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Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: remmie on August 30, 2014, 07:22:07 PM

Title: Another DIY Quick Charger
Post by: remmie on August 30, 2014, 07:22:07 PM
After seeing the DIY charger from DoctorBass with his 3 mean-well RSP2000 I decided to make a similar DIY charger for my 2014 Zero SR
The (relatively) high cost of the mean-well made me search for cheaper but suitable alternative.

After a lot of searching and comparing i ordered 2 TDK Lambda FPS-1000-48S power supplies. These power supplies  can be found on ebay for around 100$ each. I got mine from a bloke in Israel for a total of € 250 (shipping was quite expensive)
These power supplies are in size and weight exactly the same as the Mean-Well RSP-2000.
Downside is these power supplies have a very perculiar connector but by soldering the wires directly to the pins it can be done.

The block fits easily into a tank bag, weighs around 5 kilograms and during charging it hangs on the passenger foot peg to keep it slightly of the ground.
Much like the mean-well's the FPS-1000 delivers more than 1000 Watts (about 1200) as it's output power. (about 22 amps at 57 Volts)
There is also a connector for the onboard charger, so if i connect all 3 I can charge the bike with 22+13 = 35 Amps.
The total pack is 10kWh 100V 100Ah (4*25Ah) So 35 Amps of charging let's me charge the bike from 10% to 90% in slightly over 2 hours.
 
Total Power draw is just under 4 kW which is (just) suitable for a household 230V 16A connection. (230*16 = 3680W but the circuit breaker holds, even when charging for 2 hours)

I won't use it very often because my commute is just 27 km one way, but it is good to know that if we want to make a trip beyond 150 km we are able to have a lunch and charge the bike at the same time.
Title: Re: Another DIY Quick Charger
Post by: remmie on August 30, 2014, 07:23:09 PM
more pics
Title: Re: Another DIY Quick Charger
Post by: Doctorbass on August 30, 2014, 08:57:37 PM
Congrat!

 It's clean compact and powerfull! ;)

You can also connect the actual onboard charger to add 1300W ! I'm doing that too.

did you added parallel shottky diodes to each power supply connected in serie?

what max voltage do you get ? 114V ( 57x2) or di you tweaked a bit the output by playing with resistor on the pcb?

Doc

Title: Re: Another DIY Quick Charger
Post by: remmie on August 30, 2014, 11:35:21 PM
Yep, off course.

Attached is the basic schematic.
Both PSU's are set to 57 Volt and the senses lines make sure it's 114 Volts at the anderson connector.

These PSU also have I2C output, so i used that to add a 2x16 character LCD connected to an Atmel AVR microcontroller showing the output current and the output voltage, calculates the output power and also shows the chargers temperature. (all from the I2C interface)

The current stays at 22 A up to a voltage of 113,3 Volt (measured at the anderson connector) and then decreases rapidly in 8 minutes to 0 at a voltage of 114.0 Volt. The bike shows 95% at that point so that is excellent, I then let the onboard charger continue to do the balancing.


Title: Re: Another DIY Quick Charger
Post by: BrianTRice@gmail.com on September 02, 2014, 08:27:02 AM
Thanks for sharing this with schematic. I like that this is much closer to an off the shelf or kit-built unit than a hobbyist effort. The idea of soldering connections that will take a lot of amps is daunting. :)
Title: Re: Another DIY Quick Charger
Post by: remmie on September 06, 2014, 05:07:32 PM
And charging at a public charge point also works with a Mennekes type 2 to Schuko converter cable  :)
Title: Re: Another DIY Quick Charger
Post by: firepower on September 06, 2014, 06:07:09 PM
Can you mark on the PDF the Diodes ref D1 etc and list part numbers.
Title: Re: Another DIY Quick Charger
Post by: remmie on September 06, 2014, 06:23:06 PM
I have used MBR1660 Schottky diodes (TO-220) because I had them lying around.
Title: Re: Another DIY Quick Charger
Post by: camosoul on September 11, 2014, 10:23:57 PM
I'm not trying to be a jerk, but these numbers don't add up for me... 2x1200w != 4kw != 2hr charge time. It adds up to being only twice as fast as the built-in charger for my math... 4.5hr.

I'm interestex because I'm considering a Zero S and an doing research on fast charging since I will not buy the bike without a fast charger.
Title: Re: Another DIY Quick Charger
Post by: remmie on September 11, 2014, 11:02:30 PM
2x1200W (external charger) + 1300W (internal charger) = ~4kw
The 4 kW was measured power from the grid.

The 2 hours stated were from 10% to 90% (see original post) because you're hardly ever down below 10% before quickcharging and the last 10% takes longer because of balancing

35Amps of charging a 100Amphour pack for 80% :
80% * 100 Ah / 35 A = 2 hours 17 minutes and some seconds

Some may consider 17 minutes not to be 'slightly' but to me it is.  :) ;)

If you would need more charging power you can use 2 rsp2000-48 meanwells instead of the fps1000. They have exactly the same shape and weight. These however cost 450 dollars a piece instead of 100 but that's up to you. The 2 meanwells would give you 42A + 12A = 54A of charging a 100Ah pack.

1 hour and a half from 10 to 90%
Title: Re: Another DIY Quick Charger
Post by: ultrarnr on September 11, 2014, 11:05:37 PM
Camosoul,

Talk to Hollywood Electrics about fast chargers. Consider two of the 2500 watt Elcons. You mentioned in another post about J1772 outlets being few. So get 30 and 50 amp plugs so you can charge at campgrounds and RV parks. Benswing has done this a lot in his travels. I wouldn't bother with the 1KW chargers that Zero sells.

Title: Re: Another DIY Quick Charger
Post by: camosoul on September 14, 2014, 09:34:49 AM
Camosoul,

Talk to Hollywood Electrics about fast chargers. Consider two of the 2500 watt Elcons. You mentioned in another post about J1772 outlets being few. So get 30 and 50 amp plugs so you can charge at campgrounds and RV parks. Benswing has done this a lot in his travels. I wouldn't bother with the 1KW chargers that Zero sells.

Nothing against Hollywood Electrics or the Elcons. I'd just prefer to build something like this than buy it flat. Home plug will be a 50A RV outlet.your suggestions are alreadyvthe plan. Cinfirms I'm going the correct dirdction.

Plans are slightly adjusted. 2x RSP-2000-48 at max v. I can double that if I feel the need. Need to know fastest safe charge rate and temp monitor... Of course, this is tentative. Anticipating 2015 info on Oct 1st...
Title: Re: Another DIY Quick Charger
Post by: frode on April 23, 2015, 05:23:48 PM
Bringing back a dead thread...
Attached is the basic schematic.
Both PSU's are set to 57 Volt and the senses lines make sure it's 114 Volts at the anderson connector.

These PSU also have I2C output, so i used that to add a 2x16 character LCD connected to an Atmel AVR microcontroller showing the output current and the output voltage, calculates the output power and also shows the chargers temperature. (all from the I2C interface)
Great work!! But I have few questions since I am really interested in doing the same :D

The manual states this: "The I2C bus address lines, serial clock and data are referenced to the -Sense potential. When using series connection of FPS1000 units, do not connect the I2C  linesof the units together."
How did you wire this? Do you use two separate i2c-interfaces on the microcontroller?
What wire gauge did you use on the output and input cables?

Frode



Title: Re: Another DIY Quick Charger
Post by: firepower on April 23, 2015, 06:00:51 PM
Manual for FPS-1000-48S

http://www.tdk-lambda.com/products/sps/ps_unit/fps/pdf/fps_ins_e.pdf (http://www.tdk-lambda.com/products/sps/ps_unit/fps/pdf/fps_ins_e.pdf)

http://www.tdk-lambda.com/products/sps/ps_unit/fps/tec_mnue.html (http://www.tdk-lambda.com/products/sps/ps_unit/fps/tec_mnue.html)
Title: Re: Another DIY Quick Charger
Post by: frode on April 23, 2015, 06:24:58 PM
Manual for FPS-1000-48S

http://www.tdk-lambda.com/products/sps/ps_unit/fps/pdf/fps_ins_e.pdf (http://www.tdk-lambda.com/products/sps/ps_unit/fps/pdf/fps_ins_e.pdf)

http://www.tdk-lambda.com/products/sps/ps_unit/fps/tec_mnue.html (http://www.tdk-lambda.com/products/sps/ps_unit/fps/tec_mnue.html)

Thanks, but I have already read the manual. That was the reason I asked :)
Since manual says that the i2c bus should not be shared between two of these PSUs in series. 


Frode
Title: Re: Another DIY Quick Charger
Post by: firepower on April 23, 2015, 06:44:49 PM
Yes I would like more info too on how to use the I2C as well.
Title: Re: Another DIY Quick Charger
Post by: remmie on April 23, 2015, 11:07:25 PM
You're correct. You can't use both I2C together or you would have to have an isolated I2C to I2C converter.

I just used the I2C information from one PSU. The current is exactly the same between the 2 PSU's as they are in series. The temperature is from the PSU the I2C is connected to. The voltage is measured by a voltage divider connected to an analog input on the atmel microcontroller. also read from the I2C bus. This way i can show temperature, current and total voltage (multiply the I2C value by 2) and calculate and show power to the Battery .

The power for the microcontroller comes from the 12V 0.25A auxiliary (isolated) supply the PSU generates. Be sure to use a 12 to 5 volt converter as the maximum voltage for the microcontroller is 5.5 Volts.

The wire gauge for the output wire is 10mm2 I believe, i'm not really sure as it was a piece of super flexible Car audio amplifier wire I had lying around. The wire gauge for the input cable is 2.5mm2 which is standard for a 16A 230V supply we have here.
You could do with less than 10mm2 on the output wiring but don't go below about 4mm2 as both the voltage drop over the wire would become greater than the sense-lines can compensate for and the PSU charges less than it can. Also anything less than 2.5mm2 can fry your wire if charging with 22A !

In the mean time i switched from the standard 230V 16A connector to a Mennekes type 2 connector to be able to charge from a charging point here in Holland. This is a three phase connection which allowed me to wire each PSU to one phase and connect the internal charger to the remaining phase. This distributes the current much better than using all three on a single phase.

As described above the total of 2 PSU's plus the internal charger asks about 4000 watt from the charging station and connecting it all to a single phase can lead to tripping of the breaker. Wiring it all to a separate phase prevents tripping the breaker.

Title: Re: Another DIY Quick Charger
Post by: remmie on April 23, 2015, 11:15:52 PM
Here is the complete code (in MIKROE BASIC for AVR, use similar code for other programming languages)
Also amended the previous post because the voltage is also read from the I2C (assumed is that the other PSU has exactly the same voltage)

[code start]

program ZeroChargerReadout

' * Description:
'     This code shows the voltage, current and temperature on n FPS1000-48 PSU
'     initialized, then some text is written, then the text is moved.
' * Test configuration:
'     MCU:             ATTiny28L
'                      http://www.atmel.com/dyn/resources/prod_documents/doc2466.pdf (http://www.atmel.com/dyn/resources/prod_documents/doc2466.pdf)
'     Dev.Board:       EasyAVR6 -  ac:LCD
'                      http://www.mikroe.com/eng/products/view/321/easyavr6-development-system/ (http://www.mikroe.com/eng/products/view/321/easyavr6-development-system/)
'     Oscillator:      External Clock 08.0000 MHz
'module ZeroChargerReadout v2
'                      http://www.mikroe.com/eng/products/view/277/various-components/ (http://www.mikroe.com/eng/products/view/277/various-components/)
'     SW:              mikroBasic PRO for AVR
'                      http://www.mikroe.com/eng/products/view/226/mikrobasic-pro-for-avr/ (http://www.mikroe.com/eng/products/view/226/mikrobasic-pro-for-avr/)
' * NOTES:
'     - Turn on the LCD backlight on the EasyAVR6 board (SW10.7).
' *

' Declarations section

' LCD module connections
dim LCD_RS as sbit  at PORTD2_bit
dim LCD_EN as sbit  at PORTD3_bit
dim LCD_D4 as sbit  at PORTD4_bit
dim LCD_D5 as sbit  at PORTD5_bit
dim LCD_D6 as sbit  at PORTD6_bit
dim LCD_D7 as sbit  at PORTD7_bit

dim LCD_RS_Direction as sbit at DDD2_bit
dim LCD_EN_Direction as sbit at DDD3_bit
dim LCD_D4_Direction as sbit at DDD4_bit
dim LCD_D5_Direction as sbit at DDD5_bit
dim LCD_D6_Direction as sbit at DDD6_bit
dim LCD_D7_Direction as sbit at DDD7_bit
' End LCD module connections

' Software I2C connections
dim Soft_I2C_Scl_Output    as sbit at PORTD0_bit
dim Soft_I2C_Sda_Output    as sbit at PORTD1_bit
dim Soft_I2C_Scl_Input     as sbit at PIND0_bit
dim Soft_I2C_Sda_Input     as sbit at PIND1_bit
dim Soft_I2C_Scl_Direction as sbit at DDD0_bit
dim Soft_I2C_Sda_Direction as sbit at DDD1_bit
' End Software I2C connections

dim txt1,txt2 as char[16]
dim strvoltage as string[17]
dim strcurrent as string[17]
dim strtemperature as string[17]
dim strenergycalc as string[17]
dim strpower as string[17]
dim voltage as byte
dim current as byte
dim temperature as byte
dim channel4 as byte
dim voltagecalc as float
dim currentcalc as float
dim temperaturecalc as float
dim powercalc as float
dim energycalc as float
dim statusbyte as byte
dim displayrotation as byte

Main:
initialize:
    Lcd_Init()                                                                  ' Initialize LCD
    Lcd_Cmd(_LCD_CLEAR)                                                         ' Clear display
    Lcd_Cmd(_LCD_CURSOR_OFF)                                                    ' Cursor off
    LCD_Out(1,1,"Zero SR Charger")                                                           ' Write text in first row
    LCD_Out(2,1,"V2 Made by RH")                                                           ' Write text in second row
    Delay_ms(2000)                                                              ' Display splash screen for 1 second
    LCD_cmd(_LCD_Clear)                                                         ' Clear Display
    Soft_i2c_init()                                                             ' Initialize I2C bus
    Soft_i2c_Start()                                                            ' Issue start signal
    Soft_i2c_Write(0x9E)                                                        ' Address PCF8591, see PCF8591 datasheet
    Soft_I2c_Write(0x44)                                                        ' Set analog output and auto increment channel
    Soft_I2c_Stop()                                                             ' Close I2C bus
    displayrotation = 1                                                         ' Set display rotation byte
    energycalc = 0
loop:
while TRUE
read_I2C_analog:
    Soft_I2C_Start()            ' Issue start signal
    Soft_I2C_Write(0x9F)           ' Address PCF8591, see PCF8591 datasheet
    channel4 = Soft_I2c_Read(1)    ' first channel4 because it's always the result from the previous input (by design)
    voltage = Soft_I2C_Read(1)     ' Read voltage byte
    current = Soft_I2C_Read(1)     ' Read current byte
    temperature = Soft_I2C_Read(0) ' Read Temperature byte and send not ack to indicate last byte read
    Soft_I2C_Stop()                ' Issue stop signal

read_I2C_digital:
    Soft_I2C_Start()               ' Issue start signal
    Soft_I2C_Write(0x4F)           ' Address PCF8574, see PCF8574 datasheet
    statusbyte = Soft_I2C_Read(0)    ' first channel4 because it's always the result from the previous input (by design)
    Soft_I2C_Stop()                ' Issue stop signal

Calculations:
    voltagecalc = voltage*2.0*60.0/255.0                 '8 bit resolution up to 60 Volts
    floattostr(voltagecalc,strvoltage)               'convert to a string
    strvoltage[5]=0                                  'truncate the first 5 characters of the string

    currentcalc = current*25.0/255.0                                            ' 8 bit resolution up to 25 Amps
    floattostr(currentcalc,strcurrent)                                          ' convert to a string
    strcurrent[4]=0                                                             ' truncate to first 4 characters of the string

    temperaturecalc = temperature*100.0/255.0                                   ' 8 bit resolution up to 100 degrees celcius
    floattostr(temperaturecalc,strtemperature)                                  ' convert to a string
    strtemperature[4]=0                                                         ' truncate to the first 4 characters

    powercalc = voltagecalc*currentcalc/1000                                         ' calculate power from voltage * current and divide by 1000 to get kW
    floattostr(powercalc,strpower)                                              ' convert to a string
    strpower[4]=0                                                               ' truncate the first 4 characters of the string
 
    energycalc = energycalc + powercalc/3600
    floattostr(energycalc,strenergycalc)
    strenergycalc[5]=0
    statusbyte =statusbyte or 96
 
 displayoutput:
    txt1 = "V=" + strvoltage + "V I=" + strcurrent + "A"                        ' first line of the LCD : always displays the Voltage and Current
    txt1[16]=0                                                                  ' truncate to 16 characters if neccessary to avoid weird screens
    LCD_Out(1,1,txt1)                                                           ' Write text in first row

    statusbyte = statusbyte and displayrotation                                 ' check 1 alarm each loop (displayrotation shifts one bit to the left each loop)
    Select case statusbyte
      case 1                                                                    ' output fail
        txt2="Output Fail     "
      Case 2                                                                    ' overtemp protect
        txt2="Overtemp Protect"
      Case 4                                                                    ' Temperature alarm
        txt2="Temp alarm      "
      Case 8                                                                    ' Fan Fail
        txt2="Fan Fail        "
      Case 16                                                                   ' Input Fail
        txt2="Input Fail      "
      Case 32
        txt2="E=" + strenergycalc + "kWh      "
      Case 64
        txt2="E=" + strenergycalc + "kWh      "
      Case else
        txt2 = "P=" + strpower + "kW T=" + strtemperature + "C"                 ' this line is displayed if
    End select
    txt2[16]=0                                                                  'truncate to 16 characters if neccessary to avoid weird screens
    LCD_Out(2,1,txt2)                                                           ' Write text in second row

    displayrotation = displayrotation *2                                        ' Shift displayrotation one bit to left
    if displayrotation = 128 then displayrotation = 1                            ' the second line shifts through 6 possible displays, 1 for each of 5 alarms and 1 for the power and temperature
    end if
    delay_ms(980)                                                                'rest of the cycle is about 20ms, this generates a more excact 1 sec timebase without using interrupts :)
wend
end.
Title: Re: Another DIY Quick Charger
Post by: firepower on April 24, 2015, 04:41:29 AM
Thanks for sharing your code and info of I2C.

The PCF8591 and PCF8574 are they the I2C devices in the Powersupply your monitoring?

http://www.nxp.com/documents/data_sheet/PCF8591.pdf (http://www.nxp.com/documents/data_sheet/PCF8591.pdf)
http://www.nxp.com/documents/data_sheet/PCF8574.pdf (http://www.nxp.com/documents/data_sheet/PCF8574.pdf)
Title: Re: Another DIY Quick Charger
Post by: MotoRyder on April 24, 2015, 10:03:59 AM
Hey firepower,
(If I'm covering things you already know, then the following may help others on the forum.)

Those two devices (PCF8591  &  PCF8574) almost certainly reside on the  EasyAVR6  Dev  Board (I haven't checked the board schematic, but have seen many, so taking an educated guess).
 
The  EasyAVR6  is a general purpose Printed Circuit Board Assembly (PCBA) that the manufacturer (Atmel) devises for people to investigate their microcircuits and prototype with, such as the  ATTiny28L MCU utilized here (MCU stands for Micro-Controller Unit). 

The PCF8591  is  8-bit A/D (Analog to Digital) and D/A (Digital to Analog) converter.
The voltage is measured and then converted to a digital number (with the A/D portion of the chip) to obtain the value to display on the digital LCD display.

The PCF8574 Remote 8-bit I/O expander for I2C-bus
is a parallel 8-bit port that changes the 8-bits wide 'Voltage' data into a serial stream of data, because the data is transmitted on the I2C-bus to get it into the MCU to be processed.

If anything else other than this same circuit is used for processing the data for the display, then one would be able to use remmie's code as an example to generate their own program because it is commented very well so it can be 'ported' to a different processor.
Title: Re: Another DIY Quick Charger
Post by: zerovolt on April 24, 2015, 10:51:11 AM
hi Remmie,

how do you activate the contactor to begin the flowing charge? On the picture of you charger , i dont see nothing
at the small pins in the center of your anderson connector.

tanks !
Title: Re: Another DIY Quick Charger
Post by: frode on April 24, 2015, 03:01:02 PM
You're correct. You can't use both I2C together or you would have to have an isolated I2C to I2C converter.

I just used the I2C information from one PSU. The current is exactly the same between the 2 PSU's as they are in series. The temperature is from the PSU the I2C is connected to. The voltage is measured by a voltage divider connected to an analog input on the atmel microcontroller. also read from the I2C bus. This way i can show temperature, current and total voltage (multiply the I2C value by 2) and calculate and show power to the Battery .

The power for the microcontroller comes from the 12V 0.25A auxiliary (isolated) supply the PSU generates. Be sure to use a 12 to 5 volt converter as the maximum voltage for the microcontroller is 5.5 Volts.

The wire gauge for the output wire is 10mm2 I believe, i'm not really sure as it was a piece of super flexible Car audio amplifier wire I had lying around. The wire gauge for the input cable is 2.5mm2 which is standard for a 16A 230V supply we have here.
You could do with less than 10mm2 on the output wiring but don't go below about 4mm2 as both the voltage drop over the wire would become greater than the sense-lines can compensate for and the PSU charges less than it can. Also anything less than 2.5mm2 can fry your wire if charging with 22A !

In the mean time i switched from the standard 230V 16A connector to a Mennekes type 2 connector to be able to charge from a charging point here in Holland. This is a three phase connection which allowed me to wire each PSU to one phase and connect the internal charger to the remaining phase. This distributes the current much better than using all three on a single phase.

As described above the total of 2 PSU's plus the internal charger asks about 4000 watt from the charging station and connecting it all to a single phase can lead to tripping of the breaker. Wiring it all to a separate phase prevents tripping the breaker.
Thank you for explaining this! I have a lot of experience in micro-controller dev and PCB-design, but not with voltage levels above 24V :)
And really nice of you to share the source code for the micro!

Title: Re: Another DIY Quick Charger
Post by: remmie on April 24, 2015, 09:25:27 PM
The 2 pcf ic's are not on the easy avr dev board but integrated in the PSU. One is used to measure voltage, current and temperature (1 pcs 4 channel 8 bit a/d converter) the other pcf is for status of the PSU (see code or PSU datasheet for details)

i use the internal charger to activate the contactor and do not use the 2 additional pins on the anderson connector.

So the I2c part is really easy. 5v converter, microcontroller, lcd and  Enclosure.
Title: Re: Another DIY Quick Charger
Post by: frode on April 27, 2015, 02:47:17 PM
So the I2c part is really easy. 5v converter, microcontroller, lcd and  Enclosure.
Do you use pin 10 (signal return) as ground reference for your 5v voltage regulator and microcontroller board?

Title: Re: Another DIY Quick Charger
Post by: remmie on April 27, 2015, 03:41:06 PM
Yes, correct

Also -sense is connected to this pin sigal return as -sense is the referencepin for the I2C

This is the reason that you cannot use  both I2C signal from 2 PSU's in series.
Title: Re: Another DIY Quick Charger
Post by: Ronen on April 28, 2015, 04:11:17 PM
Hi Remmie,

Thank you for all the information.
I plan to use your schematic and make that quick charger but without the I2C.
Did you use a 50K potentiometer to adjust the voltage? do i need a special potentiometer?
what do you mean when you draw 2 diodes together at the top of the schematic (connect to PSU1-1_V+)?
Can you please give more closer pictures?

Thanks, Ronen.
Title: Re: Another DIY Quick Charger
Post by: remmie on April 28, 2015, 04:17:49 PM
Yes i used a 50k potmeter. I used a multiturn  trimpormetertype for more accuracy
The 2 diodes were because i used mbr1660 diodes with a max current of 16A. Therefore 2 to distribute the current. I had them lying around.

If you would use a diode with a higher current rating you would only need one.
Title: Re: Another DIY Quick Charger
Post by: zerovolt on April 28, 2015, 05:49:22 PM
Hi Remmie,
Are these diodes very important, because there is no inductive load? probably never reverse current.... :)

Thanks
Title: Re: Another DIY Quick Charger
Post by: Ronen on April 29, 2015, 12:39:24 PM
Hi Remmie.

Thanks again!
Can you please give more closer photos?
Title: Re: Another DIY Quick Charger
Post by: Doug S on April 29, 2015, 08:25:58 PM
Are these diodes very important, because there is no inductive load? probably never reverse current.... :)

Inductive kickback isn't the problem. The diodes prevent reverse voltage on the power supplies from occurring. When the supplies are turned off, you need to isolate them from the battery, or you'll have the battery voltage impressed on the power supplies instead of the other way around. Also, if you have a power supply fail, and for a brief period at turn-on (the two supplies are not going to turn on at exactly the same time), there will be just one power supply trying to apply 57 volts onto a 103V battery. The diodes are cheap insurance against that happening.
Title: Re: Another DIY Quick Charger
Post by: trikester on April 30, 2015, 01:08:52 AM
I was wondering about the diodes also. Thanks for the explanation. I have two Mean Well supplies in series without diodes and have not had any problem with having the battery voltage at the supply outputs when they're off, but as you say it would be good practice. However, in case of a supply failure the Shottky diodes would probably fail under the high reverse voltage unless they have greatly increased Shottky diode voltage ratings since I last used them in a design. For complete protection the diodes should be at least 150 VDC reverse rated. Do they make Shottky diodes that high now (I've been retired for 15 years)?

Trikester
Title: Re: Another DIY Quick Charger
Post by: Doug S on April 30, 2015, 01:18:02 AM
Do they make Shottky diodes that high now (I've been retired for 15 years)?

Oh yeah. Quite a bit higher, in fact, and plenty of current capability, even in surface mount packages. Since you've been retired for 15 years, perhaps you need to be introduced to today's EE's best friend: The Digikey search utility. Here I've specified a couple of parameters (voltage > 150 and current > 50A), but you can specify exactly the specs you need, RoHS compliance, in what package you want it, in singles or on reel, select a mfr or mfrs if you wish, and sort by price, quantity in stock, or just about anything else. Type in any search word or partial part number if you want to start a search from scratch. It's just wicked cool.

http://www.digikey.com/product-search/en?pv914=37&pv914=60&pv914=312&pv914=65&pv914=43&pv914=343&pv914=347&pv914=313&pv914=216&pv914=80&pv914=344&pv914=339&FV=fff40015%2Cfff8007f%2Ce500005%2Ce500006%2Ce500007%2Ce500013%2Ce50001b%2Ce50001d%2Ce500023%2Ce50006f%2Ce500082%2Ce50008f&k=schottky&mnonly=0&newproducts=0&ColumnSort=0&page=1&stock=1&rohs=1&quantity=0&ptm=0&fid=0&pageSize=25 (http://www.digikey.com/product-search/en?pv914=37&pv914=60&pv914=312&pv914=65&pv914=43&pv914=343&pv914=347&pv914=313&pv914=216&pv914=80&pv914=344&pv914=339&FV=fff40015%2Cfff8007f%2Ce500005%2Ce500006%2Ce500007%2Ce500013%2Ce50001b%2Ce50001d%2Ce500023%2Ce50006f%2Ce500082%2Ce50008f&k=schottky&mnonly=0&newproducts=0&ColumnSort=0&page=1&stock=1&rohs=1&quantity=0&ptm=0&fid=0&pageSize=25)
Title: Re: Another DIY Quick Charger
Post by: MotoRyder on April 30, 2015, 02:45:46 AM
+1 on the recommendation for Digi-Key's website.
I was probably online searching their site while Doug S was doing the same.
I was going to make a similar recommendation, however with 1000's of devices to choose from, more specific parameters would be needed.
Too Much Fun Indeed in devising Another DIY Quick Charger.
Title: Re: Another DIY Quick Charger
Post by: trikester on May 01, 2015, 02:15:04 AM
Gees! I remember when Digi-Key was just a small distributor. But even back then the thing that was great about them was that they would sell to individuals. Most electronic distributors, back in those days, would only sell to you if you were buying through an OEM.

Good to know that there are HV shottky's now. However, I'm sure the forward voltage drop is higher than the low voltage ones I used (that's how the physics works). How much better is the forward drop than a "regular" silicon diode of a similar RV and current rating?

Trikester
Title: Re: Another DIY Quick Charger
Post by: pulsartaildragger on May 04, 2015, 04:31:20 AM
H regime, I like your idea for power supplier. I would like to make one for my 2014 . Sr I would like to run it on single phase 220. I assume you run one hot wire to each psu pin 23. Each psu is running on 110 volt. On the out put  pin v+ 1 2 4  is each  pin supplying 7.3 amps output in order to get 22 amps total? 

Title: Re: Another DIY Quick Charger
Post by: Ronen on May 19, 2015, 06:29:13 PM
I almost finished to build it just need the SBS75XBRN connctor.
Small question, I understand that the connector is http://www.mouser.com/ProductDetail/Anderson-Power-Products/SBS75XBRN/?qs=sGAEpiMZZMtjzVbpKqo2YSP9yhNX%252bXMWJdsZ56J4zvk%3d (http://www.mouser.com/ProductDetail/Anderson-Power-Products/SBS75XBRN/?qs=sGAEpiMZZMtjzVbpKqo2YSP9yhNX%252bXMWJdsZ56J4zvk%3d) do I need to order the pins to it? if yes, what are the correct pins this http://www.mouser.com/Search/ProductDetail.aspx?R=1339g1virtualkey57880000virtualkey879-1339G1 (http://www.mouser.com/Search/ProductDetail.aspx?R=1339g1virtualkey57880000virtualkey879-1339G1) or that http://www.mouser.com/Search/ProductDetail.aspx?R=1339g2virtualkey57880000virtualkey879-1339G2 (http://www.mouser.com/Search/ProductDetail.aspx?R=1339g2virtualkey57880000virtualkey879-1339G2)?

Thanks!
Title: Re: Another DIY Quick Charger
Post by: Burton on May 19, 2015, 07:05:27 PM
This might help Ronen

http://electricmotorcycleforum.com/boards/index.php?topic=4603.msg30589#msg30589 (http://electricmotorcycleforum.com/boards/index.php?topic=4603.msg30589#msg30589)
Title: Re: Another DIY Quick Charger
Post by: Ronen on May 19, 2015, 07:26:03 PM
Thanks, Burton, I saw it but still confused...
Title: Re: Another DIY Quick Charger
Post by: Ronen on July 21, 2015, 10:27:58 PM
Hi Remmie,

Just got the connector now and tested it.
It works great, but it got very hot, is it normal?

Thanks.
Title: Re: Another DIY Quick Charger
Post by: TomerBA on June 02, 2016, 01:36:57 AM
Not sure I understand correctly, so I'm asking here... and DC supply of ~100V can be used for fast charging?
If I'll buy this one:
http://www.alibaba.com/product-detail/1-year-warranty-high-power-3kw_60384617221.html?spm=a2700.7724857.29.9.vWFDEF&s=p (http://www.alibaba.com/product-detail/1-year-warranty-high-power-3kw_60384617221.html?spm=a2700.7724857.29.9.vWFDEF&s=p)
And just add the correct plug to charge my FX, I'll have 3KW charger for 600$??

Thanks in advance, and sorry if I asked stupid question :-)
Tomer
Title: Re: Another DIY Quick Charger
Post by: remmie on June 02, 2016, 02:14:21 AM
Not sure I understand correctly, so I'm asking here... and DC supply of ~100V can be used for fast charging?
If I'll buy this one:
http://www.alibaba.com/product-detail/1-year-warranty-high-power-3kw_60384617221.html?spm=a2700.7724857.29.9.vWFDEF&s=p (http://www.alibaba.com/product-detail/1-year-warranty-high-power-3kw_60384617221.html?spm=a2700.7724857.29.9.vWFDEF&s=p)
And just add the correct plug to charge my FX, I'll have 3KW charger for 600$??

Thanks in advance, and sorry if I asked stupid question :-)
Tomer

100Vdc is not gonna be enough, 100V dc is only about 25% SOC. You need around 112-114 Volt DC to reach 90%
Title: Re: Another DIY Quick Charger
Post by: TomerBA on July 25, 2016, 06:10:12 PM
No stock of Anderson SBS75 connector?
Tried the major suggestion in this forum, mouser, lead time is 11 weeks...
http://www.mouser.co.il/Search/ProductDetail.aspx?R=SBS75XBRNvirtualkey57880000virtualkey879-SBS75XBRN (http://www.mouser.co.il/Search/ProductDetail.aspx?R=SBS75XBRNvirtualkey57880000virtualkey879-SBS75XBRN)

any other vendor / other part that is compatible?

Thanks
Tomer
Title: Re: Another DIY Quick Charger
Post by: TomerBA on August 14, 2016, 05:19:53 PM
Answering my own question  :)
after consulting with Mouser representative,
that's what I've ordered:

Mouser Part Number

879-1339G3 http://www.mouser.co.il/ProductDetail/Anderson-Power-Products/1339G3-BK/?qs=sGAEpiMZZMtjzVbpKqo2YZRH3O%252bLIhj7jkKVyDeq%252b7Q%3d (http://www.mouser.co.il/ProductDetail/Anderson-Power-Products/1339G3-BK/?qs=sGAEpiMZZMtjzVbpKqo2YZRH3O%252bLIhj7jkKVyDeq%252b7Q%3d)
879-SBS75XCLP1-BKhttp://www.mouser.co.il/ProductDetail/Anderson-Power-Products/PSBS75XCLP1/?qs=sGAEpiMZZMtjzVbpKqo2Yc8093%2fw3b0t9dL1X6P8TsI%3d (http://www.mouser.co.il/ProductDetail/Anderson-Power-Products/PSBS75XCLP1/?qs=sGAEpiMZZMtjzVbpKqo2Yc8093%2fw3b0t9dL1X6P8TsI%3d)
879-SBS75XBRN-BK http://www.mouser.co.il/ProductDetail/Anderson-Power-Products/SBS75XBRN-BK/?qs=sGAEpiMZZMtjzVbpKqo2YSgTPamdpnrnmQKL7cEes88%3d (http://www.mouser.co.il/ProductDetail/Anderson-Power-Products/SBS75XBRN-BK/?qs=sGAEpiMZZMtjzVbpKqo2YSgTPamdpnrnmQKL7cEes88%3d)

All available in stock

 
Title: Re: Another DIY Quick Charger
Post by: Shadow on August 14, 2016, 08:17:24 PM
also could have a look at powerwerx.com for powerpole connectors (as commonly used by amateur emergency 2-way radio operators).
Title: Re: Another DIY Quick Charger
Post by: wijnand71 on November 02, 2016, 03:25:02 AM
I'm busy collecting stuff for my 2 Eltek HE charger setup (Thanks Remmie for all your work, Ronen, Burton and TomerBA for the shopping list  ;D) and was wondering if the two little pins in the middle of the brown Anderson connector should be wired or not. I believe the chargers from Holywood Electrics are using them?

(https://dl.dropboxusercontent.com/u/14638644/Zero_Anderson.jpg)
Title: Re: Another DIY Quick Charger
Post by: BrianTRice@gmail.com on November 02, 2016, 04:49:22 AM
I'm busy collecting stuff for my 2 Eltek HE charger setup (Thanks Remmie for all your work, Ronen, Burton and TomerBA for the shopping list  ;D) and was wondering if the two little pins in the middle of the brown Anderson connector should be wired or not. I believe the chargers from Holywood Electrics are using them?

Yes, they are. Evtricity figured out what's going on at least for 2014 models here:
http://electricmotorcycleforum.com/boards/index.php?topic=6167.msg48993#msg48993 (http://electricmotorcycleforum.com/boards/index.php?topic=6167.msg48993#msg48993)

Also copied to the wiki (end of the Charger section):
http://zeromanual.com/index.php/Unofficial_Service_Manual#Charger (http://zeromanual.com/index.php/Unofficial_Service_Manual#Charger)
Title: Re: Another DIY Quick Charger
Post by: wijnand71 on November 02, 2016, 11:28:07 PM
Really? Isn't he talking about another connector? I'm talking about the Brown Aux port. And I leave my onboard charger just in place and use this one to close the contactor. Parallel to this I want to charge via this brown Aux port. In the posts of Remmie I can't find any hints about the usage of these middle pins..
Title: Re: Another DIY Quick Charger
Post by: BrianTRice@gmail.com on November 03, 2016, 03:49:25 AM
Sure, it's not a direct recipe for emulation. I don't have verified information to relay.
Title: Re: Another DIY Quick Charger
Post by: remmie on November 03, 2016, 03:28:30 PM
Really? Isn't he talking about another connector? I'm talking about the Brown Aux port. And I leave my onboard charger just in place and use this one to close the contactor. Parallel to this I want to charge via this brown Aux port. In the posts of Remmie I can't find any hints about the usage of these middle pins..

As described in the other threads : I don't use the middle pins. I let the onboard charger activate the contactor and just use the 2 main contacts of the brown aux charging connector