EBC-A10H BatteryTesting Machine Mosfet Failure when activate dose not turn off

[CapLeaker]

I am still trying to find as much information about the XL4015 buck converter as I can but I think that I going to just modify the voltage control and add my own XL4015 that just adjust the voltage and be done with and modify it where it goes to the power supply relay and cut the trace into so I have a way to install the second XL4015 buck converter and put it in an enclosure and mount it on the top of battery testing machine and be done with it

And start testing BMS protection boards because I been taking chances doing it on the battery testing machine with out this modification and I do not want to fry another battery testing machine

I am on this forum from time to time when I have time and nothing else better to do get project ideas

https://www.eevblog.com/forum/search2/ Then you have to type in XL4015 then search

On the topic of the XL4015 buck converter module

I am there too, but post not much at all there.

[sam_sam_sam]

I had forgotten about this thread. Interesting outcome. 👍

I am still trying to find as much information about the XL4015 buck converter as I can but I think that I going to just modify the voltage control and add my own XL4015 that just adjust the voltage and be done with and modify it where it goes to the power supply relay and cut the trace into so I have a way to install the second XL4015 buck converter and put it in an enclosure and mount it on the top of battery testing machine and be done with it

And start testing BMS protection boards because I been taking chances doing it on the battery testing machine with out this modification and I do not want to fry another battery testing machine

I am on this forum from time to time when I have time and nothing else better to do get project ideas

https://www.eevblog.com/forum/search2/ Then you have to type in XL4015 then search

On the topic of the XL4015 buck converter module

[CapLeaker]

I had forgotten about this thread. Interesting outcome. 👍

[sam_sam_sam]

I had another brain storm idea obviously the charge controller does not control the voltage however it does control the current after I thought about it some more in the aspect of okay it dose not control the voltage then it must control the current so I did the test

Set the charge parameters as follows the voltage always the same value ( 4.20 volts the actual battery voltage was 3.994 volts ) what I change the current as follows
Used two 28 volt incandescent light bulbs in parallel set current values as follows

100 milliamperes light bulbs did not light the software shows 100 milliamperes
200 milliamperes light bulbs did not light the software shows 200 milliamperes
500 milliamperes light bulbs lights very dimly the software shows 500 milliamperes
1000 milliamperes light bulb lights as though there was no current controlling the current but have to think that I had a load that was high than 820 milliamperes it probably follow along with the same results until you reach the 5 amp limit of the battery testing machine

Which is what I suspect would be the case but I had to verify if this was the case so I could decide how I want to proceed with the modification to the charging circuit

Here is the type of buck converter

https://www.ebay.com/itm/11581948219...Bk9SR-iHnrm8ZA

But now my question still is how is buck converter is being controlled in the current mode when the data sheet does not have an example of it and it does not mention how you would go about controlling it that way

Because in the buck converters that have the voltage/current module it has a ic chip that controls the current function now can assume that the module that has both functions in fact if I remember correctly it does not mention a circuit that has both function it shows how to use it in the voltage mode

Is there anyone that knows how you could have a controller control the amperage on a buck converter that is used in this battery testing machine

Before I start to modify the charging controller circuit I going to try to take a very close picture of the buck converter ic chip and the surface mount components so that hopefully some can understand what was done in this situation because I would like to understand how this was accomplished

[sam_sam_sam]

Here is a very important update this issue with this battery testing machine and why you can not use it to charge battery cells that have a BMS protection board
Before I get into what the real issue is to why you should NOT under no circumstances try to charge any battery cells that use a BMS protection boards this question has bothered me ever since this issue started to WHY ??? I could not leave it alone I just wanted answers to this question I had a brain storm ( yeah not a brain fart ) today about this when I was at work today

I wondered what would happen if you hook the voltage leads to a battery cell and you hooked up the charging wires to an incandescent light bulbs what would happen would it have voltage or not and how much voltage would you have ( take a guess what the answer to this question is)

The answer to this question ( CapLeaker ) is the following ( sense you were very interested in this topic)

You have 24 volts on the charging/discharging wires and the battery testing machine shows around 820 milliamperes and 3.94 volts the battery testing machine was set to 4.2 volts @ 1.00 amps interesting results this explains why you can NOT charge battery cells with BMS protection boards…>

[ some BMS protection boards limit the voltage and current that can be put to the board and if you are over these limitations it refuses to charge the battery cells now granted you do not know which BMS protection board will do this and work this way ]

<…unless you control the voltage and current which would require you to modify the charging circuit meaning you would have to control the voltage at a minimum and to be on the safe side it would not hurt to control the current as well

So the plan of attack is going to be little bit different now that I understand what and how this battery testing machine controls the charging circuit
I going to take one that is working correctly and has no issues with the controller or the charging circuit and disable the buck converter in fact take it completely off the board and use a 24 volt switching power supply that you can control the voltage and current but I have to limit the current to 5 amps this is going to be a challenge because I have not seen a switching power supply that is only 5 amps output have this feature

Or leave the buck converter in and use the buck converter that I mentioned earlier in this post but hook up in such a way that it has to go through the second buck converter to control the voltage and current or just use one that just control the voltage would probably work I have to think about this issue a little bit more to come up with the best way to solve this issue so I do not fry anymore battery testing machine controller mosfets/buck converter boards

Look how long this has taken me to figure out how and what caused this issue to accrue

Now I can put this question to rest and move on figure out a work around solution to this problem SLOVED

Took over 3 years to solve this mystery of why you can not charge battery cells with a BMS protection board
Now granted I was not dwelling on it continuously but it would raise it ugly head every once in awhile and it just would not leave me alone so I knew that I would have to find answer to this question

One question that remains is how does the controller controls the buck converter this is a question that I do not think that I will ever get an answer to this question and I do not think that the engineer who designed this circuit will ever disclose this information

Unfortunately I do not have the knowledge or the equipment to reverse engineer this controller circuit so I cannot and will not mull over this question because it beyond my knowledge and understanding of electronics

[sam_sam_sam]

Update on the larger power supply enclosure I not sure exactly what version of switching power has this screw pattern because the switching power supply that is larger does not match so will have remove the standoffs and replace them in the right configuration so I can mount the switching power supply that has voltage and current adjustments and mount the voltage and current meter module on the outside of the enclosure with an external power lightbulb

I will post some pictures of the finished project when I have it completed and ready to install in the shed with the battery testing machine and its switching power supply and it charging switching power supply as well with the computer system setup and a battery pack with a BMS protection board installed

The plan for this weekend is to run the power for the wall outlets so I can hook up the computers and monitors and battery testing machines and maybe do some test runs on testing battery packs that have BMS protection board and see how well this setup works

I had done this as a proof of concept about a year ago and the results were satisfactory which is why I pushing full speed ahead and hopefully this will work as I hope that this will be the case

I still have to finish modifying the battery testing machine that the mosfets boards that are damaged and use them in this new configuration I have one more that I found recently that was also damaged slightly that I still have the mosfets still on the board but the 24 volt switching power supply was replaced with a 12 volt switching power supply just to power the controller board and the battery power supply for the charging function will now be done with a switching power supply that has an adjustable voltage and current control this is one that I did the proof of concept on the reason I forgot about this one was I had misplaced this one and found it again a couple of weeks ago but that is reason I bought another battery tester that only does discharging function which is the version that uses an external switching power supply and I will switch them around but I also have to modify the communication cable because the pin outs are a little bit different from each other and the length of the cable is also different as well

[sam_sam_sam]

Update I finally got the switching power supply in it own enclosure and now I am doing a burn in test it is Mean-Well switching power supply 12 volts @ 5 amps and the enclosure came from Electronic Goldmine which this the first time that they have had this type of enclosure made for small switching power I have seen them on AliExpress before but were a little pricey for what they are and what is nice about these enclosure is that they have holes with stand offs but they are not that long but not long enough to use 3mm screws to switching power supply enclosure so I had to use some short stand offs that are threaded on one end the other end takes a thread screws as you can see in the pictures below

I removed the LED light from the board and mounted a LED light on the enclosure lid so it is easier to see it which also came Electronic Goldmine that I bought many years ago when they were practically giving them away I have a lot of them and I used them when I want an indicator light on the enclosure so I can see weather or not it has power or not

So now I need to make the power supply distribution center for the battery testers that I am going to hookup to it but that is for another weekend might not be very soon because I have other projects that need to be finished but yesterday and today it has done nothing but light rain so I got busy and finally finished this part of the project and the soldering / desoldering stations that I finally finished yesterday and I am using one of today for this project

I probably buy a couple more of these enclosures before they are finished at Electronic Goldmine for a couple of other switching power supplies that have the power connections at one end of enclosure I like this type of switching power supply but I do not like the idea and fact that electrical connections are done this way and make using them very limited but these enclosures make it a lot safer to use them

The enclosure that I used for this project The second link is the other enclosure that they also sell and third link is the switching power supply that was used for this project

https://theelectronicgoldmine.com/products/g27675

This is the other size of enclosure that they also sell

https://theelectronicgoldmine.com/products/g27643

Here is the switching power supply that I use for this project

https://theelectronicgoldmine.com/products/g27679

[sam_sam_sam]

I had emailed the company about getting replacement parts for this model and another model that I have and did get a response but when I went to respond to there email I now get a non delivery notification and now there website does not have there email address posted anymore so I have wondered if they are about to go under or it is being sold to someone else and who knows what will happen next with there product line

This is unfortunate because they have a decent graphic display for there battery testing machine but they have some issues with there with either the mosfets / charging board or the controller board that controls that section of the device and to make matters worse is there manual make it seem like you can charge battery packs with BMS protection board but it does not say this in actual words but in reality this should be avoided at all cost because it spikes the voltage when turning off the charging current or the BMS protection board does not want to turn on because of to high of voltage and then you see the voltage spike on the graphic display chart so in reality it should only charge naked battery cells and nothing else

If you only charge and discharge naked battery cells you will not have any issues with the battery testing machine but I found this out the hard way the bright side of this story is that I learned how this system works for the most part and more importantly I learned that you can not use this battery testing machine to charge battery packs that have BMS protection boards the other side of this story is that the EBC-A10H is around $100.00 well worth the money if use with the understanding that you can never use it with battery packs that have BMS protection boards on them

The fortunate thing is that if the mosfets / charging board malfunctions you can still use the battery charger but you have to remove the mosfets from the board and do a little bit rewiring to the board in the monitoring mode and then you can use it to test battery packs that have BMS protection boards but you also have to manually adjust the charging current and then you have to have a discharging device to load test the battery pack

I have a few things left to do in my shed so that I can do the type of battery testing on battery power tool packs I still have to run power on one wall and put a power strip on the battery back up for the computers that are going to be used for this battery testing stations so stay tuned for to come maybe in couple of months

[sam_sam_sam]

Re: EBC-A10H BatteryTesting Machine Mosfet Failure when activate dose not turn off

I have not abandoned this project just some more important things have gotten in the way and were more important to deal with but hopefully I will have some more time and will get some of these modules mounted in a couple of enclosures and do some BMS testing because I have some that I recently bought and want to see just how good they are in controlling cutoff voltage in the charging mode and what the cutoff voltage in the discharge mode and how well the temperature sensor behaves under torquer testing externally heat source

I also plan on testing the Milwaukee BMS protection board for the same type of testing that I mentioned above I have plans to test the Ryobi packs the same way and the other tool battery packs that I have so stay tuned more to come these testing results are in the future when I get my shed setup for this type of project battery testing

[CapLeaker]

Re: EBC-A10H BatteryTesting Machine Mosfet Failure when activate dose not turn off

Oh wel… sometimes things don’t go very well as planned. In my post 39 I complained about being busy. geez… nothing changed here… still busy as eff.

[sam_sam_sam]

Re: EBC-A10H BatteryTesting Machine Mosfet Failure when activate dose not turn off

I really need to find the time to finish this project I have it mostly done but I have not finished putting the buck converter in the enclosure yet and modified the switching power for this project yet

[CapLeaker]

Re: EBC-A10H BatteryTesting Machine Mosfet Failure when activate dose not turn off

Given I haven’t been around much lately, but I still follow this thread. Just so effing busy with tons of installs and repairs and a recent response, I already feel the need for another vacation. Lol

[sam_sam_sam]

Re: EBC-A10H BatteryTesting Machine Mosfet Failure when activate dose not turn off

Now I have to put the XL4015 voltage/current module in an enclosure with a switching power supply so I can safely use this setup

But now I can charge battery packs that have a BMS protection board the battery pack that refused to charge on the EBC-A10H plotting software which is a relief that I now have it working

Which is the one that you see in the picture above

I posted this update for the followers of this post and the interest in this project

[sam_sam_sam]

Re: EBC-A10H BatteryTesting Machine Mosfet Failure when activate dose not turn off

I tried to use the controller output from the EBC-A10H will not work correctly in the configuration of the voltage/current controller module with the meters on not a big deal but it would have been nice if I could have gotten it to work

I had removed the buck converter ic chip and it components completely because I want to see if I could have it controlled by the software but it does not work correctly the way it should

[sam_sam_sam]

Re: EBC-A10H BatteryTesting Machine Mosfet Failure when activate dose not turn off

Now this module works correctly on the current but does not come with the voltage/current meters it just so happens that the board are very similar but I had to use the pots from the one that the current control does not work correctly

Now I have a voltage/current controller that actually works correctly the way it should

One note about this setup it is very difficult to get this setup to work correctly because the voltage ( going UP turns in one direction but to lower the current limit you have to go in the same —>

( which you think that lowering voltage/current would be in the same direction )

<— direction for turning down the current which was a little confusing at first

[sam_sam_sam]

Re: EBC-A10H BatteryTesting Machine Mosfet Failure when activate dose not turn off

“ Because I have been very curious about how this is done because I have not been able to find any examples of how this is done ” from the above post

Major update on the XL4015 buck converter that has voltage/current control capability but more importantly the current control that has a voltage/current module meter on top of the buck converter

The TenStar Robot does not work correctly on the current control the current light comes on very dim but does not control the current

The meter seems to be very accurate for the type of meter that it is but the current control circuit is crap and does not work at all

[sam_sam_sam]

Re: EBC-A10H BatteryTesting Machine Mosfet Failure when activate dose not turn off

Well I had some time yesterday and finally found out how the charging circuit works they do not use the mosfets like it appears to at first instead they use the TTL mode on the buck converter ic chip but what I do not completely understand is how they are controlling the current not the voltage like you would normally how you would use this ic chip

I going to buy some new XL4015 and reinstall them with a wire on the feedback pin and switching output pin and see how this is done

Because I have been very curious about this is done because I have not been able to find any examples of how this is done

[sam_sam_sam]

Re: EBC-A10H BatteryTesting Machine Mosfet Failure when activate dose not turn off

EBC-A10H

I just realized that the ribbon cable can be plugged in wrong way and it will power up but it this is when it shows nearly 6 amp even though it’s not really there but this is when if you hook up a battery to the load then it does pull nearly 6 amps

But this does not change what I going to do with the ones that I thought had this issue

On one of the mosfet board I removed the buck converter but left the capacitor for the output side of the buck converter to the relay that turns on the charging circuit I also left the diode that is across the input positive and negative power supply rails and just hook up the buck converter that has the voltage/current adjustable power supply and see how well this setup actually works

Hopefully I will be able to charge BMS protection board with out tripping the battery testing machine or the BMS protection board

[sam_sam_sam]

Re: EBC-A10H BatteryTesting Machine Mosfet Failure when activate dose not turn off

Are you using the same battery chemistry?
Some chargers stop for a fracture of a second, take a measure then continue changing. That’s with NICD, NIMH.
Lithium Ions are different and the charger constantly monitors CC and CV.

This is weird thing about this charger it does have have those options and I was charging a battery with out the BMS protection board hooked up and it did this that why I am a little confused about what was happening when I saw that it going 200 milliamperes to 1.0 amp which it did this quite a few times and went back to normal then a few minutes later it dose the same thing again I had it set to now if I set it for 500 milliamperes it so far has not done this so I do not know what going on with this

[CapLeaker]

Re: EBC-A10H BatteryTesting Machine Mosfet Failure when activate dose not turn off

Are you using the same battery chemistry?
Some chargers stop for a fracture of a second, take a measure then continue changing. That’s with NICD, NIMH.
Lithium Ions are different and the charger constantly monitors CC and CV.