🛠 TEARDOWN: LiIon Battery Charger HZ-48V 168W 54.6V 3A
Intro
Let's look inside the super cheap ebike 48V battery charger, typically charger like these come with the vehicle.
Specs
- Li-Ion Battery Charger
- Model: HZ-48V
- Input: 110-240VAC 50/60Hz
- Input Power: 168W
- Output: 54.6VDC 3A
- Size (case): L170mm x W74.4mm x H30mm
- Indicator: LED (green — charged and disconnected and red — charging)
Aliexpress
| Check DC connector and AC plug type | 🛒 54.6V 3A Lithium Battery Charger 48V 13S Kugoo G1 Charger High quality Li-ion Battery pack Charger With Connectors |
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Teardown
The maximum voltage for common LiIon rechargeable batteries is 4.2V.
So, since output is 54.6V it's designed for:
VOUT.MAX/LiIon.MAX = 54.6V/4.2V = 13 cells in series
Housing
To dissassemble it you need to remove stickers and unscrewed two screws.
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Cables
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Board
- 143.7mm x 70mm
- Synthetic resin bonded paper (SRBP) (not FR-4)
- H=1.6mm
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Components
 | Diode Bridge |
 | AC Input protections: varistor and fuse
|
 | AC Input protections: thermistor
|
 | PWM Controller
|
 | MOSFET
|
 | Optocoupler
|
 | Diode
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| Operational Amplifier (OpAmp)
|
 | Reference Voltage Source
|
 | Fan connected using connector |
 | BLDC Cooling Fan
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Conclusions
| 🟢 | High power dissipation components (FET, diode) has small aluminum heatsinks, so cooling fan is mandatory (but noisy) |
| 🟡 | When current is low (up to ~500mA) the charger shows green indication |