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Unread 01-14-2020, 07:12 AM   #1
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Default Question on converting charger to onboard

I finally installed a 120v receptacle in the body of the cart, mounted the charger underseat and now can just plug in and charge. The issue is that it has a small continuous drain on the pack when not connected to 120v.

I'm not an electrical engineer so I don't know the difference between various types of diodes. But, I was going to just buy a 100V schottky diode and mount it in the charger wire.

Are the schottky diodes are the right choice for this? The charger will output V when not connected to a battery, so I know it isn't waiting for a Voltage to sense on the wire. Looking for opinions about what's wrong with this idea or if there is a better (and still simple) solution.

The charger is a small 5 amp charger for my lithium pack.
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Unread 01-14-2020, 01:19 PM   #2
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Default Re: Question on converting charger to onboard

A silicon diode will drop 0.6V to 0.7V, which means the charging voltage at the batteries will be that much lower and I'm not sure if that would be acceptable.

A 120VAC relay whose contacts make/break the chargers connection to the battery pack would be best.

I'd use a SPST relay with N.O. contacts and a 120VAC coil. Wire the coil to at AC that feeds the charger, so when the charger is plugged in, the N.O. contacts c;lose and connects the charger to the battery. (Could also use a DPST relay and break both wires between charger and battery pack)
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Unread 01-14-2020, 08:12 PM   #3
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Default Re: Question on converting charger to onboard

Thanks for the insight JohnnieB! I never thought about a 120v relay. I like that it completely disconnects the charger from the battery pack. I'll look for a suitable relay.
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Unread 01-14-2020, 09:30 PM   #4
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Default Re: Question on converting charger to onboard

Be sure to get a relay with an AC coil. A relay with a 120VDC coil becomes a buzzer when 120VAC is applied. (Don't ask how I know. )
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Unread 01-15-2020, 10:50 AM   #5
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Default Re: Question on converting charger to onboard

If You are using a BMS, how does it currently disable the charger during a cell HV condition?

If your charger is one of those Chinese silver brick looking box, the relay contacts will not last long due to the charger capacitors.

The schottky diodes normally have a much lower voltage drop, but since you need a higher reverse voltage breakdown version, the leakage current of two in parallel (each diode needs to be at least 65% of the total current) may be about the same as the battery leakage that is keeping the charger capacitors as well as the LED on the charger ON.
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