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[Burton]

Ok got everything I need for this build that I cannot get locally coming in the mail.

Wire, diodes, connectors, etc.

My rig will have the chargers output to the SBS 75X with inputs through the PP45's
PP45 Y adapter (should be fun to make)
14-50p to PP45
J1772 to PP45
5-15 to PP45
10' or 15' PP45 to PP45 cable (need to find a cheap sleeve)
easy250 to PP45

I will likely also replace the stock C13 connector with a PP45 connector to make things easier. Expect a full write up for each with pictures and a parts list in the near future.

[Burton]

Last night I wired my two RSP-2000-48's power in parallel to three joined PP45's then wired up the 14-50p ignoring the neutral pin to three PP45's and fired them up. Man these things are quiet. I half expected them to be whiny 0_0

Testing the voltage and each PSU gave out 48 volts on the dot. Will do some more wiring later when I get home.

I might just solder my J1772's pins as I don't have a four-way crimper and I want to have this thing working by this weekend. So a blow torch and some solder should work ^_^

This build is looking like it wont take much time at all to complete. I will likely finish it long before my extra parts I ordered come in for the signal circuit of the J1772.

[Doctorbass]

Ok great! keep us informed!

btw I have posted info on how to adjust the max current limit on the output o fthese RSP-2000. this is very usefull when the AC source you have is not rated for the max power the RSP require at full load.

Doc

[Burton]

I saw your post about the 5k external pot I will add this in the future for now I just need a way to charge fast at a L2 J1772 power source.

Completing this will let me get certain parts machined to fit as I need to travel over an hour at highway speeds to get to the machine shop I have access to.

A lot of this build seems so easy I don't really know what to document. I will likely just make a video or two to go over the parts and the circuit then provide a list of sources for the parts. (Any suggestions from those who plan on doing this are welcome)

[Nuts n Volts]

Hey Burton,

Been following all of these quick charger threads and have been trying to come up with the best quick charger option for my R6 conversion.  I came across an idea that may help you out.  Why not get a cheaper 12V power supply like this one or one with more amps available...http://endless-sphere.com/forums/viewtopic.php?f=9&t=59242&hilit=12V+server+supply

That would save you $400 and give you the same power with minimal weight penalties.  Probably the route I'll be going down in the near future. 

-Kyle

[Burton]

Already spent 900 on the ones I have

Hat said what is the power input specs or the model / manual for those PSU's?

[Burton]

More goodies. Would have powered up tonight but I don't know how I am going to connect my diodes :/

Instead I wired up my J1772 connector less the sensor circuit, then wired a C13 connector,  wired the Chargers in series, and made a Y connector.

How i soldered my pin connectors.

[Nuts n Volts]

Already spent 900 on the ones I have

Hat said what is the power input specs or the model / manual for those PSU's?

Well yes but you wont spend $450 more on that 12V supply maybe. That is if you decide to go that route.

There are quite a few supplies like the one I linked which are well documented on ES and RC vehicle forums.

The one I listed is 2.5lbs, 13"x3"x1.5".  It does 12V and maybe up to like 13V with some wiring. It is rated to 55A.

My plan right now is 2 RSP2000-48 and one of these.  12lb, 5.5kW or so for ~$900. Good reliability too based what I've seen out of reviews of both units.

[Doctorbass]

Hey Kyle,

I know also that there is some great cheap psu like the famous HP ESP120 of 3kW 52V 57A at about 150$ shipped... but some are not constant current and or require some mod to be CC-CV witch is additional cost. German people have made some PCB to do the CC-CV but they sell them like 95$ each..

The Meanwell RSP choice is wen quality and durability is required wich the meanwell does perfectly! the server psu are not made for the same environmental spec and are more sensitive and dont take alot of abuse like the RSP does. It's like comparing a A123 cell with a Headway...

As well the meanwell are more expensive but i think the high quality and nearly plug and play wort it.  These are also isolated so serie connection is not a problem.


Doc

[firepower]

How i soldered my pin connectors.


It best to crimp if you can, they are crimp terminals.

[Burton]

It best to crimp if you can, they are crimp terminals.

Is there any electrical disadvantage to soldering vs crimping?

I would have crimped if I had the tool in hand but I need the charger for this weekend and cannot get a crimper for a reasonable price that soon.

[Doctorbass]

It best to crimp if you can, they are crimp terminals.

Is there any electrical disadvantage to soldering vs crimping?

I would have crimped if I had the tool in hand but I need the charger for this weekend and cannot get a crimper for a reasonable price that soon.

Best is to solder and crimp !

All what you want  is the lowest resistance between the wire strands and the contact connector.  When crimping the wire strands and connector are closer together and nearly melted together by the incredible force of the crimp.

Just solder is not the best. solder have very high resistance compare to copper and when used as a filler between gap it is also high resistance .

Crimping + soldering is the best. all wires strands are very close to the contact and the solder fill all air gap and improve to lower the resistance and also have a better heat transfer from the conector to the wire witch increase the ampacity.

Doc

[Burton]

Figured it was something like that. I will order the 4 way crimper for pins and when they come re do my pins

When I use to assemble laboratory equipment we would always crimp then solder as well on the important connectors.

And thinking back we also used silicon insulated 10 AWG wires or 6 AWG wires for our hot plates which were mounted on a rotating platform. The wires came through the top of the housing into a plug on the rotating plate then another plate with the heater elements (RTV'ed into place) was placed on top matching the plugs up.

I really should dive back into my electrical engineering books when I have time. >_<

[Burton]

I will post an update video later tomorrow of the tests today.

I got the diodes on, made the extension cord, wired up a temporary circuit for the J1772, and then tested the whole thing through my 14-50 outlet.

I will have to test it more but there was an issue with the chargers being plugged into the anderson first. I believe I needed to plug them into the anderson after they started up and not before.

If I plugged them in before starting them up they would go into charging mode for a couple seconds then one of the two would get a red LED and both would power into standby mode.

If I started the chargers up, let them run a second, then plugged in the anderson connector they would go into charging mode and stay in charging mode.

With the voltage maxed on both photometers the pack went to 112v or 84% and it took about one hour to get there from about 30% charging at 51 amps or about 5100-5300 watts. This with the stock charger plugged in though I don't know if the app added the chargers watts together or simply took the greater of the two inputs and used it. The chargers went into standby mode the moment the voltage was 112.4


Tomorrow I will come home and get my charger, extension cord, and the J1772 connector to make sure it works. I had to get some potentiometers and set them to 1.3k and 2.74k respectively to make the sensing circuit but I believe it should work.

[Burton]

-_-

Well the J1772 circuit works but it appears I blew my quick charging fuse last night and didn't even realize it 0_0

Just tested it and it didn't ring through ... it was also a 30 amp fuse and not the 45 amp I thought it was upgraded to -_-

Going to homedepot now so I can get the terminal connectors I will need to connect to the sevcon controller directly instead and I will likely recycle the anderson connector as I have another set of pins I can use