After completing my first and second attempt at a fast charger for my 2014 Zero SR :http://electricmotorcycleforum.com/boards/index.php?topic=3949.0http://electricmotorcycleforum.com/boards/index.php?topic=5763.msg49366#msg49366
I kept searching and trying to get quotes in for a couple of Eltek Flatpack S units instead of the Flatpack 2 HE units.
The Flatpack S is an icredibly small rectifier with 1800 W of output power which is only 72x42x217mm (2.83x1.63x8.54) "tall" and weighs only 850 grammes (1.9 lbs)
I already had one of those in the 'supercharger' version 1.
My Homemade 'supercharger' version 2 now consists of 2 sets of 2 Eltek Flatpack S rectifiers with their output wired in series.
These rectifiers are Constant voltage, constant current, constant power and feature an internal "reverse current diode"
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)
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
This means that at the highest SOC (57 Volts) the output current equals 1800 W / 57 V = 31.5 A
The flatpack S rectifiers were not cheap (360 euro's including VAT each) but are so incredibly small, i just had to have them.
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 first set of 2 Flatpack S rectifiers on phase 2 (2x1800 Watt)
* the second set of 2 Flatpack S rectifiers on phase 3 (2x1800 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 = 1300 Watt, L2 = 3600 Watt, L3 = 3600 Watt)
The real plus here is that they fit comfortably in the "Frunk" tank bag of a Zero without having to carry an extra tank bag.
However i also wanted to carry a motorcycle lock in there and that was not possible without a small and easy modification.
I just cut off the tank bag about an inch from the top and screwed the top ring into the cavity where the tank bag is inserted. It still works like it did before but I now have just a little more room to place the charger and the motorcycle lock. I also made a separation consisting of an aluminium plate to be able to keep the lock in the frunk and be able to put in the charger more easily.
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.
The charger can be placed on the passenger footrest to keep it of the ground.
This charger is a little bit less powerful than the version 1 because of the use of 1800W rectifiers instead of 2000 W, but much smaller and easier to take with me.
for comparison :
Version 1 :
1x1300 W (onboard) / 12 A
1x1800 W (FP S) / 37.5 A max
3x2000 W (FP 2 HE) / 41.6 A max
Total max current (at lower SOC) = 12 + 37.5 + 41.6 = 91 Amps
Total power (at higher SOC) = 1300+1800+3x2000 = 9.1 kW
Version 2 :
1x1300 W (onboard) / 12 A
4x1800 W (FP S) / 37.5 A max
Total max current (at lower SOC) = 12 + 37.5 + 37.5 = 87 Amps
Total max power (at higher SOC) = 1300 + 4x1800 = 8.5 kW
So not too much difference there.