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Thread: DSD Charger brain transplant

  1. #1
    Flashaholic* chimo's Avatar
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    Default DSD Charger brain transplant

    I didn't like the way my DSD charger terminated the charge cycle so I gave it a little surgery.

    I used the LTC4054 chip from Linear Tech (same chip that is in AWR's Nano charger). Since the DSD will accept different cell sizes, I wanted to be able to vary the charge rate. I etched a board to allow 4 different charge currents, although, with the switches I had on hand, I only implemented it with 3 charge rates (approx 100, 300 and 500mA). This allows for charging cells down to the 10280 size.

    The LTC4054 is a CC/CV charger and terminates the charge when the charge current drops to c/10. The switch in the pic has 3 positions to select the charge rate. The LED flashes when power is applied with no cell, is on steady during the charge cycle and goes out when the charge is complete.



    Before pic


    After Pics



    Thanks for lookin'

    Paul

  2. #2
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    Default Re: DSD Charger brain transplant

    Hello Paul,

    Nice...

    Tom
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    Most batteries don't die - they are tortured to near death, then murdered...

  3. #3
    Flashaholic* chimo's Avatar
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    Default Re: DSD Charger brain transplant

    Thanks Tom, it was a fun evening project. (Even after forgetting to print the mirror image of the resist patch and having to re-etch another board ).

    I used the toner transfer system - great for making protos.

    Paul

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    *Flashaholic* LuxLuthor's Avatar
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    Default Re: DSD Charger brain transplant

    I read the other thread about all the problems with the DSD and PS, and would love to do this with the three I have, but am not sure of your details to be able to do it myself. Any chance of noobifying what you did?

  5. #5
    Flashaholic* TinderBox (UK)'s Avatar
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    Default Re: DSD Charger brain transplant

    just a quick comment, slightley off the subject.

    I got one of those cheap Chinese RC123 charger, it would only charge to 3.97volts.

    I opened it up to find a trimmer, so I adjusted it.

    It now charges to 4.22volts every time.

    It`s amazing how much extra power is between 3.97-4.22volts.

    regards.
    "Build a man a fire, and he'll be warm for a day. Set a man on fire, and he'll be warm for the rest of his life." - Terry Pratchett.

  6. #6
    Flashaholic HiltiHome's Avatar
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    Default Re: DSD Charger brain transplant

    Quote Originally Posted by TinderBox (UK)
    just a quick comment, slightley off the subject.

    I got one of those cheap Chinese RC123 charger, it would only charge to 3.97volts.
    I opened it up to find a trimmer, so I adjusted it.
    It now charges to 4.22volts every time..
    There is no trimmer in DSD charger...

    Quote Originally Posted by TinderBox (UK)
    ...It`s amazing how much extra power is between 3.97-4.22volts..
    0,1V equals 10% capacity

  7. #7
    Flashaholic* TinderBox (UK)'s Avatar
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    Default Re: DSD Charger brain transplant

    the charger is not a DSD, the model number is YL-112

    http://tjtech.org/~CPF/CY/defective%20charger.JPG

    regards.
    "Build a man a fire, and he'll be warm for a day. Set a man on fire, and he'll be warm for the rest of his life." - Terry Pratchett.

  8. #8
    Flashaholic* chimo's Avatar
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    Default Re: DSD Charger brain transplant

    Quote Originally Posted by LuxLuthor
    I read the other thread about all the problems with the DSD and PS, and would love to do this with the three I have, but am not sure of your details to be able to do it myself. Any chance of noobifying what you did?
    The thing to remember is that this chip is running in linear mode. That means that the power that doesn't go into charging the battery gets dissipated as heat in the switcher chip. So it is important to match the power supply to the charge circuit. I used one of a couple of surplus 5V regulated power supplies that I picked up surplus for a couple of bucks each. I added a dropping diode to bring the voltage down another few tenths of a volt before it hit the charger chip.

    I pretty well used the circuit from the data sheet and added a few resistors in parallel to the current set resistor so I could change charging currents. I etched the board myself, but you could purchase a nano board from Andrewwynn. They are much smaller to work with.

    Sorry, I guess this doesn't noobify it too much.

    Paul

  9. #9
    Enlightened Tacfolder's Avatar
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    Default Re: DSD Charger brain transplant

    Could one put the electronics from an HDS charger inside the DSD Charging cradle, "robbing the cradle", as it were? (I know, I know, I couldn't help it ). I use one charger to charge the battery for my EDC B42 XR GT, and the other to charge the 17670 for my SF 6P with 3W Led module. I am also building an ROP/LE and I would like to just use one charger setup for the different batteries. Just a question.
    Tacfolder
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  10. #10
    *Flashaholic* wquiles's Avatar
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    Default Re: DSD Charger brain transplant

    Nice project

    Will
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  11. #11
    *Flashaholic* LuxLuthor's Avatar
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    Default Re: DSD Charger brain transplant

    Yeah, it didn't noobify it at all! LOL!! I just ordered two Pila chargers from Burlys.

  12. #12
    *Flashaholic* KevinL's Avatar
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    Default Re: DSD Charger brain transplant

    Quote Originally Posted by TinderBox (UK)
    the charger is not a DSD, the model number is YL-112

    http://tjtech.org/~CPF/CY/defective%20charger.JPG

    regards.
    The trimmer sounded extremely familiar. I recommend you exercise extreme caution with that charger - one of those blew up on me before. Yes, I did tweak the trimpot.
    Celebrating the ROP.. 5 years of history

  13. #13
    *Flashaholic* LuxLuthor's Avatar
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    Default Re: DSD Charger brain transplant

    Quote Originally Posted by LuxLuthor
    Yeah, it didn't noobify it at all! LOL!! I just ordered two Pila chargers from Burlys.
    These new Pila Intelligent chargers are very very nice. Glad I got them vs. the DSD's.

  14. #14
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    Default Re: DSD Charger brain transplant

    This brings up a blast from the past for me. Here's my home brew two position charger using the same LT4054 chip that I built three years ago and it's still serving me very well.



    Didn't have a suitable holder for the cells so I used a Pila charger to test it:



    The LTC4054 is a great "economy" charger.

  15. #15
    Flashaholic* vacuum3d's Avatar
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    Default Re: DSD Charger brain transplant

    Can the LTC4054 charge protected cells?

  16. #16
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    Default Re: DSD Charger brain transplant

    Quote Originally Posted by vacuum3d
    Can the LTC4054 charge protected cells?
    Yes, I've used it to charge Pila's.

  17. #17
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    Default Re: DSD Charger brain transplant

    Quote Originally Posted by TinderBox (UK)
    SNIP...

    It`s amazing how much extra power is between 3.97-4.22volts.

    regards.
    Gain 25% in capacity, but loose ~50% in cycle life and cell cycle lifetime.

    Nice work Chimo and Tinderbox both. FWIW, I like ~4.22V charge cutoff myself. My DSD is seems to be drifting downwards in cutoff voltage over time. As HiltiHome noted, there is no adjustment in the stock DSD.

    And even further OT, my older cells are exhibiting some voltage depression; After 24 hours rest, they are ~4.05V, after charger cutoff at 4.17V.

    Better smarter chargers get my vote, but a Li-Ion charger is a bit scary for my modding tasts. Making a mistake can be very dangerous.
    NextLight

    from good, to better, to ...

  18. #18
    Flashaholic* vacuum3d's Avatar
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    Default Re: DSD Charger brain transplant

    CM... thanks.

  19. #19

    Default Re: DSD Charger brain transplant

    Hi Paul,


    Sorry. Borrow your idea for PCB layout. I didn't do the layout job or etch a PCB before.

    My soldering work is poor, here it goes.



    The 3 resistors on the up right corner were used by slide switch at first, but not used now. If I need more charging current, I need more resisters and more wires. The selector switch is too big to fit in DSD case.

    I use a DIP switch to do the job.


    Sw 1 OFF would make the Iprog open to ground and cut of the charging. The resistors in series are 1.5k, 1.5k and 3.9k. 1&2 ON would get 1.5k, 1&3 ON 3K and 1&4 ON 6.9k. The charging current are about 660, 330 and 145mA.

    Thanks for viewing.

  20. #20
    Flashaholic* chimo's Avatar
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    Default Re: DSD Charger brain transplant

    NetKidz.

  21. #21

    Default Re: DSD Charger brain transplant

    Hey Chimo, very slick mod...
    Good to come with the idea...

    Here's my question: You said Andrewwynn sells Nano boards,
    at what currents do these run ? Are they selectable ?

    The reason I think this mod has been done, is if you would like to
    charge RCR2 cells in the DSD, do you don't have to charge them
    in pairs, am I correct ?

    Cheers !

  22. #22

    Default Re: DSD Charger brain transplant

    double post edit:

    LTC4054 Li-ion Battery Charger IC Source
    http://www.candlepowerforums.com/vb/...d.php?t=136683

    DIY Charger by djpark:
    http://candlepowerforums.com/vb/showthread.php?p=656474

  23. #23
    Flashaholic* chimo's Avatar
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    Default Re: DSD Charger brain transplant

    I believe AWR will be selling his nano chargers (assembled or in kit form). I picked up a couple of kits from him and a few spare parts.

    I built one charger head at the standard 100mA charge rate and assembled one board for 200mA. A resistor sets the charge current.

    I etched the board for the DSD because I didn't like the way the DSD charged and the lack of charging ranges for different capacity batteries.

    I also want to build myself a portable USB charger that will charge a few different battery sizes at different rates. I have a nice little folding "donor" charger that may lend its shell to the cause. Have not gotten around to assembling it yet.

    Paul

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