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Configurable 5kW Charger

Configurable 5kW  Charger
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 5kW 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  to have it "reprogrammed." As most EV builders make changes to their battery packs, move chargers between vehicles and builds, this can be inconvenient.

But the power electronics are reasonably good and the charger has been mostly reliable and accurate. EVTV has now developed an Arduino Due based serial controller that controls this charger through the CAN port on the charger... We've added 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.

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 where xxx 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 for 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 EEPROM and the new value should also be reflected in the subsequent strings 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 6kw charger.  The maximum current depends on the maximum voltage.  The 258v model can do a maximum of 27 amperes. You can charge at any voltage between 36 volts and the maximum voltage, but the maximum current will always be 6000/charge voltage and not exceed the 6000w 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.



MAX OUTPUT POWER: 5  kW
MAX VOLTAGE - by option
MAX CURRENT by option
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.

DIMENSIONS: 21.5 x 14 x 5.5 inches
WEIGHT: 45 LBS

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


Select option by maximum charge voltage and current. 

Note that these 3 limitations are inclusive - ALL have to be observed.  The charge configuration must be within 258v AND within 27 amps AND within 5kW, for example.  So at the maximum voltage of 258v, to stay within 5kW you will only see about 27 amps.  You will get the full 27 amps at lower voltages, but never more than 27 amps.



INCLUDES CANBUS CONTROLLER AND CAN ADAPTER

CAN Controlled TC Charger Manual

CA SERIES CELL USE AND CARE MANUAL - English


 

 
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