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[Doctorbass]

I had a chance to take a look to the sevcon motor controller on both 2012 and 2013 Zero S and they are the same !

That mean in theory the 2012 controller can go to a voltage up to 116V

The 2012 battery is made with 18s bank and the 2013 is made  with 28s bank so there is 10s of cells bank difference wich is 37V nominal and 42v max.

This is confirming teh great possibility to increase performances not just by a size 6 but also by increasing voltage =))

Doc

[eyeinsky]

Hi Doc

I was wondering how high before there is a safety concern about electricution? I know 120 AC volt will kill you but 48 volt DC wont, what is the point when the voltage carry enough current to kill you.

Thanks Jerry

[Doctorbass]

I have many electric bike that i built that work from 72V to 126Vdc and never had any problem of electrocution

usually they recommand to not have touch any voltage higher than 42Vdc but 100Vdc dont really snap... well my hand usually are dry so no problem with that

DOc

[CliC]

As little as 50V can push the few milliamps through needed to cause cardiac fibrillation, depending on various factors that affect the impedance of your body tissue. So we're already in the danger zone . It may be less likely with DC at that level, though.

[Lipo423]

I would not play with 3 DC digits. Your guys know what happens when you get hooked in a relatively High-voltage DC line...in my case (I have got sweaty hands)is not something to play with...

[dahlheim]

i'm not an electrocution expert, but i would not wish to expose myself to even 5V at 1amp.  it's current, applied in the right place at the right time, that matters, not voltage per se.

[NoiseBoy]

Its a how long is a piece of string question.  If you have particularly sweaty hands and you have a grounded object in one hand and 30VDC in the other it could go across your chest and cause problems.  A higher voltage is more likely to cause muscle contraction where you would be unable to let go.

All things considered, you are still much more likely to be seriously injured walking down the stairs or fuelling your ICE bike than you are to be electrocuted by your Zero.

[Doctorbass]

guys let's start another topic fo relectrocution risk please

let's go back to the original subject:

the fuse in the 2012 are 300A rated while they are 420A on the 2011. That's curious

it's like the 2012 have pretty the same power but are driving more volt instead of amp...

Absolute max battery power are:
2011 58V x 420A =24.3kW
2012 75V x 300A =22.5kW

My guess is that the sevcon size 4 are programmed with lower phase current at low speed, than once sped reach about 70kmh, max power is acheived...

apparently the 2012 can take the sevcon size 6 and i wonder if there is some mod to do on the battery to cary that current ?.. update contactor? update battery fuse?

Also the MBB is filtering the throttle signal on the 2011 but on the 2012 the throttle signal goes directly to the sevcon... but the sevcon have the Can bus data connected to the MBB... so the Can Bus might affect the performances setting too..

I now that there is the Uart on the OBDII connector so i'll try communicating with the MBB if i have time and will see of the performance smod can also be acheived on  the 2012...
Doc

[BSDThw]

the fuse in the 2012 are 300A rated while they are 420A on the 2011. That's curious

If you have a look to the datasheet it will tell you that you can use much more current for 1 sec 1min ... so it will be ok your sevon will not deliver 420A longer as the fuse can hold this current.

http://www.siba-fuses.us/upload/documents/catalogues/V_Section_Forklift.pdf   "Page 7"

The MBB is able to reprogram the Sevcon on the fly but it is only used when you switch from ECO to Sport vs I have explain it here

http://electricmotorcycleforum.com/boards/index.php?topic=2344.msg11913#msg11913

[Doctorbass]

hmm..

so the 2012 is probably the year that the zero ar ethe less reprogrammable or tweakable....  .. the only good tweak is the size 6....

About the eco and sport mode i am able to stwich on the fly between eco to sport if i need to have better regen braking. when i'm in sport mode i can switch to eco when i need to have better regen braking and it work.. so i might also connect a relay  on the high beam switch that will now be usedto switch eco momentanously.

Doc

[BSDThw]

You are a handy man, why not using a step-less regen brake with a clutch lever.

I guess you can build the mechanic or use this " http://electricmotorcycleforum.com/boards/index.php?topic=3027.msg14912#msg14912 "

I let you know how I have done the Mod, if you need support.

[KrazyEd]

   I have a 2012 XU, is the regeneration only with throttle fully closed, or, is there partial at trailing throttle?
On my Volt, if I am slowing down, or, on a slight down grade, the regeneration starts as soon as I lift enough
to cease forward propulsion.
   Also, with all these owners switching to the Size 6 controller, would I be able to put a Size 4 from an S or
DS on my XU?
Thanks
Edward J. Malkiewicz

[BSDThw]

Regeneration starts with throttle FULLY closed or when you tip your brakes ( if the brake light went on it starts the regen algorithm, I can only tell how it is at a 2012 S/DS but I think the XU work similar)

A size 2 use some pins different I think if someone like to install a size 4 it is possible but maybe it take some extra work. I have no idea how the space/mounting situation is. I would ask Harlan, maybe he has done it or has a set for you.
You also need the correct programming/setup for your motor + some tuned parameter (I guess )

If you need Sevcon data there is a manual http://www.thunderstruck-ev.com/Manuals/Gen4_Product_Manual_V3.0.pdf

[mentalvmaxrider]

KrazyEd....my dealer told me it was possible to put the bigger controller in the xu...but at a huge loss of range

[NoiseBoy]

KrazyEd....my dealer told me it was possible to put the bigger controller in the xu...but at a huge loss of range

Actually fitting a larger controller would marginally increase your range as they are more efficient at lower power.  If you used exactly the same acceleration etc. you would go further but of course most people will be using full throttle all the time so you will drain the battery much faster.