM-1 31, but same battery) and it requires a 40 AMP charge at least every 5 cycles to properly live, according to the Odyssey engineers.

Wait!? the sears battery is the same as an odyssey??? Do you have a link as to what one it is on their website?? I want odyssey's for my golf cart, but couldn't really afford them, but I could afford these!!

-Adam

[TheSGC]

Originally Posted by adamj12b

Wait!? the sears battery is the same as an odyssey??? Do you have a link as to what one it is on their website?? I want odyssey's for my golf cart, but couldn't really afford them, but I could afford these!!

-Adam

Yep, the Sears PM series are Odysseys, except with Automotive Posts along with screw terminals. They were made for Sears by Odyssey. This it the one I have my eyes on: http://www.sears.com/shc/s/p_10153_1...rine+Batteries

I am saving up for these batteries, once I build a charger capable of dumping 40 AMPS for charging.

[MPaulHolmes]

I have 6 of those exact batteries. 3 year warrantee. I've had no problems for the last 1.5 years.

[TheSGC]

Originally Posted by jackbauer

It so happens that just yesterday I had the chance to run the charger at near 30amps output for the first time as i had access to a 16amp industrial 240v supply. Worked fine albeit for a short time as the batts were not very discharged. The charger is , in theory , capable of 50 amps output. My inductor is oversized for the job if anything. The new software I developed completely eliminates the noise issue on the voltage readings.

Regards the Odyssey batts i cant sing their praises enough. On my short runs thus far they laugh at the demands made by the motor! I had a chance some weeks back to speak to the european sales manager for odyssey and he advised that when connected in series strings of more than 2 units that they be charged to 14.5v during absorption phase not 14.7v. This is to allow for slight imbalance in the pack.

I want hear about long, abusive runs! Your BMW is similar to my Civic, (96 volts setup) so I am really curious on what your range and performance is with those batteries, and how the charger works out at 40 AMPs.

[adamj12b]

Originally Posted by TheSGC

I want hear about long, abusive runs! Your BMW is similar to my Civic, (96 volts setup) so I am really curious on what your range and performance is with those batteries, and how the charger works out at 40 AMPs.

Hey Dave,

Jacks problem right now is he doesn't have a service big enough that is readily accessible to power the charger that wont cause a tripped breaker or the light dimming!!

Also, right now he only has 48V (4 batteries), but is getting 6 more very shortly.

I dont know how much you have done on your charger already, But I have a PCB of this charger all drawn out in eagle that I will be proto-typing in the next few weeks. Im working on a kit basically that this will be the logic, you supply the power stage which is just a rectifier, caps, IGBT, and inductor.

I could use a beta tester that is local...your only an hour away...If your interested.

-Adam