How to Make a Cheap High Voltage Universal Battery Charger | 12V to 150V DC to DC Boost Converter.

How to Make Cheap 1200W Universal Battery Charger | DC Power Supply

СТОИТ ЛИ СБЕГАТЬ ОТ РОДИТЕЛЕЙ? (А ЧЕ ТАК СЛОЖНО) ‍👩‍👧‍👦

Покупаю себе Грузовик. Новая ЖИЗНЬ после ИНСУЛЬТА

Какие ПРОБЛЕМЫ создают БОЛЬШИЕ ДЕНЬГИ #апвоут #реддит #апвоутистории

▼ЧЁРНАЯ МАГИЯ 🔮

DC to DC BOOST CONVERTER, High Voltage Battery Charger!

The Innovati0n Lab

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#battery #diy
This is a follow-on video for our DIY universal battery charger video. The goal of this video is to provide additional explanation regarding the operations of this battery charger, as a response to some questions and feedback received from our friends and RU-vid audience. The universal battery charger shown in this video can be used to recharge DIY ebike, electric bicycles, and electric scooters.
This is basically a DC Power Supply, and a Home Battery Charger, Using Constant Current Boost Converter.
The video addresses the following questions;
Is the universal battery charger considered a smart charger?
How does the Battery charger regulate charging voltage and current?
Is the charger capable of overcharge protection?
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23 дек 2022

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Комментарии : 77

@lycakito1814 Год назад

Hey my friend, great video, love it... could watch this type of detail all day long :) Christmas wishes from UK!

@theinnovati0nlab782 Год назад

Thanks a lot friend for your great feedback, I do appreciate it! Christmas wishes to you too!🎄

@theinnovati0nlab782 Год назад

We made this video as a follow-on video to our initial universal battery charger video - to address some of the questions and comments that we have received from friends and RU-vid audience regarding how The Innovati0n Lab's universal charger system works. Hence, we have covered the questions below; Is the universal battery charger considered a smart charger? How does the Battery charger regulate charging voltage and current? Is the charger capable of overcharge protection? I want to thank you for watching this video and for supporting our RU-vid channel. please let me know if you have any questions, comments, or suggestions. we will appreciate it if you could become a subscriber. Also, it will be great if you can help our channel grow by sharing our videos with your friends and DIY interest groups as our goal is to continue to reach a wider audience.

@theinnovati0nlab782 Год назад

Thanks!

@dragan3290 Год назад

Top job! Excellent work and great videos! I wish I found you sooner

@theinnovati0nlab782 Год назад

Thanks a lot, friend! 👍👍 I appreciate your great feedback!

@nhikoid Год назад

Very good presentation!. Are you a professional lecturer or teacher?. Great video. And excellent description if constant current constant voltage phases.

@theinnovati0nlab782 Год назад

Thank you so much for watching this video and for leaving such an inspiring comment, I greatly appreciate it! I am a professional - but not a professional lecturer or teacher. Thanks again for the wonderful remarks. 🙏👍 Please, we would greatly appreciate it if you could help our channel grow by sharing our videos. This will help us to reach a wider audience.

@njfulwider5 Год назад

Great video! I made one just like this, except I placed all my parts in a 1200 pelican. I also used a display and a relay with led to be safe when charging. I'll find the video and post it here. I'm sure you can do much better. I really like your work!!!!

@njfulwider5 Год назад

ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-ogmdTuobs8w.html

@theinnovati0nlab782 Год назад

Thanks a lot! I appreciate it. I just finished my 3D printed enclosure design for this DIY charger. I just need to assemble it and make the video. Thanks again.

@njfulwider5 Год назад

@@theinnovati0nlab782 I can't wait to see!!!! I really need a 3d printer. Someday👍👍👍👍👍👍

@sania2009855 Год назад

Good video. Hello from Ukraine

@theinnovati0nlab782 Год назад

Thanks a lot for watching our videos, friend! We appreciate your wonderful feedback. 👍👏

@sania2009855 Год назад

@@theinnovati0nlab782 this module is designed for 30 amperes at the input. why didn't it burn? Did you put 60 amps on the input? Sorry for the stupid question. I have a unit for 12v and 50a and I want to make a powerful charger for charging LG chem batteries.

@theinnovati0nlab782 Год назад

I appreciate your interaction, and I fully understand your concern. The reason why I use these boost converters for battery charging is that they actually allow you to set/adjust both your charging voltage and your charging current. Assuming that you have a power supply that could possibly deliver greater than 50A, it doesn't mean that your boost converter is going to pull that much current from that power supply. This is because the boost converter is current limited to 30A. This also means that even though you have a 12V, 50A supply (600W), you will only be getting 12 X 30 = 360W, if you use these converters. This was the reason why I doubled my input voltage to 24V. As you saw in the video.

@sania2009855 Год назад

@@theinnovati0nlab782 seems to understand, thanks for the help

@Mr.Engineer. 11 месяцев назад

Did you change anything when "it went from cc to cv mode" or did it do that by itself on the background of you setting maximum voltage and maximum current in the beginning?

@theinnovati0nlab782 11 месяцев назад

I didn't change any settings to go from CC to CV. Lithium-Ion and Lithium phosphate batteries are designed to go through both (CV and CV) charging phases/modes by default. Using a CC charger just helps them to get through the CC charging phase more efficiently. This is not the same for other battery chemistries and designs, like lead-acid batteries that mostly charge in the CV mode.

@johnshaw359 Год назад

Building one of these, but I'm going to use a riden 6024 digital control buck after the booster for convenience, thanks for the inspiration. I was thinking, perhaps you could run car power amplifiers at home from these PSUs.

@theinnovati0nlab782 Год назад

Hi friend! Thanks for the wonderful interaction and for sharing your experience. I would love to do a review of the riden 6024. Where did you get it from? To answer your question, I believe you can power your car amplifier with a good switch-mode boost/buck converter. However, I will recommend that you pay close attention to the input power requirements of your amplifier to make sure that your converters can provide/match those power requirements.

@johnshaw359 Год назад

Got it through bangood, better price if you get first purchase discount. Will try a cheap car ámp directly to the 12v HP supply at some point, can't see any problems, except maybe noise or may need to add reservoir caps.

@mattc825 Год назад

Great video!! Thanks man. One question- How do I dial down the current to zero? Is that clockwise or counterclockwise?

@theinnovati0nlab782 Год назад

Thanks a lot for watching our videos and for the amazing comments. To best answer your question, I posted some pictures in our community area. Basically, with the current adjustment potentiometer facing you, make multiple counterclockwise turns until you hear some audible clicks. Thanks again for the wonderful interaction. Our vision is to reach a wider audience, and we would appreciate it if you could help by sharing our RU-vid videos with your friends and DIY interest groups.

@mattc825 Год назад

@@theinnovati0nlab782 Thanks for the clear, detailed answer! I'm going to try it. Liked and subscribed.

@ketas Год назад

this might have minimum current in left position but you have to check. because it might as well be max in some other dc dc or new version of this. granted, so far i've found only one myself which does that (for voltage) but anyway, watch for that!

@gdangelis Год назад

ty Sir nice work and video. i wonder if by adding digital pots and a microcontroller (esp82xx) this could b remotely controlled. it would be an interesting project. in my case i am looking to charge a battery with the excess power that i would otherwise feed into the grid

@theinnovati0nlab782 Год назад

Kudos to the way you think! 👍👍👍 It is absolutely possible. However, I would recommend you have a plan to perform lots and lots of testing on it before your remote application. Battery charging can be fun, but you have to make sure that you are checking all the points of safety needed. My recommendation is usually for people to stay close and montor the battery and charging system closely because system failures do happen. Also, you should have a plan of how you can do a remote system shut down - just in case you have a failure.

@ogztnr5581 Год назад

İ am using same method for my 24s lifepo4.Can we connect parallel double regulator.for high amps??

@theinnovati0nlab782 Год назад

Thanks a lot for watching our videos and for asking such a thoughtful question. This is actually one of the best questions I have recieved so far! Connecting 2 individual boost converters in parallel is always a very challenging task. This is mostly because these are individually controlled SMPSs with different voltage and current feedback loops. I thought about doing it but I realized that it might just be easier to design a higher power boost converter of my own - I am still working on it, please stay tuned. I appreciate your feedback and if you could support our channels by sharing our videos, that will be amazing! 👍👍

@vadymskok6005 Год назад

if i use a welding machine with 25v 160 a and use 4 voltage converters in parallel, will i get about 50a 54.6v?

@theinnovati0nlab782 Год назад

Thanks a lot for the thoughtful feedback. 👍 My experience with switch-mode converters is that they usually don't play well together when you connect them in parallel. Even when you adjust the current and voltage settings to the same exact levels for all converters, there is still no guarantee that the paralleled network of boost converters will lead to a higher power output - just as you would expect for more traditional dc sources like batteries. However, you can definitely try it as an experiment and share your findings with our RU-vid community. We can learn from each other. 👍👍

@elyboyjune Год назад

i have 60v sla battery ebike set up. which is 67v if fully charge. can i use this booster converter even if the input is more than 60v?

@theinnovati0nlab782 Год назад

The maximum input voltage rating for this boost converter is 60V. I would not recommend exceeding 60V at the input As for recharging your ebike battery, the output goes up to 90-95V This means you can definitely use it to recharge your 67V SLA battery. Just make sure you pay close attention to the recommended charging voltage and current for your battery.

@gregorothor Год назад

Can this device be used to feed the energy from a wind turbine into an on-grid inverter to simulate input from a set of solar panels ? down the line after a rectifier bridge or wind turbine controller of course.

@theinnovati0nlab782 Год назад

Hi friend, Thanks a lot for the very thoughtful question. 👍👍 Personally, I will recommend using this converter for simpler applications. It seems to me that you will need a smart converter with a lot more controls/functions to be able to manage your power distribution.

@roanbrand7358 Год назад

Would be amazing to combine this later with inverter and control from arduino. To make a ups with switchover project. I so want to build it

@theinnovati0nlab782 Год назад

Thanks a lot for the wonderful feedback! 👍👍 You read my mind! I appreciate such thoughtful suggestions. A UPS project is definitely on my bucket list. Stay tuned, friend!

@Zomby_Woof 9 месяцев назад

Great video, though I think people are going to be confused by use of the term 'mode' which implies a directed mode switch rather than the process be a natural effect of the way internal resistance goes up a the cells charge. Have you tried paralleling the boost converters? If I were to drop my full home electrical service, that would be 12kw - my pack would take up to 23kw... Hmmm....is electrical service based solely on current? If I used 220v*100a that would be 22kw, or 450a @ 48vdc. That would almost max my pack. that would require 15 boost converters, fed by 8 2950w 48v server p/s. I bet I could charge at work directly from the 48v supply if I could make my pack portable. 0 to Full in 5 minutes would rock. More realistically, I would need 4 D2D's to support 2 p/s. That would give me 30 minute charge times

@theinnovati0nlab782 9 месяцев назад

Hi friend, Thanks a lot for the great constructive feedback! We appreciate it.👍👍 I see your point, and you are right that some people may find the terminology confusing. However, I believe that the word 'mode' is actually used in most battery design literature to describe this phenomenon. Let me know if you found something different. Please share links here. I am always happy to learn from our audience. 👍👍 Regarding your electrical service comment, what I would say to that is for you to be mindful of super high currents because they lead to massive heat dissipations on your electrical systems - unless your system is designed to handle industrial level current draw. As you know, electrical systems, commercial and industrial wire guages, have evolved over the years to get to a good balance between the voltage and current components of transmitted power. The goal is usually to keep your current draw as low as recommended for your electrical wiring. As for your battery systems, I would recommend consulting your battery's manufacturer datasheet for the recommended charging currents and voltages. I hope this helps. Thanks again. 👍😎 The Innovati0n Lab

@sania2009855 Год назад

Hi friend. I have another question. Can I charge LG Chem lithium assemblies without a booster module? Directly from the power supply unit with a 12.6 volt supply? And also having previously used BMS

@theinnovati0nlab782 Год назад

Thanks for the interaction. I really appreciate your thoughtful questions. 👍 However, I am not sure of what the specs of your battery are so as to speak to the charging conditions. The reason why I recommend using the boost converter is because it is a constant current converter and allows you to control both the charging voltage and charging current to match what your battery is designed for. This prevents you from damaging your battery cells due to high charging currents. Reason: Lithium ion and lithium phosphate battery cells have low internal resistance when the batteries are fully discharged. This means that if you do not control both your charging voltage and current, you may end up with super high charging currents going into your batteries. When this happens, your power supply could either trip off, blow a fuse, get damaged, or your battery cells could get overheated, and they may burst after a while. Overall, I honestly won't recommend that you do any charging if you don't have a way to control/adjust your charging current.

@sania2009855 Год назад

@@theinnovati0nlab782 but a charge of 5 or 15 amperes will take a long time if the battery has a capacity of 200 amperes and 12 volts. How to charge it faster? is this possible?

@theinnovati0nlab782 Год назад

Very true. 15 Amps of charging current will take a long time. The 1500W boost converters I used can give you up to 30A - depending on your power source. At 30A, your battery will still take about 7 - 8 hours to recharge. Is this the lithium battery? What is the battery voltage?

@sania2009855 Год назад

@@theinnovati0nlab782 LG Chem 3S4P 2.65kWh 12v I have a server power supply unit 12V 65A

@Full_Throttle_no_Brakes 2 месяца назад

Hi mate. I'm big fan of your channel. Can you charge a 72v lithium battery at 10 or 15 amps with this setup?

@theinnovati0nlab782 2 месяца назад

Amazing question!! 👍👍👍 Let's do some math. Assumptions: Please correct me where I am wrong. 💥 72V nominal LiFePO4 battery should have a series group of 24 cells in series (24S).....correct? If so, research shows that you need a charging voltage of 3.65V per cell. Hence, the recommended charging voltage is about; 3.65V X 24 = 87.6V Now, 10A at 87.6V means that you will need greater than 876W at the overall input of your converter system. Looking at the worst case converter efficiency of say....80% you will need a power supply that can supply; 876/0.8 = 1095W. I would recommend planning for about 1300W. and for this converter, I would also recommend a minimum input voltage of 48V - for this much power. We found a hack that would make it possible for you to possibly get this much power with just a 24V input power. See our last full video. Update is coming soon. We will also be able to sell the modified converter soon enough at our website. CAUTION: ⚠️⚠️ High voltage DC power is quite lethal. Make sure that you are protecting yourself by using the proper PPE. Always double-check all connections. Also, as a matter of personal preference, make sure that your barrel system is well protected....and make sure you check on it regularly during charging. I hope this helps. Please, we need your help the help our channel and to promote our website. You can help by sharing our videos on social media and by visiting our website at www.theinnovati0nlab.com. 👍😎 The Innovati0n Lab💥

@Full_Throttle_no_Brakes 2 месяца назад

@theinnovati0nlab782 Thank you for taking the time to reply me. My battery is 20s Lipo. So max voltage is 84v. Still, the formula is the same. What I didn't understand is this: With such cheap step-up, it's not possible to make a fast charger only with 2 server power supplies? Do I really need 4? I was thinking about getting only 2 Servers PSU 1200W each FIY my step-up is the Drok 900w

@TheOtherSide777 Год назад

So with this setup of 24v power supply would I be able to charge my 12v battery to 14.6v @60a ?

@theinnovati0nlab782 Год назад

Hi friend. Thanks for asking such a wonderful question. The 24V setup is meant to charge batteries 24V and higher if you are using a boost converter. However, you can charge a 12V battery with the same setup, but you will need a buck converter to step the voltage down. As for doing a high current charging at 60A, that is a tough challenge. I am working on finding a cheap way to do that, and once I have a solution, I will make a video for it. If you can help us grow our channel by sharing our videos, that will be wonderful.

@TheOtherSide777 Год назад

@@theinnovati0nlab782 thanks for the quick response. That’s the project I’m working on right now. I have a computer power supply with dual 12v rails at 30a each. I already own this boost converter. Maybe I’ll buy another to run them in parallel @14.6v for the 60amp then to battery.

@mattc825 Год назад

May I ask one other question and apologies if I missed it in the video...Once the current and voltage are set up, what happens when a cloud blocks some sunlight? Does this maintain voltage while reducing current? Then when sunny again will it return to the programmed settings? Thanks in advance man

@theinnovati0nlab782 Год назад

Thanks a lot for the wonderful interaction. Please know that all your questions are welcome. Please never apologize for asking great questions. 🙂 The boost converter is a constant current converter, and in order for it to perform as designed, it must be connected to a power source that provides more power than your load is demanding of it. Your load in this situation will be the batteries that you are charging. It seems to me that what you need is a solar MPPT charge controller. MPPT controller will provide exactly the function that you were describing because as the name goes, they actually do Maximum Power Point Tracking/Control. The MPPT charge controllers are designed to scale down the charging current when the solar irradiance on your panels is low ==> in order words a cloudy/ rainy/snowy day.

@mattc825 Год назад

@@theinnovati0nlab782 Fantastic. That answers my question perfectly! Thanks a million.

@mattc825 Год назад

So if the constant current cannot be maintained it will shut down? And if that's correct, this type of unit isn't a good match for solar charging battery banks, etc ? (Is my understand correct now?)

@technicaldada5384 11 месяцев назад

Can u make universal overcharge protection circuit board ,which works for all battery charging I.e, 12v ,24v, 36v, 48v 60v, 72v

@theinnovati0nlab782 11 месяцев назад

Honestly, I really like the way you think! 👍👍👍 It will be easier to do for lead acid batteries, where cell balancing is not as critical. However, with lithium phosphate or Lithium-Ion batteries, there are some added complexities because the protection circuit has to protect each individual group of (3.2V or 3.7V) cells connected in series to achieve those voltages. Usually, Lifepo4 and Li-ion battery BMSs are designed with comparators or voltage level monitors and MOSFET switches that monitor the charge discharge levels of the battery cells which are connected in series. Yeah, it gets complicated. But I will give it some more thought. Thanks again for such a wonderful insight. 👍😎

@technicaldada5384 11 месяцев назад

@@theinnovati0nlab782 I am going to make universal battery charger, using boost convertor + 12v-50amp smps power supply with auto cut off. But the problem is that , I find the auto cut off circuit board online which supports only max 60v ,means for 48v lithium batteries. Cut off voltage below 60v. But for 60v & 72 v batt charging , I didn't find any cut off circuit. So I am asking that if u could make it possible than it will be very helpful. .. Thank uuu..

@theinnovati0nlab782 11 месяцев назад

@technicaldada5384 Ah, I see. It is definitely a good project idea. I have added it to my to-do list for future projects. 👍 But first, I will do some search to see if there isn't a product out there that I can recommend. It is usually more cost-effective to just by a cheaper product off the shelf than to try to develop one from scratch.

@martingunawan1827 2 месяца назад

Hi mate, im planning to build evbike charger from this step up module. Im using lifepo4 24s, my target voltage is 87.6V and 10-12 Amps max. Input power from huawei r4850n6 server psu 53V 56A Questions: 1. Will the step up module last long if i use it every day? Well regular use, i only use 5-6Amps 2. When first time connect the psu and step up module, before we set the potensio, is the default current set to the max? Thanks before.

@theinnovati0nlab782 2 месяца назад

I honestly can't speak to the reliability of the converter because it is not really my product. However, if you are using it as a battery charger - with a good cooling system. It should last. As long as you are not overloading it. Using a high input voltage should definitely be very helpful in reducing the overcurrent stress.

@sokdolla 4 месяца назад

Can we add full charge light indicator?

@theinnovati0nlab782 4 месяца назад

Yes. In the land of electronics designs, a lot of things are possible. Great thinking. 👍👍 The Innovati0n Lab 💥

@sokdolla 4 месяца назад

Do you have video how to add that?

@theinnovati0nlab782 4 месяца назад

@sokdolla No, I don't. That seems to be a project of its own. But I like the idea, though. I will research that topic to see if it will be worth my time - as a future project. 👍😎 The Innovati0n Lab💥

@mrtechie6810 Год назад

I put the 1800W version on an ebike and it failed after 5 minutes, halfway up the hill. Output voltage is now the same as input. :-( 16V to 55V, to a 48V 18A peak ebike controller.

@theinnovati0nlab782 Год назад

Hi friend! Thanks a lot for sharing your experience with our community.👍👍 This was what I was afraid would happen with these boost converters, especially when the applied input voltage is low. I will see if there could be a way to boost the power output of these converters - even at a lower voltage input. Stay tuned. However, for now, my recommendation would be to increase the input voltage level to your boost converter if you are still willing to try using it again on your ebike. Personally, I won't use anything less than 36V as the input voltage. That means a 36 - 48V boost.

@mrtechie6810 Год назад

@@theinnovati0nlab782 thanks! There appear to be 4 (3 used as rectifiers?). The large one in the middle must be switching driver.... Using diode test I am NOT getting open reading between source and drain.... I lifted the large MOSFET and there appears to be a scorch mark in between the area near the source and drain of the chip.... Yup, an actual crack in the large MOSFET chip -- labeled HY3912 FL277S02 C. What MOSFET do you recommend as a replacement? Is there a way to protect it, prevent the failure from recurring?

@theinnovati0nlab782 Год назад

Hi, friend. My first guess would be that your MOSFETs died, but the damage could have spread to other components as well - PWM IC, output diodes, etc. Those boost converter units use the HY3912 MOSFETs, and you can order those from eBay and give it a try. However, if you consider the cost of parts, plus your time, it might just be better and faster to buy another converter unit - giving how cheap they are. I made a video where I took the converter apart and explained the component - please check it out to see if you could find some helpful information. ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-iQnXLZqpSpo.html

@mrtechie6810 Год назад

@@theinnovati0nlab782 Thank you kindly! I was considering to replace just the large switching MOSFET in the middle. I haven't even visually inspected under the other three -- if I bend them, it may weaken their legs?

@theinnovati0nlab782 Год назад

Just gently raise the MOSFET. The pins should break that easy. I have done the replacement before with no issues.

@sathyaprasad1411 9 месяцев назад

👌👌👌👌👏👏🤝🤝🤝

@theinnovati0nlab782 9 месяцев назад

Thanks a lot, friend! 👍👍

@sathyaprasad1411 9 месяцев назад

🤝🤝🤝🤝👏👏👏👏👍👍👍

@theinnovati0nlab782 9 месяцев назад

Thanks! I am glad you liked it. 👍👍

@cighals Год назад

these boost converters easily to get burned. be carefull. they are not long lasting.

@theinnovati0nlab782 Год назад

Hi friend, Thanks a lot for the great feedback. However, make sure that you are adding external fans to the converter to give them some additional cooling under heavy loads. Never trust the small fan and heatsink that some of these converters are designed with, and they are not sufficient in cooling the converters. As you know, excessive heat is the number one enemy of any power electronics. Honestly, I have a different experience with these converters. I bought my first 1200W model of these converters more than 5 years ago, and it still works until today. Discliamer: I am not affiliated with any vendors. My reviews and feedback are unbiased.

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