Preface
The charging head network purchased a special charger for lithium batteries from Maverick Electric, this charger model is DZL482002, supports 180-240Vac input, the output specification is 52V3A, the maximum output voltage is 54.6V, and it is dedicated to 15 strings of lithium iron phosphate batteries. The charger comes with a 1 meter input cable and an 85 cm output cable, and is equipped with an indicator light to indicate the charging status.
Compared with traditional electric vehicle chargers, the special charger for Maverick lithium battery adopts a high-efficiency power architecture, which significantly reduces the heat generation, does not require a built-in fan, is compact and portable, easy to store, and has a better user experience. Let's bring the special charger for lithium batteries of Maverick Electric, and take a look at the internal design and materials.
The appearance of the special charger for Maverick electric lithium battery
The product is packaged in a kraft paper box, and the Chinese and English names and specifications of the product are printed on the front.
The charger model is DZL482002 150W Fe-Li.
Product parameter information is printed on the back.
On the other side are precautions and manufacturer information.
The package contains the charger, warranty card and instruction manual.
The charger has a black plastic shell and input and output cables on both sides of the fuselage.
The front of the fuselage is printed with the word POWERLAND, and the Maverick 48V lithium battery charger label is pasted, and there is a power indicator in the upper right corner to visually feedback the charging status.
There is a charger nameplate on the bottom of the fuselage, printed with product parameters and certification and other relevant information.
The charger model is DZL482002, supports 180~240V input voltage range, the rated input voltage is 220V, the rated output voltage is 52V, the rated output current is 3A, and the maximum output voltage is 54.6V.
The lower part of the label is marked with precautions, and the shell is marked with the words "iron and lithium".
In addition, there are protrusions at the bottom four ends of the fuselage to effectively prevent the nameplate from wearing.
Both the input and output lines are bent resistant.
Turn on the power and the green indicator lights up.
The input cable of the charger is a two-pin plug of the national standard.
The length of the input line was measured to be about 105cm.
The output line is a special terminal for Mavericks.
The length of the output cable is about 86cm.
The measured length of the charger is about 171mm.
The width of the fuselage is about 86mm.
The thickness of the fuselage is about 52mm.
The size of the charger body in the hand is intuitively felt.
The measured weight of the charger is about 665.6g.
Maverick electric lithium battery charger dismantling
After reading the appearance display of Maverick Electric's special charger for lithium batteries, let's disassemble it and take a look at the internal workmanship and materials.
First of all, the charger shell is disassembled along the seam of the fuselage, and the PCBA module is partially potted.
The inside of the lid is equipped with a plastic pillar for the light guide of the indicator light.
The power input line is connected by wire welding.
The output wires are also connected by wire welding.
Remove the PCBA module from the inside of the housing.
Paste foam on the back of the PCBA module to fill the space.
The foam edges are filled and sealed with potting compound.
Clean off the potting compound, and the power input and output lines are cold-pressed terminal soldering.
The length of the PCBA module is about 159.5mm measured by vernier calipers.
The width of the PCBA module is about 77.1mm.
The height of the PCBA module is about 31.8mm.
The front of the PCBA module is at a glance, with a fuse, NTC thermistor, rectifier bridge, high-voltage filter capacitor and power supply filter capacitor of the main control chip on the left side. The left heat sink is the LLC switch tube for heat dissipation. In the middle position is the resonant capacitor, the resonant inductor and the transformer. The heat sink on the right side of the transformer is a rectifier diode for heat dissipation. The right side is the output filter capacitor, the upper part is equipped with a thermistor to detect the internal temperature, the lower side is provided with an output control tube, and the right side heat sink is an anti-reverse diode for heat dissipation.
Solder the LLC controller on the back of the PCBA module, and solder the main control MCU, power supply circuit and current-sense resistor on the right side.
Through the observation of the PCBA module, it is found that the special charger for lithium battery of Maverick adopts LLC switching power supply scheme, Schottky diode rectification, and the output adopts Hetai MCU for charging constant voltage and constant current control, and controls the MOS tube to stop charging output to improve safety. Let's start with the input to learn about each device.
Charger input at a glance, soldered fuse, NTC thermistor, rectifier bridge and high-voltage filter capacitor.
The input fuse is from Better Electronics, the discharge number is 932, and the specification is 4A 250V.
The NTC thermistor is from Shiheng and is the MF72 series, model number 2.5D11.
At a glance from the side, components such as rectifier bridges, high-voltage filter capacitors, LLC switches, transformers, rectifier diodes, and output filter capacitors are welded sequentially.
The other side is welded with resonant capacitors and resonant inductors at the position of the corresponding transformer.
The rectifier bridge is from Yangjie Technology, model KBJ410, specification is 4A1000V, and KBJ package is used.
The high-voltage filter capacitor comes from Jiangsu Farah Electronics.
The capacitance specification is 400V150μF, which is a general high-temperature standard of the FPH series.
The LLC controller from ST ST, model L6599A, is a fixed 50% duty cycle half-bridge controller with a built-in 600V high-voltage driver and integrated synchronous DMOS, eliminating the need for an external bootstrap diode. The L6599A supports switching frequencies up to 500KHz, supports PFC control, and is available in an SO16N package.
One electrolytic capacitor is from Farad, with a specification of 450V 3.3μF, which is a high-frequency, low-impedance and long-life capacitor of the FZW series.
The other filter capacitor is from Aihua and has a specification of 50V100μF.
A total of 12 resistors are connected in series and parallel to form a close-up of the starting resistor.
The other set of resistors consists of 6 resistors connected in series and parallel.
Two LLC switches are attached to the heat sink.
The switch is from Dongwei Semiconductor, model OSG65R380FEF, NMOS, withstand voltage 650V, conduction resistance 380mΩ, TO220F package.
The resonant capacitance specification is 0.027μF 1000V.
Close-up of resonant inductance.
Close-up of LLC transformer.
The blue Y capacitor is from SEC Success Industries.
The LITE-ON LTV-817 optocoupler is used for output voltage feedback regulation.
The rectifier diode is available in a ESR30V150 and TO220 package.
The two output filter capacitors are 63 V and 330 μF, and are 130°C heat-resistant for the FTR series.
The other filter capacitor is 35V 560μF.
A MOS tube for output control and a Schottky diode to prevent backfill are welded on the output side.
The main control MCU is from Hetai, model HT45F5Q-3, is an 8-bit FLASH microcontroller dedicated to charger applications, the single-chip microcomputer has a built-in multi-channel 12-bit ADC, an integrated battery charge management module for CV and CC control, and has I2C, SPI and UART interfaces, and adopts a 24 SSOP-A package.
Two 0.1Ω sampling resistors are connected in parallel to detect the charging current.
The transistor of the silkscreen BL is used to supply power to the MCU voltage regulation.
A thermistor is used to detect the internal temperature of the charger.
Two-color LEDs are used for charge status indication.
The MOS transistor for output control is from CR Micro, model CS3710B8, NMOS, withstand voltage 100V, conduction resistance 14mΩ, and TO-220AB package.
Zhaolong CT357B optocoupler is used to control the output switch.
The diode used for the output backfill proof is from MHCHXM, model number EBR2EL60, and is available in a TO-220AB package.
A list of all dismantling and a family photo.
Summary of the dismantling of the charging head network
The special charger for Maverick electric lithium battery is dedicated to 15 strings of lithium iron phosphate battery, the maximum output voltage of the charger is 54.6V, the nominal output voltage is 52V, and the output current is 3A. The charger supports 220Vac input, and comes with a 1m long input cable and an 85cm long output cable to meet daily use. It is equipped with a two-color indicator to indicate the charging status.
Through dismantling, the charging head network learned that the special charger for Maverick electric lithium battery adopts LLC switching power supply, the primary switch tube and rectifier tube are fixed on the heat sink, and the transformer, high-voltage filter capacitor and other components are fixed with glue. The charger uses STMicroelectronics' L6599A LLC controller internally, and the charging control is carried out with the Hetai HT45F5Q-3 MCU.
The internal primary switch of the charger is from Dongwei Semiconductor, the internal filter capacitor is from Aihua and Farad, and the internal capacitor and switch are made of domestic brands. The charger PCBA module is covered and sealed with potting glue, and the NTC thermistor is welded to detect the internal temperature, equipped with MOS tube for output control, and equipped with an anti-backfill diode, the charger has comprehensive protection functions and solid materials.