FCDS - FERCSA's charger/discharger station. (MM giveaway inside!)

Nice! :)

Looking good. You've come a long way from your first model :) Looking closely for more progress. Right now I'm just charging and resting my cells. I haven't gotten to the capacity testing yet.

First note: Might wanna have a better mic, or change your arrangement up or something. I had to turn all my volumes up to hear you. Or, maybe you're talkin softly to not wake up the wife/baby :p
 
Yeah I know, it's just a hobby project for me, so no rush. There is some minor changes on the main code and it's done. Later I'll publish the schematic for the master module. For the discharge module is already published, ever since I added an extra cap, but I'll update the zip file too. Finally the slave module, it's too complex for a beginner, at least the soldering part, a TQFP48 package can be a nightmare, the programming is an another part. So I thinking about if someone interested I can make a few (BOM cost only), but I need an another pcb run. Hmm maybe I should include the pcbs of the discharger module too.. then it's simplify the assembly for you guys. So let me know.

Video: Hm, I should make audio normalization next time, thx for the fb.
 
Link for the master module schematic: click
I'm not included the pcb because it's so simple and it can be vary. I mean different voltage regulator, sd card reader pinout etc.
If you look at the schematic I'm currently using a dual sd card reader so it may complicate things (added extra jumper for example).
Note: the external usb connector is optional, but if you're using external stabilized power supply which is highly recommended you should consider adding it, because in this case the usb power rail(+5V) on the devkit's usb connector is not allowed. Otherwise magic smoke come..

Link for the updated discharger module sch+pcb: click
 
Hahah, you got your "click" links backwards :p The top link is the discharge, and the bottom one the master ;)

Looks good. But, Umm, I wanted to download a ready made prototype ready to plug in and get started :p
 
I guess there is time for an update.
The second batch of the PCBs are here. I already started the assembly then I realized making a photo is a good idea. So not all of them included here.


So theoretically the whole system can handle around thousand cells. No one gonna build it I'm sure. In reality I limited around hundred, because the devboard's memory. It's still impressive, but if there any interest I willing to port it for ESP32. Beginning of this year when I started all of this, it was not available yet.
[img=300x224]http://www.fercsa.com/fcds/fercsa_pcbs.jpg[/img][img=300x224]http://www.fercsa.com/fcds/fercsa_discharger_module_revd.jpg[/img]
[img=300x224]http://www.fercsa.com/fcds/fercsa_discharger_module_revd2.jpg[/img][img=300x224]http://www.fercsa.com/fcds/fercsa_discharger_module_revd3.jpg[/img]
The firmware for my master module is kind of ready. If somebody started making my modules pls let me know then I can provide a beta firmware!

Otherwise looks like I have a few spare modules so if you want a kit or a complete build, it can be possible. Contact me for details.

My next video is coming, but my first video-shot was a disaster so I should make a new one. Please be patient I hate this kind of stuff.
 
FERCSA said:
I guess there is time for an update.
The second batch of the PCBs are here. I already started the assembly then I realized making a photo is a good idea. So not all of them included here.


So theoretically the whole system can handle around thousand cells. No one gonna build it I'm sure. In reality I limited around hundred, because the devboard's memory. It's still impressive, but if there any interest I willing to port it for ESP32. Beginning of this year when I started all of this, it was not available yet.
[img=300x224]http://www.fercsa.com/fcds/fercsa_p.../fcds/fercsa_discharger_module_revd.jpg[/img]
[img=300x224]http://www.fercsa.com/fcds/fercsa_d...fcds/fercsa_discharger_module_revd3.jpg[/img]
The firmware for my master module is kind of ready. If somebody started making my modules pls let me know then I can provide a beta firmware!

Otherwise looks like I have a few spare modules so if you want a kit or a complete build, it can be possible. Contact me for details.

My next video is coming, but my first video-shot was a disaster so I should make a new one. Please be patient I hate this kind of stuff.
Click to expand...

THIS is extremely exciting. You have come a long way. Have you thought of incorporating a DS18B20 one wire thermo-sensor? I can see that cost is a big factor in making this rig. But using off the shelf components should be just as important. This could so easily be ported to my rig design and have a single OLED per rig and then you can daisy chain more if you need it. My rig can house 10 cells at a time
image_qistda.jpg

image_ljwlcb.jpg

image_armxsp.jpg

image_untugb.jpg
 
FERCSA said:
I guess there is time for an update.
The second batch of the PCBs are here. I already started the assembly then I realized making a photo is a good idea. So not all of them included here.


So theoretically the whole system can handle around thousand cells. No one gonna build it I'm sure. In reality I limited around hundred, because the devboard's memory. It's still impressive, but if there any interest I willing to port it for ESP32. Beginning of this year when I started all of this, it was not available yet.
[img=300x224]http://www.fercsa.com/fcds/fercsa_p.../fcds/fercsa_discharger_module_revd.jpg[/img]
[img=300x224]http://www.fercsa.com/fcds/fercsa_d...fcds/fercsa_discharger_module_revd3.jpg[/img]
The firmware for my master module is kind of ready. If somebody started making my modules pls let me know then I can provide a beta firmware!

Otherwise looks like I have a few spare modules so if you want a kit or a complete build, it can be possible. Contact me for details.

My next video is coming, but my first video-shot was a disaster so I should make a new one. Please be patient I hate this kind of stuff.
Click to expand...

Cool, would you be willing to sell me a few of the boards or even full kits that we could put together ourselves?
 
Wow! This is truly awesome - a job very well done indeed.

The master and discharge modules look simple enough that I can do these, but what about the slave module? Is that something that could be built 'at home'?

I am looking towards a rather different form factor so I don't mind if it takes up more space...

Once again however, WOW!
 
Grumplestiltskin said:
Wow! This is truly awesome - a job very well done indeed.

The master and discharge modules look simple enough that I can do these, but what about the slave module? Is that something that could be built 'at home'?

I am looking towards a rather different form factor so I don't mind if it takes up more space...

Once again however, WOW!
Click to expand...

Nope the SM is not DIY friendly and it has a custom programmed (logic) ic. I went down on this route because it's still cheaper than putting many discrete components on the module with the same functionality and another big advantage is I'm not limited on the i2c addresses so one i2c port is enough for everything.
 
So I liked this project so much I have asked FERCSA to ship me a 32-battery capacity kit of his components and have ordered the remaining parts off of ebay. This is in no way a commitment to doing so but I am pretty motivated to do up a video on this, so this is just a bump to this thread.

Cheers!
 
FERCSA said:
I started to gather all the necessary information from the topic and put together an all in one guide to help people.
It's very basic but I'll update it on regular basis if I found something useful.
https://www.fercsa.com/fcds/

And yes a lot of slave modules out in the wild already. :cool:
Click to expand...

Great project mate. I am doing a similar one. About half way done. I am using an Arduino based one with 16x Charger / Dis-chargers that will eventually upload to my sitehttp://vortexit.co.nz/battery_statistics.php


image_wbodxn.jpg
 
Little update again.In the last month I ported my code to the ESP32 platform.
[img=300x256]https://www.fercsa.com/fcds/fercsa_master_module_esp32_01.jpg[/img]
w/ DevKitC board

Also I designed a new master module with a factory made PCB, it's already sent to the fab so I can't wait to have it. I made this because it's give me a more compact design and there is a few people out there with lack of soldering skill to make his own on a protoboard.

[img=300x266]https://www.fercsa.com/fcds/fercsa_master_module_esp32_02.jpg[/img]
w/ ESP-WROOM32

Early users who already own one of my slave modules please contact me and to show my appreciation I can give you one for free.
In next few days I'll update my site too, especial the ESP32 section.
 
image_odcbpf.jpg

FERCSA said:
Okay I think I just found a solution for the temperature sensor. I stepped back a little and rethink the design. What if I use the mosfet driver's pwn pin for switching the tp4056 enable pin to high and low?
So I added a little not gate inverter which turns on the tp4056 when the pwm zero, then switch off when the pwm signal reach a certain level. But this level is way too low to turn the mosfet on aka no load(discharge) at this point.

In reality it's works, I just tested. Any concern about this solution?

So after all I got a free pin which can be used for an analog ntc temperature sensor. This solution allows me to use 4 slot/cell with a 16 channel multiplexer which is great!
Currently the pinout for my discharger module: PWM, Temp, Battery voltage and current.
Click to expand...

I'm lost ... i have tried the CE pin on 3 boards and nothing :(
I used the hot air station to remove chip, tried just bending pin from pad .. tried disconnecting pad itself from +VCC
Added resistor of 1.5k later 10k to +VCC . Tried the ather way .. connecting to Ground

But chip still charges ... red light ... and ~0.9A charging ...

i even left the CE pin alone not connected to anywhere .. and it still charges .. unable to control the chip :(
I think i have bad charger chips .. or what.

I noticed that you bridge the TP4056 charger protection.. you are not using it right ? You discharge straight from B-..
 
A lot of clones out there(TP4056ES, weird logos etc..), most of them just works fine, but looks like yours a strange one.
Look at this picture:
[img=459x243]http://jimlaurwilliams.org/wordpress/wp-content/uploads/2014/12/BothChips.jpg[/img]
The right one is a genuine NanJing Top Power.
So if you lift up pin8 and connect it to ground then still charging.. those ICs are definetly the weird ones.

This isthe reason why I'm strongly thinking about I should redesign my DM to accommodate a proper charger IC. It'll be still compatible with my system but gives us less error factor.
 
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