4kW Configurable Charger
For budget minded EV builders, the Hangzhou TieCheng charger (TC Charger), also known as the Chennic or Elcon charger (two trading companies that sell it). has emerged as the low cost charger option. The drawback is that you must select a charge profile when you order it, and it is permanently configured. It cannot be changed by the end user. If you make changes to your battery pack and need it to charge to a different voltage, you must send it off for to have it reprogrammed. As most EV builders make changes to their battery packs, move chargers between vehicles and builds, this can be very inconvenient.
But the power electronics are reasonably good and the charger has been mostly reliable and accurate. EVTV has now worked with the manufacturer to develop a controller allowing you to change those values directly. We've put it in a sturdy aluminum enclosure for this to help block EMI/RFI, a DC to DC converter and powerup relay to startup when the charger starts up and isolate our power source from the noisy vehicle 12v system, and added a hardened USB port .
The result is a reasonably priced charger you CAN easily control to change the charge voltage, current, and termination. And we've made it ridiculously simple. The controller puts out a serial ASCII one line messege that shows your target voltage, charge current, termination setting, ampere-hours, and kilowatt hours. You can plug in ANY laptop with ANY serial terminal program to this device and watch it for hours on end - the fun never ends. Better, you can use your laptop to change the voltage, current, and termination current easily and quickly.
To change the charge voltage - simply enter the command vxxx
where xxx is the voltage. v192
would set 192v as your charge voltage.
To change the current, similarly enter axxx
is the current. a14 would set the charge current to 14 amps while a8
would set it to 8 amperes.
And finally to set the termination, which is the level of current the charger should taper to after reaching the constant voltage stage, typically 0.05C e5 f
or example would set this to 5 amps, perfect for a CA100FI pack. Or e9
for 9 amperes - 0.05C of a CA180FI pack.
That's the entire configuration process. The new value will immediately be saved to permanent memory and the new value should also be reflected in the subsequent strings received from the charger. You can then disconnect the laptop entirely.
When you apply AC power to your vehicle, the charger and controller will both come up and begin charging your car using those entered values. If at any time the controller fails to send the appropriate command for 5 seconds, the charger terminates - a safety to prevent overcharging if the controller gets "lost".
During a power outage/interruption, the charger will discontinue wth an AC error, and when power resumes it will restart the entire process automagically.
This is a 4kw charger. The maximum current depends on the maximum voltage. The 168v model can do a maximum of 30 amperes and the 258v model can do up to 18 amps. You can charge at any voltage between 36 volts and the maximum voltage, but the maximum current will always be 4000/charge voltage and not exceed the 4000w limit of the charger.
Note that there is a minimum charge voltage of about 36 volts and that when charging at less than half maximum, the charger also charges at half the entered current parameter, though curiously, it still reports the full current value.
Also note that this controller is NOT available separately and will not work with other TCCH chargers already in the field. The controller works with a special CANbus version of the charger that is somewhat more expensive and so almost never stocked or used here in the U.S. We special order these chargers directly from Hangzhou TieCheng as the CAN bus controlled version so that it will work with our controller.
MAX OUTPUT POWER: 4 kW
AC INPUT RANGE - 85-265vac
AC INPUT FREQUENCY: 45-65 Hz
AC POWER FACTOR: >0.98
FULL LOAD EFFICIENCY: >93%
ENVIRONMENTAL ENCLOSURE: IP46
OPERATING TEMPERATURE: -40C to +55C
DIMENSIONS: 352 x 366.5 x 138.8 mm
INTERNAL CURRENT LIMIT TEMPERATURE: 75C
INTERNAL SHUTDOWN TEMPERATURE: 85C charger automatically restarts if temperature falls.
REVERSE POLARITY PROTECTION: Charger will not charge if battery terminals are reversed.
SHORT CIRCUIT PROTECTION: Charger terminates during short circuit on output. If this is removed, it will automatically restart within 10 seconds.
OVER/UNDER VOLTAGE PROTECTION: If input out of range, charger terminates. It will restart automatically when power is restored.
LED FAULT INDICATIONS
RED/GREEN/6 sec pause Wrong battery
RED/GREEN/RED/ 5 sec pause Overcharged
RED/GREEN/RED/GREEN/RED/3 sec pause AC input out of range
RED/GREEN/RED/GREEN/RED/GREEN/RED/1 sec pause - CANbus communications error
GREEN/RED/6 sec pause Charger Overtemp
GREEN/RED/GREEN/RED/4 sec pause Charger Fault
RED/GREEN flash on 1 second interval Battery Disconnected
RED FLASH one second interval - Constant Current Phase
YELLOW FLASH - one second interval - Constant Voltage Phase
GREEN FLASH - one second interval Charge complete
We currently carry the charger in several different voltage models.
Note that these 3 limitations are inclusive - ALL have to be observed. For the 168 volt model, for example, the charge configuration must be within 168v AND within 30 amps AND within 4kW, for example. So at the maximum voltage of 168v, to stay within 4kW you will only see about 24 amps. You will get the full 30 amps at lower voltages, but never more than 30 amps. And never more than about 4kw.
Select the voltage at the time of order.
INCLUDES CANBUS CONTROLLER
CAN Controlled TC Charger Manual
CA SERIES CELL USE AND CARE MANUAL - English