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Author Topic: Another DIY Quick Charger  (Read 6445 times)

remmie

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Another DIY Quick Charger
« 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.
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Black Zero SR 2014 11.4 kWh
Homemade "Supercharger" 4x eltek Flatpack S (8.5 kW including the onboard charger)

remmie

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Re: Another DIY Quick Charger
« Reply #1 on: August 30, 2014, 07:23:09 PM »

more pics
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Black Zero SR 2014 11.4 kWh
Homemade "Supercharger" 4x eltek Flatpack S (8.5 kW including the onboard charger)

Doctorbass

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Re: Another DIY Quick Charger
« Reply #2 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

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remmie

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Re: Another DIY Quick Charger
« Reply #3 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.


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Black Zero SR 2014 11.4 kWh
Homemade "Supercharger" 4x eltek Flatpack S (8.5 kW including the onboard charger)

BrianTRice

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Re: Another DIY Quick Charger
« Reply #4 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. :)
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remmie

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Re: Another DIY Quick Charger
« Reply #5 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  :)
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Black Zero SR 2014 11.4 kWh
Homemade "Supercharger" 4x eltek Flatpack S (8.5 kW including the onboard charger)

firepower

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Re: Another DIY Quick Charger
« Reply #6 on: September 06, 2014, 06:07:09 PM »

Can you mark on the PDF the Diodes ref D1 etc and list part numbers.
« Last Edit: September 07, 2014, 07:14:04 AM by firepower »
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remmie

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Re: Another DIY Quick Charger
« Reply #7 on: September 06, 2014, 06:23:06 PM »

I have used MBR1660 Schottky diodes (TO-220) because I had them lying around.
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Black Zero SR 2014 11.4 kWh
Homemade "Supercharger" 4x eltek Flatpack S (8.5 kW including the onboard charger)

camosoul

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Re: Another DIY Quick Charger
« Reply #8 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.
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remmie

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Re: Another DIY Quick Charger
« Reply #9 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%
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Black Zero SR 2014 11.4 kWh
Homemade "Supercharger" 4x eltek Flatpack S (8.5 kW including the onboard charger)

ultrarnr

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Re: Another DIY Quick Charger
« Reply #10 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.

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camosoul

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Re: Another DIY Quick Charger
« Reply #11 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...
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frode

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Re: Another DIY Quick Charger
« Reply #12 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



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firepower

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« Last Edit: April 23, 2015, 06:08:45 PM by firepower »
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frode

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Re: Another DIY Quick Charger
« Reply #14 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/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
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