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Dismantling report of the 105W new national standard lead-acid battery charger for Reactor Micro electric vehicles

Publisher:Reactor Microelectronics


Zhejiang Juyuan Electronics is a company specializing in electric vehicle chargers and electric vehicle chargers. Its products are matched with many well-known domestic manufacturers of electric vehicles, electric bicycles, and sold on board. Charging Head Network has obtained a 48V lead-acid charger launched by Juyuan Electronics, which has an output current of 1.8A and is suitable for 48V18Ah batteries. It is compatible with multiple brands of electric vehicles.

This charger has a 1-meter long input and output cable, making it convenient for daily use. It is also equipped with LED indicator lights to indicate the charging status. The cooling fan can timely discharge internal heat, ensuring stable operation. Below is the disassembly of Juyuan Electronics, a lead-acid battery charger. Let's take a look at the internal design and materials used.

Juyuan 105W new national standard lead-acid charger unboxing

The packaging box is the same as the previously disassembled Juyuan 144W new national standard lead-acid charger, with the front printed with the Juyuan electronic brand, product name, selling points, and the pattern of the robot holding the charger.

The relevant precautions for the product are listed on the side.

The end is printed with information such as the working environment temperature, humidity, charging method, and execution standards of the product.

The packaging includes a charger and user manual.

The charger also comes in a black color scheme, with a PC flame-retardant material on the body shell and a frosted surface treatment, giving it an overall industrial feel.

The input power cord adopts a national standard double pin plug.

The plug specification is 10A 250V and has passed CCC certification.

The top of the body is printed with the words "New National Standard Lead Acid Charger", and there is also a prominent yellow warning label on the left side.

The indicator light turns green when powered on.

The bottom of the body has instructions and manufacturer information for using this charger, and the four ends are designed with circular protrusions to prevent wear and tear on the bottom information.

Product parameter close-up, model DZQS481811, input 220V~1A 50Hz, output 48V (maximum 58.8V) 1.8A, manufacturer Zhejiang Juyuan Electronics Co., Ltd.

There is a grille cooling window at one end of the body, and the staggered design plays a dust-proof role.

The other end also has a built-in fan for active cooling.

The output DC wire head has a character design, and the charging contact adopts an anti reverse connection design.

The measured length of the input power cord is approximately 107cm.

The length of the fuselage is 171.35mm.

The width is 90.86mm.

The thickness is 58.35mm.

The length of the output DC cable is 105.5cm.

The size of the charger body feels intuitive when held in hand.

Finally, the total weight of this charger was measured to be approximately 664g.

Disassembly of Juyuan 105W New National Standard Lead Acid Charger

After reading the unboxing of the lead acid charger from Juyuan Electronics, let's take a look at the internal solution and materials used.

Firstly, unscrew the fixing screws on the outer shell, disassemble the outer shell, and install the cooling fan in the primary area of the charger.

Close up of the light guide column inside the shell, used for indicating the charging status of the charger.

The cooling fan is a zero pole brand, model DH5012, with a diameter of 5CM and a specification of 12V 0.08A.

The internal PCBA module is fixed inside the plastic casing.

The input wire is connected by welding.

The output wire is also connected by welding.

Remove the PCBA module from the casing.

The PCBA module is fixed inside the plastic casing and sealed by potting to prevent moisture and foreign objects from entering. It also increases the mechanical strength of the charger and strengthens the components.

On the back of the PCBA module is a plastic shell with a hole in the middle for fixation.

The back of the PCBA module is covered with sealant.

The back of the PCBA module is covered with sealant.

The length of the PCBA module measured using a vernier caliper is approximately 132.2mm.

The width of the PCBA module is approximately 77.3mm.

The thickness of the PCBA module is approximately 36.8mm.

A front view of the PCBA module, with the bottom left corner showing the AC input terminal, soldered fuse, common mode inductor, safety X2 capacitor, NTC thermistor, varistor, rectifier bridge, and high-voltage filtering capacitor. Weld the primary switch tube in the upper left corner, weld the transformer in the middle, and the charging output end in the lower right corner. Weld the filtering inductor, fuse, rectifier tube, and filtering capacitor. Weld the indicator light and fan socket in the upper right corner, and weld two sets of Y capacitors below the transformer.

The back of the PCBA module is soldered with a primary controller, feedback optocoupler, and a dual operational amplifier and control MCU for secondary soldering. The first level is marked with a black boundary, which is very obvious.

Overview of PCBA module inputs, soldered fuses, common mode inductors, safety X2 capacitors, rectifier bridges, varistors, and high-voltage filtering capacitors.

The input fuse specification is 3.15A 250V.

The first level common mode inductor is wound with enameled wire and insulated wire.

The safety regulation X2 capacitor specification is 0.68μF.

NTC thermistor screen printing 5D-13, used to suppress surge current when charging the charger.

The second level common mode inductor is wound with flat copper wire.

YFT10D621K varistor is used for surge protection.

The rectifier bridge model is GBP310, with a specification of 3A 1000V.

The specification of the high-voltage filtering capacitor is 82 μ F400V.

The primary control chip comes from Reactor Micro, model RM6500S, which is an offline switch power supply chip. The chip adopts current mode control and supports valley detection switches, meeting the sixth level energy efficiency standard. The chip supports CCM, DCM, and burst mode, which can improve conversion efficiency across the entire range. The chip has multiple built-in protection functions, suitable for power adapter and charger applications.

The side of the PCBA module is welded with filtering capacitors and fan sockets, and the right side is the primary switch tube heat sink.

The primary switch tube is fixed to the heat sink with screws.

Primary switch tube screen printed CS6N65E, specification 6A 650V, packaged in TO220F.

The specification of the filtering capacitor powered by the main control chip is 22μF 50V.

The transformer adopts PQ3225 magnetic core winding, with an output specification of 48V2A.

The side of the PCBA module is soldered with blue Y capacitors and heat sinks.

Two blue Y capacitors come from Weidi.

The other two blue Y capacitors are also from Weidi, using two in series to improve the voltage resistance level.

PC817C optocoupler is used for output voltage feedback regulation.

The output rectifier tube is fixed on the heat sink.

Screen printing of rectifier tube DSE1DS04F.

The output filtering capacitor specification is 220 μ F80V.

The output end is soldered with a filtering inductor, thyristor, and indicator light.

Close up of output filtering inductance.

The output fuse specification is 5A 250V, used for output overcurrent protection.

The MCU used for charger control is from Huimang Micro, screen printed Y3H6CGM.

The 78L05 voltage regulator chip is used to stabilize the operational amplifier.

UTC358 is used for output current detection amplification.

The specification of the filtering capacitor is 330μF 35V.

BT151-600 thyristor is used for output anti reverse connection.

Green and red LED indicators are used to indicate the charging status.

NTC thermistor is used to detect the internal temperature of the charger.

Another NTC thermistor is used to detect the temperature of the PCB board and provide overheating protection.

Take a complete breakdown and take a family photo.

Summary of dismantling the charging head network

The Juyuan electric vehicle charger supports charging 48V lead-acid batteries with a maximum output current of 1.8A. The charger comes with a 1-meter long power cord and a 1-meter long output cable to meet daily charging needs. The charger is equipped with a built-in cooling fan, which can accelerate the airflow and take away the heat generated internally during charging, ensuring stable operation. The charger supports the use of 48V18-20Ah batteries and adopts new national standard wiring terminals.

According to the dismantling of the charging head network, the Juyuan electric vehicle charger adopts a partial sealing process. The PCBA module is fixed in a plastic shell and sealed, which increases mechanical strength and reliability while preventing moisture. The internal switch tube is equipped with heat dissipation fins, which dissipate heat through the fan airflow.

The charger adopts a flyback architecture, using the Reactor Micro RM6500S primary control chip, Schottky diode rectification, and the output is controlled by the Huimang Micro MCU for charging. Both the input and output of the charger are equipped with fuses for overcurrent protection. Two NTCs are soldered onto the PCB for detecting airflow temperature and PCB temperature, respectively. Safety measures are in place.