CCR-HP - Revision history

WikiSysop: /* PCB Files */

2020-08-12T10:40:12Z

PCB Files

← Older revision		Revision as of 10:40, 12 August 2020
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	====PCB Files====		====PCB Files====
	Eagle schematic/board files and gerber files can be found here: https://github.com/jkenny23/CCR-HP-HW		Eagle schematic/board files and gerber files can be found here: https://github.com/jkenny23/CCR-HW/tree/ccr-hp_v1p1

	==Enclosure==		==Enclosure==

WikiSysop: /* Hardware Revisions */

2020-08-12T10:37:53Z

Hardware Revisions

← Older revision		Revision as of 10:37, 12 August 2020
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	* Pull-down for C1ON (discharge/charge enable protection FETs) R72 should be pull-up to default to off		* Pull-down for C1ON (discharge/charge enable protection FETs) R72 should be pull-up to default to off
	* Inverting/Non-inverting inputs to MCP6002 U11 are swapped		* Inverting/Non-inverting inputs to MCP6002 U11 are swapped

			====Revision 1.1====
			[[File:Ccr-v10_sch.png\|thumb\|right\|The complete system schematic for the CCR v1.0.]]
			[[File:Ccr_both.png\|thumb\|right\|The PCB layout (Gerber view from JLCPCB) for the CCR v1.0.]]

			This is the second revision of the CCR-HP, fixing errata of v1.0 and changing to LM5106 gate driver due to unresolved issues with FD2203S gate driver. Additionally a 4th protection FET was added in series to handle 40A; v1.0 could only achieve 35A for thermal limits, and 30A safely. Some minor improvements to power routing were made also.

			'''Errata:'''
			* TBD

	====PCB Files====		====PCB Files====

WikiSysop: /* Version 1 */

2020-04-03T11:24:01Z

Version 1

← Older revision		Revision as of 11:24, 3 April 2020
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	* Voltage Range (Charge): 0-84V		* Voltage Range (Charge): 0-84V
	* Max Current (Charge): ~~10A~~ (~~TBD~~)		* Max Current (Charge): 8A (12V -> 4.2V)
	* Max Current (Discharge, Regen): ~~10A~~ (TBD)		* Max Current (Discharge, Regen): 8A (TBD)
	* Max Current (Discharge, Resistive): ~~40A (TBD)~~, 200W max power		* Max Current (Discharge, Resistive): 35A, 200W max power
	* Min Current Readback Precision: 6mA (Lo range, -5-20A), 12mA (Hi range, -10-40A)		* Min Current Readback Precision: 6mA (Lo range, -5-20A), 12mA (Hi range, -10-40A)
	* Min Voltage Readback Precision: 2.3mV (Lo range, 0-9.46V), 23mV (Hi range, 0-94.6V)		* Min Voltage Readback Precision: 2.3mV (Lo range, 0-9.46V), 23mV (Hi range, 0-94.6V)
	* Sample Rate: 1 Hz (Reporting rate), 2 kHz (Loop/Integration rate)		* Sample Rate: 1 Hz (Reporting rate), 2 kHz (Loop/Integration rate)
	* Efficiency: xx% (Buck/charge mode, ~~average, 3A~~ output), xx% (Boost/discharge mode, average, 3A output)		* Efficiency: 85.4% (24.5V -> 4.06V) (Buck/charge mode, 2.5A output), xx% (Boost/discharge mode, average, 3A output)
	* Modes: Charge, Discharge (CC with voltage cutoff, CC-CV with current threshold cutoff), Power Supply (no cutoff below current threshold), Cycle (N times), IR measurement		* Modes: Charge, Discharge (CC with voltage cutoff, CC-CV with current threshold cutoff), Power Supply (no cutoff below current threshold), Cycle (N times), IR measurement

WikiSysop: /* Revision 1.0 */

2020-03-10T21:32:28Z

Revision 1.0

← Older revision		Revision as of 21:32, 10 March 2020
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	* TO-247 FETs Q2, Q4, Q5, Q6 footprints were reversed		* TO-247 FETs Q2, Q4, Q5, Q6 footprints were reversed
	* Footprint for discharge feedback op-amps U3, U7, U8, U13 are incorrect (MCP6001 instead of MCP6001U style)		* Footprint for discharge feedback op-amps U3, U7, U8, U13 are incorrect (MCP6001 instead of MCP6001U style)
	* Footprint for bootstrap capacitor C1 is too small (needs to use 100V capacitor, 1210 size)		* <s>Footprint for bootstrap capacitor C1 is too small (needs to use 100V capacitor, 1210 size)</s> Bootstrap cap only has 12V across it, existing footprint is ok
	* Pull-down for C1ON (discharge/charge enable protection FETs) R72 should be pull-up to default to off		* Pull-down for C1ON (discharge/charge enable protection FETs) R72 should be pull-up to default to off
	* Inverting/Non-inverting inputs to MCP6002 U11 are swapped		* Inverting/Non-inverting inputs to MCP6002 U11 are swapped

WikiSysop: /* Revision 1.0 */

2020-02-20T22:41:33Z

Revision 1.0

← Older revision		Revision as of 22:41, 20 February 2020
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	[[File:Ccr_both.png\|thumb\|right\|The PCB layout (Gerber view from JLCPCB) for the CCR v1.0.]]		[[File:Ccr_both.png\|thumb\|right\|The PCB layout (Gerber view from JLCPCB) for the CCR v1.0.]]

	This is the first revision of the CCR~~, which only natively supports regenerative discharging mode~~.		This is the first revision of the CCR-HP.

	'''Errata:'''		'''Errata:'''
	* TO-~~263 FET~~ footprints were reversed		* TO-247 FETs Q2, Q4, Q5, Q6 footprints were reversed
	* Footprint for op-amps are incorrect		* Footprint for discharge feedback op-amps U3, U7, U8, U13 are incorrect (MCP6001 instead of MCP6001U style)
			* Footprint for bootstrap capacitor C1 is too small (needs to use 100V capacitor, 1210 size)
			* Pull-down for C1ON (discharge/charge enable protection FETs) R72 should be pull-up to default to off
			* Inverting/Non-inverting inputs to MCP6002 U11 are swapped

	====PCB Files====		====PCB Files====

WikiSysop: /* Revision 1.0 */

2020-02-20T01:07:04Z

Revision 1.0

← Older revision		Revision as of 01:07, 20 February 2020
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	'''Errata:'''		'''Errata:'''
	* ~~Pin A11 was used for the P-channel MOSFET control on cell 2, which is not usable for this function (pin is natively used as USB D+).~~		* TO-263 FET footprints were reversed
	* There are no pull-up/pull-down resistors to keep the buck/boost converter "safe" when in programming mode (IO in Hi-~~Z) or when no power is applied to USB~~		* Footprint for op-amps are incorrect
	* There is no power applied to the MCU when there is no USB plugged in
	* ~~There is no PTC protection~~ for ~~the cell~~
	* Output of op-~~amp for voltage reading is 5V capable but going into 3.3V only ADC pin, needs series resistor to prevent damage~~

	====PCB Files====		====PCB Files====

WikiSysop: /* Comparison to Other Cell Testers */

2019-11-27T00:53:04Z

Comparison to Other Cell Testers

← Older revision		Revision as of 00:53, 27 November 2019
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	\|Max Li-Ion s config		\|Max Li-Ion s config
	\|'''20 (84V)'''		\|'''20s (84V)'''
	\|8 (34.8V)		\|8s (34.8V)
	\|8 (34.8V)		\|8s (34.8V)
	\|10 (43.5V)		\|10s (43.5V)
			\|-

			\|Max Balance Current
			\|0.38A**
			\|1A
			\|2A
			\|'''2.4A'''
	\|-		\|-

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	* *Peak power with 20s pack, 24s buffer pack		* *Peak power with 20s pack, 24s buffer pack
			* **With separate balancing board, resistive only

	===Thingspeak===		===Thingspeak===

WikiSysop: /* Comparison to Other Cell Testers */

2019-11-27T00:47:44Z

Comparison to Other Cell Testers

← Older revision		Revision as of 00:47, 27 November 2019
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	===Comparison to Other Cell Testers===		===Comparison to Other Cell Testers===
	The CCR v2.0 can exceed the discharging current of all currently available 18650/cylindrical specific cell testers currently on the market, and is on par with or better than most chargers for charging current. It beats the popular Opus BT-C3100 for number of cells per day it is able to cycle test (assuming a 2.6 AH cell, charging at 1C and discharging at 3A, more is possible with higher charge current though few cells can accept >1C charge rate). It is nearly able to meet the number of cells per day of the SkyRC MC3000 4-slot charger, despite only having 2 slots and a lower cost.

	~~[[File:Ccr-vs-others-cellsperdayprice.png\|thumb\|400px\|center\|Cells per day possible to test and tester cost of the CCR vs. other common 4-bay cylindrical cell testers.]]~~

	The CCR also produces a more accurate CC-CV Li-Ion charge curve vs. other testers, which are limited in their design by either PWM output (not true constant current) or power/voltage limited (in the case of the Opus), which causes early current taper. This also improves the charging time of the CCR vs. other testers.

	~~[[File:Ccr-vs-opus-zanflare.png\|thumb\|400px\|center\|Discharge/Charge curves for the CCR vs. Opus BT-C3100 and Zanflare C4, showing smoother CC/CV profile and faster cycle time.]]~~

	A table comparing the features of some of these common testers is below:		A table comparing the features of some of these common testers is below:

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	\|Charge Current (Max)		\|Charge Current (Max)
	\|10A (TBD)		\|10A (TBD)
	\|40A		\|'''40A'''
	\|30A		\|30A
	\|30A		\|30A

WikiSysop: /* Comparison to Other Cell Testers */

2019-11-27T00:47:09Z

Comparison to Other Cell Testers

← Older revision		Revision as of 00:47, 27 November 2019
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	{\| border="1" style="text-align:center;"		{\| border="1" style="text-align:center;"
	\|'''Feature'''		\|'''Feature'''
	\|'''CCR ~~v2.5'''~~		\|'''CCR-HP'''
	~~\|'''Opus BT~~-~~C3100~~'''		\|'''PowerLab-8T'''
	\|'''~~Liitokala Lii~~-~~500~~'''		\|'''iCharger X8'''
	\|'''~~Zanflare C4~~'''		\|'''iCharger 4010Duo'''
	\|'''~~SkyRC MC3000~~'''
	\|-		\|-

	\|Price		\|Price
	\|$89.99		\|$149.99 (TBD)
	\|$30.46		\|$329.95
	\|'''$21.99'''		\|'''$119.99'''
	\|$32.99		\|$385.00
	~~\|$109.99~~
	\|-		\|-

	\|~~Cell Slots~~		\|Max Li-Ion s config
	\|2		\|'''20 (84V)'''
	\|'''4'''		\|8 (34.8V)
	\|~~'''4'''~~		\|8 (34.8V)
	\|~~'''4'''~~		\|10 (43.5V)
	\|~~'''4'''~~
	\|-		\|-

	\|Charge Current (Max)		\|Charge Current (Max)
	\|~~'''6A'''~~		\|10A (TBD)
	\|2A*		\|40A
	\|1A		\|30A
	\|1A**		\|30A
	~~\|3A~~
	\|-		\|-

	\|~~Charge~~ Current ~~(All Slots~~)		\|Discharge Power (Current)
	\|'''6A'''		\|'''200W (40A)'''
	\|1A		\|95W (8A)
	\|1A		\|50W (15A?)
	\|~~0.5A~~		\|'''200W''' (7A)
	~~\|3A~~
	\|-		\|-

	\|Discharge Current ~~(Max~~)		\|Regen Discharge Power (Current)
	\|~~'''6A~~***/5A'''		\|840W* (10A)
	\|1A		\|1350W (40A)
	~~\|0.5A~~		\|1100W (30A)
	\|~~0.5A~~		\|'''2000W (70A)'''
	~~\|2A~~
	\|-

	~~\|Discharge Current~~ (~~All Slots~~)
	\|'''~~6A***/3A~~'''
	~~\|1A~~
	~~\|0.5A~~
	~~\|0.5A~~
	~~\|1A~~
	\|-

	~~\|Cells per day per $~~
	~~\|0.20~~
	~~\|'''0.52'''~~
	~~\|'''0.51'''~~
	~~\|0.26~~
	~~\|0.20~~
	\|-		\|-

	\|}		\|}

	* *~~Outer 2 slots only~~, ~~2 cells max simultaneously, current tapers down from 2A starting at 3.65V~~		* *Peak power with 20s pack, 24s buffer pack
	* **Charge mode only, in test mode 0.5A is maximum
	* ***Regenerative mode using 3s buffer pack

	===Thingspeak===		===Thingspeak===

WikiSysop: /* Version 1 */

2019-11-27T00:29:37Z

Version 1

← Older revision		Revision as of 00:29, 27 November 2019
Line 11:		Line 11:
	* Max Current (Discharge, Regen): 10A (TBD)		* Max Current (Discharge, Regen): 10A (TBD)
	* Max Current (Discharge, Resistive): 40A (TBD), 200W max power		* Max Current (Discharge, Resistive): 40A (TBD), 200W max power
			* Min Current Readback Precision: 6mA (Lo range, -5-20A), 12mA (Hi range, -10-40A)
			* Min Voltage Readback Precision: 2.3mV (Lo range, 0-9.46V), 23mV (Hi range, 0-94.6V)
	* Sample Rate: 1 Hz (Reporting rate), 2 kHz (Loop/Integration rate)		* Sample Rate: 1 Hz (Reporting rate), 2 kHz (Loop/Integration rate)
	* Efficiency: xx% (Buck/charge mode, average, 3A output), xx% (Boost/discharge mode, average, 3A output)		* Efficiency: xx% (Buck/charge mode, average, 3A output), xx% (Boost/discharge mode, average, 3A output)