Tried my new homemade supercharger yesterday. (Wintertime is tinkering time

)

Managed to charge with 83 ! Amps from 52% to 90% in under 30 minutes

For my first attempt at a fast-charger see :

http://electricmotorcycleforum.com/boards/index.php?topic=3949.msg24310#msg24310The following data is from the Zero App (ZF11.4 battery pack, 10.500 kWh capacity reported by the Zero App)

18:40 52% SOC, 0:30 to full charge, 83 Amps, 8628 Watt

18:46 60% SOC, 0:25 to full charge, 83 Amps, 8801 Watt

18:48 65% SOC, 0:22 to full charge, 83 Amps, 8863 Watt

18:52 70% SOC, 0:20 to full charge, 78 Amps, 8431 Watt

18:56 75% SOC, 0:16 to full charge, 78 Amps, 8554 Watt

19:00 80% SOC, 0:13 to full charge, 78 Amps, 8693 Watt

19:04 85% SOC, 0:10 to full charge, 78 Amps, 8805 Watt

19:05 87% SOC, 0:10 to full charge, 67 Amps, 7601 Watt, this is where the rectifiers started tapering off (reduce their current because constant voltage is reached)

19:08 89% SOC, 0:12 to full charge, 51 Amps, 5804 Watt

19:09 90% SOC, 0:13 to full charge, 46 Amps, 5244 Watt

So from 52% to 87% (+35%) in 25 minutes would mean 84% per hour

My Homemade 'supercharger' consists of 2 sets of Eltek Flatpack rectifiers.

The first set is a Flatpack S charger (48 Volts 1800 Watts) and a Eltek flatpack 2 HE rectifier (48V 2000W)

The second set are 2 pcs Eltek flatpack 2 HE rectifiers (48V 2000W)

These rectifiers are Constant voltage, constant current, constant power and feature an internal "reverse current diode" (ask me how i know

)

max current of the flatpack S is 1800/48 = 37.5 Amps when below 48 Volts and 1800 Watts above 48 Volts (sadly no overcurrent possibility as with the mean well RSP2000)

max current of the Eltek Flatpack 2 HE is 2000/48 = 41.7 Amps when output is below 48 Volts

All rectifiers have been reprogrammed to have a default output voltage of 57.0 Volts (factory default is 53.5 Volts) with each 2 in series a total output voltage of 114 Volts which is around 90% SOC for the Zero. (follow how the reprogramming was done in the following thread on endless-sphere :

https://endless-sphere.com/forums/viewtopic.php?f=14&t=71139 )

The flatpack 2 HE rectifiers can be sourced from eBay between 100 and 200 euro's each. Unfortunately the much smaller and lighter flatpack S cannot but maybe in due time.

The charger setup consists of :

* type 2 mennekes plug for 32Amps (standard in europe for 3 phase 400 VAC, each phase-neutral 230 VAC) with a 680 Ohm resistor between PP and PE to ask for 20A charging power and a 880 Ohm resistor and diode between CP and PE to indicate "ready for charging". Reference :

http://visforvoltage.org/forum/13357-mennekes-type-2-plug-officially-not-vectrix* 5G1.5mm2 PUR cable to carry the 3 phase voltage to the rectifiers and onboard charger lead

* Lead for onboard charger (1300 Watt) on phase 1 (this also takes care of engaging the contactor)

* the Flatpack S on phase 2 (1800 Watt)

* the first Flatpack2 HE on phase 3 (2000 Watt)

* the second Flatpack2 HE on phase 1 (2000 Watt)

* the third Flatpack2 HE on phase 2 (2000 Watt)

* 10mm2 (8 AWG) cables to the anderson connector, these are highly flexible amplifier power leads commonly found in any Car-HIFI store

* Anderson SBS75X-BRN connector for the fast charging port on the Zero.

All the rectifiers (and onboard charger) are spread as evenly as possible on each of the three phases (L1 = 3300 Watt, L2 = 3800 Watt, L3 = 2000 Watt)

It (just) fits into a simple tankbag to easily take it on longer trips.

I've also set it up so I can take either of the 2 sets to reduce weight (at the expense of less charging power)

I have to do some more testing from lower SOC, that would theoretically increase the amps above the stated 83 Amps, at 0% SOC the voltage is around 96 Volts where the rectifiers can deliver their maximum current of 37,5 and 41,7 amps. Together with the 12A onboard charger this would deliver 91 Amps. And that's pretty close to the charge fuse of 100A. I hope i don't blow that one

It is by no means a waterproof setup because the rectifiers are air-cooled by fans but i don't ride in the rain anyway.