Poor mans ChaDeMo charger (1-phase)

Development and discussion of fast charging systems eg Chademo , CCS etc
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Re: Poor mans ChaDeMo charger (1-phase)

Post by grgumxlm »

johu wrote: Thu Jul 21, 2022 10:11 am To my surprise the bridge rectifier has survived and the logic board seems fine as well.
Should I decide to repair this with a new IGBT brick I should be aware that it won't be cooled so well:

Some of the heatsink has been turned into plasma
Have you fixed yours or build a new one?
If you have a spare one (broken or not), what would be the cost for it with a local pickup in Kassel/Germany(no shipment cost, no money transfer cost)?

Commercial single phase 32A(max AC input) 17,5A(max DC output) chargers are complete financial disaster at 6000€ without even the taxes - https://www.carplug.eu/wallbox-quasar-c ... -bluetooth
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Re: Poor mans ChaDeMo charger (1-phase)

Post by johu »

I'm currently in Sweden but will be back in March.
If you want to repair it yourself you can just pick it up for a donation. I won't be using it anymore as I've got the Outlander charger in the car now.
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Re: Poor mans ChaDeMo charger (1-phase)

Post by grgumxlm »

Thanks! I take it and would pick it up in March then. Until then i would continue to follow your charging experiment videos at negative temperatures in Sweden.
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Re: Poor mans ChaDeMo charger (1-phase)

Post by arber333 »

grgumxlm wrote: Thu Jan 26, 2023 12:17 pm Have you fixed yours or build a new one?
If you have a spare one (broken or not), what would be the cost for it with a local pickup in Kassel/Germany(no shipment cost, no money transfer cost)?

Commercial single phase 32A(max AC input) 17,5A(max DC output) chargers are complete financial disaster at 6000€ without even the taxes - https://www.carplug.eu/wallbox-quasar-c ... -bluetooth
I would advise against this method of charging. Device is unstable and spare parts are difficult to get. Power factor is horrendous though.
I could possibly make one 3 phase 15kW charger for 1000€. But faults were common and catastrophic for IGBT.

One possibility would also be to assemble two 3kW eltek chargers together on single cooling plate and run 6kW.

If you are a DIY i would also recommend you invest in Prius Gen2 inverter and set it up for charging from 3 phase :).
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Re: Poor mans ChaDeMo charger (1-phase)

Post by johu »

Oh hello :) Power factor in boost mode is actually quite good. One thing boost mode does not like is being randomly disconnected from the battery, as I've demonstrated ;)

yes, will get back to you when I'm home.
No technical videos on tap right now so here's a nature one :)

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Re: Poor mans ChaDeMo charger (1-phase)

Post by grgumxlm »

I picked it up and now i start fixing and fiddling with it.
Because it was not mentioned in the thread: The 2x680µF in series (340µF) caps have been replaced in later pictures by the white motor cap with 40 uF and 550V (moro PMP 55400).
I have few parts laying around. I would like to know what would be the perfect cap value? What is the smallest possible value? The cap also protects the BMS in the car from voltage spikes. But simply choosing a huge capacity one in such a setup with known IGBT-explosion when failure at some capacity value only make the explosion stronger and do not protect any more the circuit/car-bms.
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Re: Poor mans ChaDeMo charger (1-phase)

Post by johu »

The motor cap is a random donation from pm_dawn in Östersund. Usually the output caps can be quite low value, like 10 uF at least. Doesn't hurt if it's more.
The over voltage limiting is too slow, that's why it kept blowing up should something go wrong with the battery connection. Maybe a Varistor or TVS will help? Not sure if they can cope with that much excess energy.
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Re: Poor mans ChaDeMo charger (1-phase)

Post by grgumxlm »

johu wrote: Tue May 12, 2020 7:53 pm [*] About 50A IGBT brick (half bridge)
What Snubber size was used with the IGBT (the one in the first post)? Have you changed the size of the Snubber later when you used the TO247/TO220 IGBT? How have you chosen/calculated the perfect value for the circuit? :lol:
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