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A dual cell charger (5V 4A in, 8.4V 3A out) combined with active balancing (2A)

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DoganM95/CN3302-ETA3000-2S-Charger-Balancer

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Intro

A dual cell charger (3-6V 4A in, 8.4V ~3A out) combined with active balancing (1.3A).

  • The charging part makes sure to load the battery pack to 8.4v
  • The balancing part makes sure to keep both batteries at the same voltage always, by charging the lower one using the higher one (active balancing)

Having these combined will in theory give the perfect 2S bms, so that batteries won't die, charge fast and don't waste energy.

Any buyable bms i have tested so far fails to keep both batteries at the same voltage, so that one is e.g. 4.6v and the other 3.8v, resulting in 8.4v total but leading to damage/death of the overcharged cell, hence this proect to solve the issue and have a reliable, hackable solution.

Still in concept phase, highly experimental and untested. Even the pcb traces are not wide enough to support the supplied current and would probably delaminate or catch fire.

Releases starting with v1 or higher can be used and are tested.

PCB

PCB Top View PCB Bottom View

BOM

Most parts a salvaged from commercially available modules, which are dirt-cheap on aliexpress:

So all parts of those modules can be desoldered using a hot-plate and solder3d on this project's pcb.

Component Symbol Size Value Side Notes
C1060310nF
C2120622uF
C3060310nF
C4060310nF
C5060310nF
C6120622uF
C7120622uF
C8120622uF
C9120622uF
C10060310nF
C11120622uF
C12120622uF
C13120622uF
C14120622uF
D1smaSS54 (Schottky)
L10630 (6.6x6.6x3mm)2.2 uH
L2 / L3any2.2 uHany that fits there by size
LED10603ledany color, check R3
Q1TO-252-2KND3203b
R106035.1 kOhm
R206035.1 kOhm
R30603var Ohmchoose one that fits your LED1
R4060325 kOhm
R525120.015 Ohm
R6060310 kOhm
R7060310 kOhm
U1sot23-6ETA3000
U2smtPC817X
U3sop8CN3302
U4sot23-5MIC5219 3.3v

Schematic

By Datasheets

Follows the recommendations and schematics of the datasheets

image

By reverse engineered chinese modules

Follows the reverse engineered chinese pcb modules, so they are merged into this pcb to minimize the need of additional components (just move parts over).

Todo

Key Takeaways

  • The status group of the ETA3000 consisting of a red led and a 1k resistor use BatC as one pole and SW as the other. Thus it does not have a real GND but current flows with BatC acting as Vcc and SW acting as GND for the led
  • The said red status led connections could also be exploited to power an optocoupler, so the GND stays independent for this part of the circuit and status becomes measurable using e.g. an arduino
  • Connecting BIAS or SW of the ETA3000 to the GND, which is the negative side of the 2 batteries connected in series, kills the IC and from there it gets very hot while being powered
  • None of the 2 ic's (CN3302 && ETA3000) have a symbol in snapeda, so generic packages are used and pins renamed to match this ic

Resources

Charger IC: CN3302 (sop-8)

Active balancer IC: ETA3000 (sot23-6)

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A dual cell charger (5V 4A in, 8.4V 3A out) combined with active balancing (2A)

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