Monday, September 7, 2009

07/09/2009 Progress

EV Charger
  • Got 3 x 10W 4.7ohm resistors.
  • Using resistors, did thorough "burn it" test at higher currents.
  • After much experimentation, discovered that:
........TL431 works perfectly !!
........Breadboard resistance affects voltage control (ie allows "drift").
........Crucial to have no resistance between source, TL431, TIP137
.......and source
  • Even further analysis, shows that it is the resistance of the balance wires that fouls up perfect balancing.
  • Simple hook-up wire is sufficient to give bad enough readings, that the "Shunt Balancer" loses accuracy at around 1.4 Amps.

  • Even further analysis (and testing) shows that the shunt balancer is much more effective if the balance wires are connected FIRST AND FOREMOST directly to the +ive into the TIP137, and the ground from the resistor.
  • THIS WILL MEAN A RE-DRAW of the PCB permitting the largest possible traces directly to the TIP137, fuse, and primary resistor.
  • Also, Futurlec boards are $8.00 each, $16.00 to set up ...
  • ... so really can easily spend an extra $8.00 so to spread out the components, with larger traces, and order two boards instead of one.