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replacing resistors for mini psu
#1
Good morning everyone.

I am looking for a way to replace the resistor's on the zb's dischargers with some sort of mini power supply.

The goal would be: instead that the energy is burned off in heat, i would like to load a battery and store that energy again.
To charge the "new" 18650 cells.

The battery is going to be 6v to 8v with low amp cells

When testing 1000's of cells, times 2 amp for charge........and discharge 2 amps....(up to 3.2 amp)

I lost a little bit track on aliexpress, does anybody have a good idea?

Thanks in advance, best
Still learning English. Learning Li ion and solar technology.
+/- 3500 Li ion cells harvested, none checked and counting.

Time is our enemy, must work to, the sun is our friend, must relax to.
With best regards
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#2
A Boost converter with CC option might be the go?
Depending on how the circuit works in the ZB, the converter would probably need to be isolated from input to output.
Can you find or draw out & post the circuit diagram for the ZB?
Running off solar, DIY & electronics fan :-)
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#3
We had several discussions here about that theme.
In effect, if you count the savings of this energy loss in Cents of your energy bill, then you will hardly have any room for investments to be paid off.

I wanted to do that as well, i have saved my time and left it off.
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Electronics ? No clue. Am machinery engineer.
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#4
You wont find any easy solution that saves you money in short term. Use the heat to heat your house or something Smile Or just get a solar panel to power them instead. That solar panel will be cheaper, easier and save you time than reusing the energy lost discharging Smile

For instance my larger install did cost 200kWh in lost energy.. But that 200kWh if we translate that to money then it was not even worth looking at regenerative Big Grin
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#5
Thanks for your replay's, some helpful, and good for a second thought.
How ever, despite the calculation on cent level.(one kwh here is 23 euro cent)
It is fun to play (and learning)
And i had some very nice worm feet in the shed, the psu is really getting hot when full in use.
Rated 5 volt and 30 amps, but with 40 amps at 6.2 volt, the psu was getting 65 degrees celcius Tongue Tongue Tongue Tongue
So this would be a double/triple base small project, just like growing and harvesting your own tobacco Angel
Fun to make and with some benefits and a small practice learning experience regarding pack making, at least that is my thought.

My electronics knowledge is stuck and left behind somewhere in the 80's, bear with me Confused. a lot is changed.

I would like to buy 3 of those:

https://www.aliexpress.com/item/DC-DC-Au...3fe4tFLe4v

Those ones are going to be used to get the cells up to 3.5v again for storage, because charge them halfway with the tc/tb's and then discharge them again to 3.5 takes to much time, and use of the board while other units could go to work.
The one i that i have now is/was actually for the sleepers and the dead cells, but seems to work perfect to get them up to exactly 3.5v after discharge to 2.8v.

For the "battery/pack" project i would like to buy 2 of these to experiment with.
https://www.aliexpress.com/item/DC-DC-Co...2407XQzcoQ

I want to replace every resistor on the zb2l3 with one of those:
https://www.aliexpress.com/item/5-pcs-DC...st=ae803_4

Those draw a 500-600ma each and there output will be soldered to a powerline that has at the end a 12a 160w converter to power up my pack.
On the same line will be a other one that is going to power up 10 of those tb/tc to charge the "fresh" cells.
I think this is better than hook up a bunch of 78s05 ic to every tc/tb charger.
The disadvantage of this converter it stops at 4.8v, so i have to manually check the remaining volt.
I think some resistors and some LED's in different colors will cure the problem, you only have to look at it.


For my pack design i am going to use the math and method that daromer used in one of his video's.
But than in 24v.
If i may add: Perfect explanation, well done video!

The first test setup will be with one unit 10 zb and 10 tc's, to complete the story.

To get back to the solar panel, i found a cheap 55w 30v. and a 6 dollar 5 amp mppt solar charger!

For the safety reasons, i don't think its necessary, but some 4001 diode's i must have a bunch of them somewhere.

I hope all the links will work.
Thanks in advance, best
daromer and Redpacket like this post
Still learning English. Learning Li ion and solar technology.
+/- 3500 Li ion cells harvested, none checked and counting.

Time is our enemy, must work to, the sun is our friend, must relax to.
With best regards
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#6
(04-28-2019, 06:40 PM)100kwh-hunter Wrote: I want to replace every resistor on the zb2l3 with one of those:
https://www.aliexpress.com/item/5-pcs-DC...st=ae803_4

Those draw a 500-600ma each and there output will be soldered to a powerline that has at the end a 12a 160w converter to power up my pack.
These are not isolated** so you need to do more research of the circuits before you connect them or you will get the bad smoke & burn things out!
You have to open the ZB charger & find out how the resistor is connected inside and post that part of the circuit here.
(maybe someone else has a circuit for it?) 
** if you look at the circuit diagram in aliexpress, see how the GND (0V) line is connected from one to the other?
Running off solar, DIY & electronics fan :-)
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#7
@ Redpacket,
Yes i see how that gnd is connected.
I going to look for a other one.
Any idea?
Maybe one of those:

https://nl.aliexpress.com/item/5pcs-Smar...3c00SJcCF3

https://nl.aliexpress.com/item/5-PCS-MT3...3c00SJcCF3


Sorry i did not succeed in finding a circuit diagram(zb2l3), i spent good time looking for it, but sorry nada.
I was planning to buy 5 more zb dischargers to have in spare and play a little with it.

When they done discharging i will disconnect one from the board and take a look at it, when i have some time.

Thanks in advance, best
Still learning English. Learning Li ion and solar technology.
+/- 3500 Li ion cells harvested, none checked and counting.

Time is our enemy, must work to, the sun is our friend, must relax to.
With best regards
Reply
#8
(04-30-2019, 05:31 PM)100kwh-hunter Wrote: Maybe one of those:
https://nl.aliexpress.com/item/5pcs-Smar...3c00SJcCF3

https://nl.aliexpress.com/item/5-PCS-MT3...3c00SJcCF3
Sorry, both of those are NOT isolated & things could fry.
Can you study the zb you have now (or one of the new ones) & try to follow the pcb tracks from the balancing resistors?
Maybe post some close up pics of the board? Front & back...
Running off solar, DIY & electronics fan :-)
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#9
(04-28-2019, 10:47 AM)Redpacket Wrote: A Boost converter with CC option might be the go?
Depending on how the circuit works in the ZB, the converter would probably need to be isolated from input to output.
Can you find or draw out & post the circuit diagram for the ZB?

(05-01-2019, 11:21 AM)Redpacket Wrote: Sorry, both of those are NOT isolate & things could fry.
Can you study the zb you have now (or one of the new ones) & try to follow the pcb tracks from the balancing resistors?
Maybe post some close up pics of the board? Front & back...

Best I can do for the ZB circuit diagram Found it on a Russian web site. (Use the Google translator if you are not fluent in Russian) Tongue
https://mysku.ru/blog/china-stores/58857.html

And also here
http://herman.pp.ua/rulevaya/art.php?n=112328
 

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#10
Hmm, the current sense resistor "0R05" or "R020" means if you used a non-isolated converter, the current & mAhr reading would not be correct (likely be = 0).
Also because of the way the existing MOSFETs are arranged, it would not switch off.
No bad smoke, just poor function.

By adding a pch MOSFET & a resistor controlled by the existing MOSFETs, even a non-isolated converter should then work. The current sensing would still be off.
Again not the outcome you want, you need the current measurement to be good for cell mAhrs reading.

Have searched for a while & can't find a suitable step up converter that is ISOLATED & suitable voltage range input (need about 3 to 4.5V).

This is not looking good, sorry!
Running off solar, DIY & electronics fan :-)
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