Mega-Mod MW 15-29V 0-10A for 5-500w charger

DrkAngel

1 GW
Joined
Dec 15, 2010
Messages
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Location
Upstate-Western-Southern Tier NY. USA
Previously, I have documented a wide variety of mods for the MeanWell S-150-24.

Spotted a cheap Volt amp meter that inspired me to one further mod.
<$5 100V 10A dual color meter

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MW 15-29V 0-10A PS-Charger

I lucked into a supply of Genuine MeanWell S-150-24's with the switch and shroud that made this build extra nice.

file.php


Using my documentation on values for different mods ...
DrkAngel said:
Wider Amp adjustment:
Disconnect, or remove R33 & R38.
Replace with adjustable" pot"
Working with 12.6V LiPo pack through inverter

Amps ...... Ohms
1A ... from ... 70 ohms
2A ... from ... 175 ohms
3A ... from ... 287 ohms
4A ... from ... 392 ohms
5A ... from ... 500 ohms
6A ... from ... 610 ohms
7A ... from ... 715 ohms
8A ... from ... 855 ohms
9A ... from ... 920 ohms
10A .. from .. 1050 ohms = 1.05 k
11A .. from .. 1140 ohms
12A .. from .. 1293 ohms
13A .. from .. 1357 ohms
14A .. from .. ? ohms
15A .. from .. ? ohms
16A .. from .. ? ohms
17A .. from .. ? ohms
18A .. from .. ? ohms
19A .. from .. ? ohms
20A .. from .. ? ohms
etc.

I disabled R33 and R38 and ran wires to a 1K large turn pot.
This gave me an amp adjustment from .17A to 10A.
Surprisingly, the amp graduations are fairly equidistant!

I wanted a minimum 15V capability and could have used a 2K pot to acquire the capability, but I preferred more precision.
So, instead of removing the SVR1 pot I cut the leg nearest the power bar and ran wires to the leg and to the circuit, then added the 1K large turn pot in series.
The result?
19-29V adjustment from the top mounted pot, with the optional adjustment of the on board pot shifting the top mounted pot to as low as 14.5-19.3V.

I wanted 15V capability for a full 10A @ 15V.

Since I intend this as a fairly universal power supply, I used a Deans T-Plug for mounting various output connections.
 

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The MeanWell S-350's and the S-150's can both provide adjustable current regulation.

The S-350-xx with an annoying buzzing ...
The S-150-xx, however seems to provide seamlessly quiet regulation. Which makes it my ideal choice as a control unit for multiple PSs in series.

In series with any generic S-350-48, the S-150-24 is adjustable to provide:
5w to 500w of 54 - 84V

S-150-29V @6A + S-350-55V = 500w of 84V-6A regulated power

S-150-15V @9.25A + S-350-39V = 500w of 54V-9.25A regulated power

This provides an adjustable or "programmable" 13s to 20s Li-ion - Lipo charger

Notes:
Additional active cooling is necessary (highly recommended) for continuous full rated output!!!
Each PS should be voltage adjusted to not exceed its watt rating!
S-350-48 V are rated at 7.3A, but typically limited at 130-135% = 9.5-9.85A
Replacing voltage pot on S-350-48 unit with 2K pot will allow lower voltage charging, possibly >10s, but <500w ...

Important! S-150-xx are not AC-DC electrically isolated.
Place S-150 on the low voltage end of any "series".
Confirm S-350 equivalent to be electrically isolated = no continuity between neg DC and "ground".
 
5 to 500w 27-42V CC\CV Charger

DrkAngel said:
13s -20s 54-84V 500w CC\CV charger might be great ...
But many run at more moderate voltages.

My next MeanWell project will be a 7s-10s 27-42V 500w CC\CV charger
This will cover all of my present battery builds

Should be as simple ... using:
MeanWell S-150-12 - S-150-12 mods = values not complete ... yet
Generic S-350-24
and same methodology

Yes ... !
I will also, eventually, build and document a similar 9s-13s 500w CC\CV charger ...
 
Just purchased a 0 - 10 pot knob which, by luck, looks to be graduated nicely to match actual amp adjustment.



Update
Not positive that 10 - 0 graduations will be perfectly accurate so I ordered 10 to 1 graduated dial also.

$(KGrHqR,!jYE-cm8By9PBPrIq2K6mw~~60_12.JPG
 
0 - 10 knobs look pretty accurate, 1-10 knobs don't track well.
0 - 10 dial is large enough to cover marks, will scratch a line and fill with black paint, nail polish or similar as graduation marker.

Update
Received 0-10 knob and is very precise, within 5%!

Amp meter is not necessary, after installing graduated knob and confirming accuracy, but it does indicate actual charge rate and diminishes as full charge attained.
This model was my prototype, I will add 24V cooling fan to next build.

I will purchase generic S-350-48 to run in series for 500w charger.

I, also, will similarly mod and document a Genuine MeanWell S-350-48!

MeanWell S-150-48 Mega-Mod built also!
MeanWell S-150-12 Mega-Mod also built partially tested and burnt up will finish post soon.
 
DrkAngel said:
Previously, I have documented a wide variety of mods for the MeanWell S-150-24.

Spotted a cheap Volt amp meter that inspired me to one further mod.
<$5 100V 10A dual color meter

file.php
It is recommended to confirm that item has V and A adjustments on rear of unit before ordering.
Very small silver pots with +.

Compare and adjust to known good meter before installation ... easier.

WARNING! - DANGER!
There seems to be a cadre of ES member who feel most eBikers are totally ignorant of electricity and its dangers.
Unless you understand electricity, its theory and dangers ... do not read this thread! >>> ≤2000W Charger - $5 - Experiment - in progress ...
 
Wow. You have done an amazing job with this!
Question-
I am using the newer RS-150-24 and the pcb layout is totally different than the S-150-24!!!
I need to raise the OVP level to 29 volts to stop hiccuping.
Can you help?
I assume I need to change a zener?
 
proto7 said:
Wow. You have done an amazing job with this!
Question-
I am using the newer RS-150-24 and the pcb layout is totally different than the S-150-24!!!
I need to raise the OVP level to 29 volts to stop hiccuping.
Can you help?
I assume I need to change a zener?
Follow the SVR1 circuit back to a resistor.
Changing resister to slightly lower value will raise voltage adjustment.
Too low will shift voltage range to the point where zener engages, might want to use adjustable pot if you need to vary-adjust voltage often - to get precise range..
Not a big factor if using 1 specific voltage.

See - S-150-24 for my original "raising voltage range" research

Probably not a factor for ≤30V ... but
Cap limit is likely 35V.
Zener on S-150-24 limited 32-33V
 
DrkAngel said:
proto7 said:
Wow. You have done an amazing job with this!
Question-
I am using the newer RS-150-24 and the pcb layout is totally different than the S-150-24!!!
I need to raise the OVP level to 29 volts to stop hiccuping.
Can you help?
I assume I need to change a zener?
Follow the SVR1 circuit back to a resistor.
Changing resister to slightly lower value will raise voltage adjustment.
Too low will shift voltage range to the point where zener engages, might want to use adjustable pot if you need to vary-adjust voltage often - to get precise range..
Not a big factor if using 1 specific voltage.

See - S-150-24 for my original "raising voltage range" research

Probably not a factor for ≤30V ... but
Cap limit is likely 35V.
Zener on S-150-24 limited 32-33V


First DrkAngel.. thanks this was extremely useful thread.

Never posted picks about what is needed for the RS-150-24 mod though I had moded min, I figured I outght to share. For an RS-150-24, to adjust the range of the pot one adds resistance in parallel to R65 (to reduce its overall resistance):
IMG_20150715_160205.jpg
I had to work on it today as I broke the built in pot as I overroated the POT too far trying to get a higher voltage to test my new BMS.. (If you over rotate it drops the voltage as it become open). Rather than trying to remove and fix it I realized I could just make the range control resiter into a POT and control it from there. So I removed the fixed resistor I had added and added a pot (which I stole from an old broken PC speaker volume knob).
IMG_20150716_162523.jpg
View attachment 1
Which let me tune it over 30V..

And while slightly off topic, I also moded an RS-60-24 (which has much lower power output). For the RS-60-24 one mods R18.

With the RS-60-24 I could only get it up to 28.99 before the unit went crazy with the voltage jumping all over the place.. same thing happens if the POT is too far out of range for the RS-150-24 mod above).

Hope that helps others.. Was not sure if I should add a new wiki page for either of these.. its basiclly adding only trival amounts of data to DrkAngle's major work
 
MeanWell S-60 specs
 

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