How to Make a Cheap High Voltage Universal Battery Charger | 12V to 150V DC to DC Boost Converter.
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- เผยแพร่เมื่อ 7 ต.ค. 2022
- This is an experimental project video to see if it will be possible to modify a DC to DC converter originally rated for 12V to 95VDC to boost the voltage up to 150VDC. This experiment uses a server power supply drive the modified boost converter. MOSFETs, rectifier diodes and output filter capacitors were replaced to match the desired output voltage of 150VDC. Detailed schematic was provided to show the modification that was done.
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I made this video to explore the possibility of being able to raise the output voltage of a DC to DC boost converter to a higher voltage than the manufacturer rating. Some people may find this useful in their personal projects and hubbies. This will also make it possible to recharge DIY Battery systems with high voltage ratings.
I LOVE this, where something is tested "live" on video...GREAT TECHNIQUE...YOU REALLY DOVE IN!!!
I read the comment about connecting two converters in series, and understand why this can't work. However, if two "isolated" server supplies (maybe even solar panels) are connected to two converters, then the converters are connected in series, may give about 180VDC out?
One more thing comes to mind concerning your removed pot replacement...it's easy to find those DUAL stacked pots (six connections), perhaps suggesting only a single simultaneous adjustment for both converters. ...probably would be handy to add a simple VOLT (/AMP) LED display to each converter output since these stacked pot values don't match up exactly...perhaps bias resistance on one pot stage can correct this.
I sure wish schematics were available!
--dALe
Thanks a lot, friend!
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I am glad you like our video format.
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The Innovati0n Lab
Been hooked on your videos for a good couple hrs very informative
Thanks a lot for the wonderful feedback.
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I am glad that you are finding our videos useful.
Please don't hesitate to let us know if you have any questions, suggestions, or ideas.
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- The Innovati0n Lab 💥
there is another boost converter which is rated for 97v max 1.8kw which does contain higher value components.. can you please check
Great content indeed. What's the possibility of having two boost converters connected in series on the output and supply 75V from each
Hi friend,
I like the way you think. Unfortunately, you will not be able to connect the outputs of these converters in series. This is because the input and outputs share a common ground. For a series connection to work, the input and output of the converters you are attempting to connect in series must be fully isolated.
This means that there can't be any common grounds between the input and output sections. You will need special converters with isolation transformers and not flyback inductors.
I hope this helps.
Success wishes on your projects, my friend.
👍😎
thank you for the video: I have a question: is it possible to connect the DC-DC booster directly to the 12V battery? I have a 72V ebike battery that I would like to charge in my campervan from 12V battery...
Hi friend,
Great question!👍
Yes, it is possible to up-convert from 12Vdc to 72Vdc using this boost converter. According to the vendor specs for the boost converter, it has an input voltage range of 10-60V and an output voltage range of 12-90V, if I remember correctly.
However, you need to do some research to figure out the recommended charging voltage and current for your ebike battery. I believe that the 72V is the rated nominal voltage of the battery, but it might need a slightly higher voltage for recharging it - depending on battery type.
However, this is not something I would recommend since I don't know your system. Also, keep in mind that a possible failure of the boost converter could backfeed the 72V power to your Van's electrical system. I'm not trying to discourage you but just making sure that you consider the good, the bad, and the ugly. 😊
But if you must do it, I would recommend that you do the charging when your camper van is running so you don't drain the 12V battery.
Safety Note:
Please make sure that your Van's electrical system (alternator, 12V battery, wiring) can support this activity. I would also recommend charging at a lower current as rapid charging a 72V battery may damage your van's electrical system.
Disclaimer:
My recommendations are a matter of personal opinion. Please conduct further research before implementing your design
Thanks again for the thoughtful question. Success wishes on your project.
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Very interesting video! I would like to know, if it's possible to go further, such as 200V too?
Thanks a lot for the feedback! We appreciate it.
To your question, it is absolutely possible. However, it will take some design modifications to withstand the modification to 200V.
@@theinnovati0nlab782could you provide some further information about what else to change to get up to that point? Since all the components you've changed should actually be able to handle more than 170 VDC isn't it?
btw. what was wrong with the driving mosfet that it blew up?
Hi! you didnt say if the mosfet were blown but I dont think it was, I had a similar experience where the fuse blew and what I found is even though you have 2 fuse in parallel both fuses are not electrically identical. eg one could be supplying 20 amps and the other 15A, the one that reaches its rated value will blow which then takes out the other one
Thanks a lot for the wonderful feedback.
I agree with you regarding the fuse issues and have encountered them as well.
However, in this specific case, both the MOSFET and the fuses actually blew.
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Love your videos
Thank you so much!
We appreciate the wonderful and inspirational feedback!
💥Stay tuned as we have more exciting videos coming soon.
Hi Sir. Why don't you redesign the PCB board for 150v boost convertor by copying the components and copper traces of the commercial 1800w boost convertor. I think it'll help us in making new things for future projects
Thanks a lot for watching this video, I appreciate it. I will be doing an original build of a DC to DC Buck-Boost converter soon. Stay tuned.
However, we do not copy designs here at The Innovati0n Lab. This video was simply an experiment done out of curiosity, plus it is be a cheaper alternative than making a completely new design.
Thanks again for the engagement and don't forget to share this video to help other DIY hobbyists as well.
@@theinnovati0nlab782
Thanks for your reply. My view is using the design as a reference why can't we make a new PCB that can be easily customisable according to our usage just by changing or replacing components that are necessary for our requirement.
I appreciate your efforts. I'm searching for this type of guidance through videos about making lithium battery charger using boost convertor since 2 years. Luckily I found your channel ☺️
I am really glad that you found these videos helpful.
Thanks a lot for all your inspiring comments!
hi, how can we solve the resistor for gate if we use dual mosfet
if the maximum 1800 watt can be achieved only with higher input of 60V, can this DC to DC converter do feedback, using the output as input, so that with 12V battery can get 60V input? or is it dangerous that the voltage becomes uncontrollable? ....my first idea is just to use 2 of this DC converter in series, but then we have to buy another one...and then I think what if I just use one and put it in a loop
Thanks a lot for watching the video and for the inspiring thoughts!
However, switch mode power supplies do not work that way. It will not be possible to feed the output back to the input because the output voltage level is being controlled by voltage and current feedback loops - already built into the control circuit.
Regarding connecting two boost converters in series, I think it could work but I will not advice you to do that because you will lose a lot of power due to low efficiency of the series system.
I will rather recommend you design your battery system to a higher voltage.
If you found this video helpful, please help our channel grow by sharing our videos.
Was thinking 2 in parallel with a high current blocking diode on each output might be a workaround for you. Have to see what the innovator thinks.
Great video. Can you please provide the link to that meter @13:02? Thanks.
Thanks a lot for watching this video and for the great feedback.
I actually made a review video for the digital power monitor and I added the product link to the video description.
Cheapest Digital Power Monitors for DIY ebikes and chargers.
th-cam.com/video/j6TGMS1C_BE/w-d-xo.html
Please help our channel reach a wider audience by sharing our videos with your friends and interest groups.
Thanks again.
@@theinnovati0nlab782 Thanks!
How did you get that potetiometer? I am not able to find the 200k version. Can you reply, please? Thanks again!
I just realized that I didn't respond to your question. Sorry about that, friend!
Regarding your question, I had the same problem, and given that my goal for the design was to achieve a high output voltage, I think I was able to use a 100k pot and added a resistor in series.
I added the schematic towards the end of the video - it is very simple. Please go check it out. Sorry again this was a project I did a long time ago and I don't remember every detail. But you can look on ebay and Amazon as well to see if you can find the 200k pot.
The only issue is that you will not be able to lower your output voltage down to the input voltage level - if you add the series resistor to the external potentiometer.
I see. Thank you very much for your reply sir!
@sree137918
Anytime, my friend!
Feel free to ask a question anytime.
You can also check out our website at theinnovati0nlab.com.
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Alright my friend, I will see you in the next video.😊
The Innovati0n Lab💥
I required 12 vdc input and output 150 vdc dc to dc boost converter with also 50 amps can you suggest any model
I haven't come across any boost converter this powerful. If I do, I will sure like to review it!
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Quick question: Is the 50A your max input current at 12V input? Asking for an output current of 50A at 150V,....with an input voltage of 12V, is simply unrealistic because your input power source will have to be able to provide continuous current >625A.
Maybe I didn't understand fully. Please clarify.
Thanks you sir
Thank you for watching our videos! We appreciate it.
thanks
Thank you for watching this video. Don't forget to check out the other videos we made regarding the same subject.
Also, we appreciate it if you can share out videos with your friends - to help our channel grow.
If we make a dual mofset, how should we make the gate resistor?
Hi friend,
This is a wonderful question. It will be easier to answer in a future video I am planning to make on how to build a DIY converter.
Stay tuned, my friend!
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Is possible to boost up to 230VDC from 100VDC?
I wanted to use this 230V DC for electronic appliances except Inductive loads, so that I can avoid to use Inverter to save 30-40% power losses.
What do you say?
I wanted to use this boost converter for charging 230V battery system.
Running electronic home appliances (except inductive loads) on 230VDC is fine or not?
Do you see any concerns as per your best knowledge ?
I like your innovative way of thinking. However, I have given your question lots of thought. The biggest concern for doing something like that will be safety. High voltage DC is really not something I would encourage you to experiment on. High Voltage dc is so much more dangerous than HV AC.
Also, the newer transformerless inverters should be able to give you above 90% efficiency. So I don't think it will be a worthwhile effort to go through all the trouble. Also, as you mentioned, this can only be used on non-inductive loads.
My recommendation will be for you to consider getting a more efficient inverter system.
Again, I wouldn't recommend this because it is not safe.
Thanks again!
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@@theinnovati0nlab782 I agree with transformerless inverters but the main problem is it's high cost in India.
Those are super expensive actually.
@vasuboya2756
Ah, I see. You are absolutely right about them being very expensive.
I have taken note of this. I will do some research to see if there could be a way for us to help come up with something more efficient and cheaper.
But you are right, pure sinewave tranflrmerless inverters are very expensive. My main issue with inverter projects is that they take a lot of time to make, and TH-cam doesn't recommend my inverter videos....and they don't get many views. Maybe you can help share the videos. More views will be motivational for us.
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th-cam.com/video/TjQzymLRl1I/w-d-xo.html
Hy. I wanna use it in-between my solar panels and solar inverter, as my panels providing 90v in series and mppt of my inverter will start on 120v, can it be used without any solar power loss, plz guide
I wouldn't recommend it, not yet. As you might have seen in the video, this was just a concept that has not been fully developed and tested. I plan to make a follow-on video to address some of the issues we had in the first video. Until then, I will not recommend you do something like this.
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you forget to explain the voltage settings (voltage feedback)... which is this board design to limit at 90v, no matter you've replace with higher voltage rating... 😉
Awesome, I will cover that in my upcoming design review video. Stay tuned.
Thanks.
The Innovati0n Lab💥
www.theinnovati0nlab.com
Can we make the input voltage 67v? Is it enough to replace the capacitor?
Hi friend,
My modification was made at the output stage only. It will be difficult to make that determination without seeing the full schematic. You have to consider the voltage ratings of all the regulators and control components at the input stage of the converter, not only the input capacitor.
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Thanks😊
почему то я считал что подписан на канал, а оказалось что нет подписался сейчас
Thank you so much!
I appreciate all your support!❤️
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The Innovati0n Lab💥
www.theinnovati0nlab.com
Can you make a step down converter 200vdc to 12-60vdc ?
Thanks a lot for the watching the video.
To answer your question, yes it is possible, but that is not something I intend doing anytime soon because it will be a risky build, requires lots of testing to make sure that the build is safe, plus it might end up being more expensive than just buying something commercial. I will recommend finding an affordable commercial product that could give you such function.
However, be sure to subscribe just in case I try something similar in the future.
Great video! I made one of these to charge my batteries over power supplies capabilities. I didn't do all that you did to the dc to dc converter, but I made a complete charger that fit in A pelican 1150 case. Video is on my channel! One thing I did for safety. I added a relay and switch to mine on the output.i also added an led, that tells me when the switch is on. This protects the unit from sparks and anything else. I've only went up to 58v 5amps charging. I haven't tried anything bigger yet. For power, I'm using a 12v 1200watt server power supply like you, but only one. Might check it out when you get a chance. But so far it works great! And it's only 3 ish years old. Great video!
Thanks a lot for the wonderful interaction!
👍👍 I really appreciate it. I will check out your video when I get some chance.
The only thing to keep in mind will be that these converters have an output power limitation when your input voltage is as low as 12V. At 12V, you can only expect a total delivered power
@@theinnovati0nlab782 I wonder if I have a different model than you? If I can remember 3 years back...lol, think the one I purchased was 1200watt. But I could be wrong? I'll have to go back and see if it's in my history? I also made a power supply using a 350-500 watt psu, the same boost converter you have and a DPS adjustable power supply. Still using that one on my table.i have that set up, to use the boost converter when needed, or just the power supply when I don't. I can find the links if you have trouble finding. Thanks again for the reply!
It's the 1800 watt version. I just double checked. Not sure it's really capable of 1800 watts, but it works for what I've needed it for😀
Just realized. You have the same converter😀
I am pretty sure it's the same one you have. The vendor gave an 1800W output power rating based on a purely ideal IV calculation, which could only happen if your input voltage is 60V. Meaning, 60V × 30A = 1800W.
But I do agree with you that this will be hard to achieve as you have to account for efficiency losses.
Realistically, these units are more like 1500W at about 48V input voltage, and a great cooling system.
Where can I get schematic?
Hi friend, if you watched the video to the end, I added a simple schematic to show what you need to do with the potentiometer to allow you to raise the output voltage.
Everything else was explained in the video - mostly about changing the driver components with ones with higher voltage ratings.
I don't have the actual skematic for the boost converter, I believe that is manufacturer proprietary information. The only thing I can tell you is that the converter uses the TL494 PWM control IC.
Selam mur 360 olan mosfetleri 3 tanesini de degistirecekmiyizz
Hello to you, my friend. We only changed the drive MOSFET. There is only one drive MOSFET.
İrfp264 olan mosfet dogrumudur irfp 264 takacagiz ortadaki olani
Diger 3 diyotu degistirmiyoruz
Hi
I want to one booster unit for my solar inverter...... I have 98 vdc which produce solar panel but my solar inverter mppt starting volt is 150 vdc...... Anything possible to on my inverter with solar 98vdc
Hi friend,
Thanks for the thoughtful question. However, given the high voltage nature of your system, I will recommend adding a few more panels to your solar panel array to raise the voltage - to match your inverter input voltage requirements.
The 98V from your solar array is already too high for these boost converters, and it will damage the converter. Also, you will encounter lots of efficiency losses by going through the boost converter first.
Thanks sir ! But I here the solar panel is so expensive .... How I will start these type of inverter to operate my requirements
Va felicit
Thanks!
Yorum icin teşekürler dostum ben suanda yaptim sizin kullandiginiz mosfet ve diyotlari kondansitörü 400v 220 uf kullandim 3 adet başarılı çalışıyor iyi bir mosfet icin yardimci olirsaniz sevinirim böyle bir projeye ihtiyacim cok
Thanks for the wonderful update. I am really happy to hear the great news about your project.
What is the maximum output voltage and power of your system?
To make MOSFET recommends, I need to know know about your power needs.
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The Innovati0n Lab💥
Irfp264 mosfet 180 volt kadar cıkıyor 350 w kadar ciktim bir sorun olmadi benim maksimum 500 w guce ihtiyqcim varr aslinda projem farkli ama bu sekilde oldu diyebilirimm sonuc harikaa
Selam irfp264 yerine
İrf740 kullansam olur mu
It is hard to give a straight answer without comparing both of them with their datasheet ratings.
My recollection it that 740 is a smaller TO220 MOSFETs with lower power ratings.
I used IRFP264 in this video just to try the concept. If I decide to revisit the project, I will do some research to select a better MOSFET.
I hope the helps.
👍😎
The Innovati0n Lab💥
Irf 264 mosfet bozuluyor ne yapmam lazimm
You should have used IRFP264. I used it in this video and it broke in the end I mentioned that I would look for a better option. You need a MOSFET with a high drain to source voltage VDS ==> close to 200V and low Drain-to-source ON-resistance, the lower the better (in milli ohms).
If not, you may need a different design - that involves a push-pull high frequency tranformer.
I will be making a similar video in the future.
Stay tuned.
👍😎
The Innovati0n Lab💥
www.theinnovati0nlab.com
Tskler bilgin icin bekliyorum videonuzu
Those are probably not rectifier diodes since you do not have any AC sine voltage to have to rectify to DC!! Its a DC/DC boost converter...
Oh, wonderful!
Thanks for the amazing feedback. So what is the function of these diodes then? What will you call those diodes?
Why do you need fast recovery diodes for asychronously rectified SMPSs?
Do you understand how DC-DC converters work and the different designs or topologies?
If so, please kindly explain. We are always open to learning things we don't know.
My knowledge is that AC power or signals can take different forms and not only sinewaves.
- Square waves
- Triangular waves
- PWM, etc.
Maybe my knowledge is flawed...I don't know.
Please, if you could, explain the stages of a DC to DC boost converter that does not involve the PWM control of your input DC power, I would really love to hear about it.
I am hoping that you are familiar with PWM control, right?
Please, next time, if you don't understand the physics behind our video concept, I would appreciate you asking a question. Don't assume that we are some uneducated guys on TH-cam playing with power and electronics.
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@@theinnovati0nlab782 Don`t waste time in answers like this.. This is pure troll mode or hate.. Also, the codes are visible and anyone can search in google to see what "thing" are these "non" diode thing AhAhgAh.. PD; amazing channel! i'm absorving all the info just in the time where i was making a laboratory and functional high power dc supply and all this info is changing all my original plans and making new ones for the setup
👌👌👌👍👍👍👏👏🤝🤝🤝🤝
Thanks a lot!
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you needed higher input voltage.
You are right. The higher the input voltage, the lower the required input current. But that was an experiment that I have been meaning to repeat, but I haven't had the time.
@@theinnovati0nlab782 I enjoy these experiments. I use this 30A model on my ebike to make my 48v battery 60v. It works great. I used clear nail polish for the weatherproofing.
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Thanks a lot.