3phase EMW charger variant

Development and discussion of fast charging systems eg Chademo , CCS etc
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arber333
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3phase EMW charger variant

Post by arber333 »

I got some requests for schematics and code for EMW charger variant i am using.

I am posting the latest code here together with my design files and Wifi module link Dima prepared for remote starting.
https://github.com/dimecho/ESP8266-EMW-Charger

Be advised code is semi-opensource. There is a disclaimer in the code header. As long as you use it for your own application you are good.
My configuration of the charger is in 3phase RST operating from phase voltage 400Vac. This means 600Vdc rectified voltage.
It can operate reliably down to cca 200Vdc with 200A IGBT.
https://github.com/arber333/3phase-EMW-kind-of-charger

My latest design is using old V9 schematic with two ISO124 isolated op amps and DCDC +/-15V supplies.
Power board is used just so i can mount driver board directly to IGBT and pickup input and output voltages and current.
ISO124 enable me to use direct voltage sensing without need for calibration before connection to a car. This eliminates that dogy uLCD and its library.
I just use D1 mini Wifi interface i linked in the start and set my voltage and current.
Since V14 code uses effective PID it is really soft on start so you dont trip any fuses and it keeps charger within 0.5A and 1Vdc range

In case i need 1phase charging i use a trick. I have 2x 5000uF capacitors rated 450Vdc wired in series for 900Vdc work. If i need to create 600Vdc from 320Vdc rectified single phase i connect N line directly to middle cap bracket. Result is good 640Vdc but sustained load is a lot less than 3.6kW single phase should allow! https://ec.kemet.com/blog/voltage-doublers/
Ill post some photos later...
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alehandro
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Re: 3phase EMW charger variant

Post by alehandro »

Hello arber333! I wonder what your charger looks like in real life in dimensions? Photos and video files will surely solve the question.
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Re: 3phase EMW charger variant

Post by arber333 »

alehandro wrote: Tue Apr 27, 2021 5:57 pm Hello arber333! I wonder what your charger looks like in real life in dimensions? Photos and video files will surely solve the question.
Sorry i never noticed this question. Some old photos. I am using it with 400Vdc now. I got 18kW out of it! I will try to make some new photos.
My aircooled unit measures 420mm x 160mm x 180mm
https://mazdamx3ev.files.wordpress.com/ ... 7_0012.jpg
https://mazdamx3ev.files.wordpress.com/ ... 15_002.jpg
https://mazdamx3ev.files.wordpress.com/ ... 222900.jpg

Liquid cooled is under development and since my assortment of 3x eltek chargers is working so well i dont expect to rush with it.
I will probably work more on Auris inverter charger. It is much more compact package and can provide DCDC 12V supply while charging the battery.
whereswally606
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Re: 3phase EMW charger variant

Post by whereswally606 »

What voltage pack are you charging with this emw charger?

Also how are you using only 3 elteks? Dont you need more to get the hv to charge your ev battery?

I scraped the emw repo ftp a while ago for these files but glad someone has hosted them on git. Thanks Arber.
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Re: 3phase EMW charger variant

Post by arber333 »

whereswally606 wrote: Sat Jan 29, 2022 4:16 pm What voltage pack are you charging with this emw charger?

Also how are you using only 3 elteks? Dont you need more to get the hv to charge your ev battery?

I scraped the emw repo ftp a while ago for these files but glad someone has hosted them on git. Thanks Arber.
EMW can comfortably charge from 230Vdc to 420Vdc or so on Prius inductor. Anything less and IGBT suffers because PWM is banging too short pulses on inductor. Remember input is 3phase with 600Vdc on the caps. In theory it should be good to 70A, but i tried up to 42A.
Like i said i am working on a liquid cooled version with a chill plate mounting IGBT, diode bridge, output diode and inductor.
Prius gen2 inductor is really good hardware. No need to search elswere. I bet gen3 is good as well.
However now i belive it would be more economical to just use complete Gen3 inverter. I have made a simple arduino nano board according to EMW control board. I have successful voltage and current reading. But when i start PWM something pulls it down. I have to test this further...

On the elteks I have them connected 3phase in star with common neutral. They are liquid cooled. All of them can run on single command CAN ID 0x2FF with explicit current and voltage instruction. What i wanted though was more control over each individual charger not to overload my house. So i thought up a system of flags and a button to switch between them. For that I needed to reprogram each charger, so they report on different IDs which i listen to. A kind of feedback loop. I describe this here:
https://leafdriveblog.wordpress.com/202 ... ogramming/
https://leafdriveblog.wordpress.com/202 ... -chargers/
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Re: 3phase EMW charger variant

Post by whereswally606 »

Hey arber after writing the previous post i found your blog which answered lots of my questions. Basically when you said eltek i presumed they were only 48v 3kw flatpacks but now i realise they are 360v eltek valere which is a different beast entirely. I am a ways of doing any this but at some stage i what to retro fit my leaf with 22kw ac charging (or close to that) i have all the parts for a i3 lim based ccs retrofit so that will give me a 3phase type2 plug for my ac chargers.
Anyway thanks for the reply, great blog btw very helpful.
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