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Author Topic: My homemade 'Supercharger' for a ZERO Version 2  (Read 12205 times)

remmie

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My homemade 'Supercharger' for a ZERO Version 2
« on: November 16, 2016, 02:10:57 AM »

EDIT :

HERE THE LINK FOR PROGRAMMING THE DEFAULT VOLTAGE

http://electricmotorcycleforum.com/boards/index.php?topic=6405.msg58171#msg58171

-------

After completing my first and second attempt at a fast charger for my 2014 Zero SR :

http://electricmotorcycleforum.com/boards/index.php?topic=3949.0
http://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.
« Last Edit: June 22, 2017, 02:02:30 AM by remmie »
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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: My homemade 'Supercharger' for a ZERO Version 2
« Reply #1 on: November 16, 2016, 02:12:46 AM »

some more pictures.
Charging with 8.5 kW  8)
« Last Edit: November 16, 2016, 02:14:54 AM by remmie »
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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: My homemade 'Supercharger' for a ZERO Version 2
« Reply #2 on: November 16, 2016, 02:14:04 AM »

and the charger with motorcycle lock in the "frunk"
« Last Edit: November 16, 2016, 02:21:57 AM by remmie »
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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: My homemade 'Supercharger' for a ZERO Version 2
« Reply #3 on: November 16, 2016, 02:15:22 AM »

and 1 more of the small display i managed to sqeeze inside 1 of the Flatpack S (really very little room in there).

It displays
In and outlet temperature
in and outputvoltage
output current
calculated output power

Remark after comment of Kucho : the picture shows the display in the flatpack S when it was still part of the version 1 charger consisting of 1 Flatpack S and 3 Flatpack 2 HE.
In version 1 I could split the complete charger in 1x FPS+1xFP2HE and 2xFP2HE. The picture shows 1FPS and 1 FP2HE
It is now integrated into the 2S2P configuration of the 4 Flatpack S rectiefiers.
« Last Edit: November 16, 2016, 06:14:23 PM by remmie »
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Black Zero SR 2014 11.4 kWh
Homemade "Supercharger" 4x eltek Flatpack S (8.5 kW including the onboard charger)

Lenny

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Re: My homemade 'Supercharger' for a ZERO Version 2
« Reply #4 on: November 16, 2016, 02:52:16 AM »

Remmie this is amazing, can't believe how small it is. Looks like a perfect fast charging solution. How much amps to you get on phase 2&3? Slightly above 16 A I guess? Only thing missing is to make it weatherproof so you could mount it to the motorcycle. Did you buy the rectifiers brand new?

On a 22 kW charge point you could easily top up the setup with another pair on phase 1 with 12 kW in total then, which would be close to the max if you don't want to exceed 1C.

Great work!

Edit: I just noticed your Typ2 plug looks very small. Did you modify it on your own or did you buy a different one?
« Last Edit: November 16, 2016, 03:13:54 AM by Lenny »
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Zero FXS 6.5 MY16
Luggage rack and Eltek FastCharger

#ride365

Cama

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Re: My homemade 'Supercharger' for a ZERO Version 2
« Reply #5 on: November 16, 2016, 02:56:59 AM »

Wow! ... Nice job!

Now we have a supercharger-maker in europe.

Here is the link to the datasheet:

http://www.eltek.com/wip4/download_doc_647.epl?id=7975

How much time does it take from 0 to 90 % for your ZF 11.4?


Thanks,
Mario.
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ZERO SR 2016

Kocho

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Re: My homemade 'Supercharger' for a ZERO Version 2
« Reply #6 on: November 16, 2016, 04:48:39 AM »

I am confused by the last photo of the chargers at the rear fender.

I thought you said you are using 4 of them 2s2p, basically, and I see 4 of them in the other photos. What is that in the photo with the voltage readout by the fender?

Thanks!
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'15 Zero SR

MrDude_1

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Re: My homemade 'Supercharger' for a ZERO Version 2
« Reply #7 on: November 16, 2016, 08:57:05 AM »

I am confused by the last photo of the chargers at the rear fender.

I thought you said you are using 4 of them 2s2p, basically, and I see 4 of them in the other photos. What is that in the photo with the voltage readout by the fender?

Thanks!
Each flat pack has 2 fans.
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remmie

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Re: My homemade 'Supercharger' for a ZERO Version 2
« Reply #8 on: November 16, 2016, 06:10:21 PM »

I am confused by the last photo of the chargers at the rear fender.

I thought you said you are using 4 of them 2s2p, basically, and I see 4 of them in the other photos. What is that in the photo with the voltage readout by the fender?

Thanks!

That's a photo of when I made the display fit into the flatpack S when it was still part of the version 1 supercharger (with the one flatpack S and 3 flatpack 2 HE). I'll take another picture of the display in action on the 4 pcs Flatpack S charger (Version 2)
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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: My homemade 'Supercharger' for a ZERO Version 2
« Reply #9 on: November 16, 2016, 06:29:39 PM »

Remmie this is amazing, can't believe how small it is. Looks like a perfect fast charging solution. How much amps to you get on phase 2&3? Slightly above 16 A I guess? Only thing missing is to make it weatherproof so you could mount it to the motorcycle. Did you buy the rectifiers brand new?

On a 22 kW charge point you could easily top up the setup with another pair on phase 1 with 12 kW in total then, which would be close to the max if you don't want to exceed 1C.

Great work!

Edit: I just noticed your Typ2 plug looks very small. Did you modify it on your own or did you buy a different one?

the rectifiers have an efficiency of around 95%. The ouput power is 1800 W so the input power should be 1800/0.95 = ~1900 Watt
2x1900 W / 220 Volt =  ~17 Amps so indeed slightly higher than 16A. Most EV stations handle it quite well.

Making these waterproof would be highly difficult. I just use it when I'm making a bigger trip and that only happens when it not raining  8)

I purchased one the Flatpack S units on ebay 2 years ago. The other 3 I ordered brand new for 360 euro incl VAT each.

I could use a third pair to charge even faster but that would blow the aux charger fuse and the charger would not fit into the frunk any more.
We have made several long trips now with this charger and so far the power is more than sufficient.

You have a sharp eye :) Yes I modified the type 2 plug. I used a sewer pipe cap of 50 mm which fits exactly around the connector. I put a cable gland in there and a small switch and now it's much smaller than the normal type 2 plug. See the pictures. I just used the part which has a red circle around it.
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Black Zero SR 2014 11.4 kWh
Homemade "Supercharger" 4x eltek Flatpack S (8.5 kW including the onboard charger)

zerovolt

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Re: My homemade 'Supercharger' for a ZERO Version 2
« Reply #10 on: November 16, 2016, 10:44:50 PM »

Congrats Remmie,

your charger is very compact, and i like very much that you can store in the front tank.  i want to know if your charger work fine if you have a low SOC, or when the voltage is below 98 volts ? i use 2 meanwell 2000 and my charger dont start under 98 volts or below 28 % SOC on my S 11.4 2014. If your charger woks fine with low SOC, i think i will buy the eltek like yours.

Thanks !
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remmie

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Re: My homemade 'Supercharger' for a ZERO Version 2
« Reply #11 on: November 17, 2016, 11:23:01 PM »

Congrats Remmie,

your charger is very compact, and i like very much that you can store in the front tank.  i want to know if your charger work fine if you have a low SOC, or when the voltage is below 98 volts ? i use 2 meanwell 2000 and my charger dont start under 98 volts or below 28 % SOC on my S 11.4 2014. If your charger woks fine with low SOC, i think i will buy the eltek like yours.

Thanks !

Thanks  :)

Attached are 2 screenshots.
The one at 7% is with the Version 1 'supercharger' with Elteks (3x FP 2 HE + 1xFP S) and the screenshot with 25% is with the 4 Eltek Flatpack S units. So it seems no problem at all.

The flatpacks are rated from 43 to 57 Volt. So i think as long as the voltage doesn't go below 43 it should be fine.
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Black Zero SR 2014 11.4 kWh
Homemade "Supercharger" 4x eltek Flatpack S (8.5 kW including the onboard charger)

zerovolt

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Re: My homemade 'Supercharger' for a ZERO Version 2
« Reply #12 on: November 18, 2016, 01:53:09 AM »

Thanks Remmie :)
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BrianTRice

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Re: My homemade 'Supercharger' for a ZERO Version 2
« Reply #13 on: November 18, 2016, 04:15:44 AM »

Below the voltage that this 2s stack would support (86V, well into "reserve"), the battery is in a tricky state, anyway, so probably just mind using the onboard charger until voltage rises sufficiently.
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Zero: 2016 DSR, 2013 DS
Also: 2012 Suzuki DL-650 V-Strom Adv

evtricity

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Re: My homemade 'Supercharger' for a ZERO Version 2
« Reply #14 on: November 18, 2016, 04:55:45 AM »

On my 2014 SR the lowest battery level I get when the battery is at 0% is 97v. I assume that is similar to other 2014 models and the Elteks would have no problem running at that level (effectively 48.5v each in series). It's seemed odd to me that the Farasis cells have a nominal rating of 3.65v (about 102v) - that would be 30% state of charge on my 2014 SR. See attached cell spec where the graph has the voltage starting about 3.4v (95V in our pack config) so I guess that's the planned minimum.
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2014 Zero SR
2014 Mitsubishi Outlander PHEV
2012 Nissan Leaf
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