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[Doctorbass]

I am  evaluating many possible solution to fast charge our zero with the J1772 Level 2.

The 2009-2010-2011 Zero are working from 42 to 58Vdc
The 2012 Zero are working from 54 to 75Vdc
The 2013 Zero are working from 84 to 116Vdc.

there is many solution, for the charger we can use. but the best are all teh one that include a PFC ( Power factor Corrector) wich increase efficiency.

Hre is some of these solution that have the PFC

-There is the 1000W DeltaQ quick charger at 500$ ( 50 cent per watt)
Sealed IP66, not compact, easy to use


-There is the Elcon charger at (34 cent per watt) that offer from 1500 to 5000W
Sealed IP66, medium  compact, easy to use

-There is the meanwell RSP power supply  at (22 cents per watt) that are REALLY COMPACT
NOT sealed, very compact, require DIY

-There is the HP 3kW server power supply sold on ebay at about (2 cent per watt)
NOT sealed, very compact, require DIY, CHEAP !!


My 2012 require about 75V full charge.

So with the server power supply i could buy two  and connect them in serie and lower their voltage to 37V each ( their output  can be isolated from the input so no ground short between both)

this would give me about 75V and 57 amp = 4.2kW for about 100$ shipped.


For my new 2012, the voltage range is quite difficult to match with some cheap power supply solution for charging but is still fesable. ! = you need to stack fome 48V and 24V in serie to get the 2012 voltage

the stock 1000W delta Q of my 2012 charge at about 800W wich take a while !!

That must change!!

Doc

[trikester]

Ah, but remember that if my 2013 FX charger had drawn more than 650 watts I wouldn't have been able to recharge from the small hyroelectric system powered by a small spring 600 feet up the mountain.

What we need is a charger that can be set at different charge rates so that we can accommodate low power sources like solar panels or small hydro. After I finished my rides each day I didn't care how long it took to recharge for the next day's ride, as long as the source could supply the load. In this case the source was 750 watts so my 2012 DS at 1100 watts would not have worked but my 2013 FX was perfect at 650 watts. We need adjustable chargers!!!

Trikester

[frodus]

Thats part of what the J1772 station is supposed to do... the pilot signal tells the charger how much current it can draw. But you'd n3ed a charger that can take that pilot and throttle the charger back.

The eltek valere charger in the Brammo does this... although I dont know what all is required.

[trikester]

It would be great if I could program the maximum charger power from my iPod, similar to what we can now do with the 2013 bikes' ECO settings.

Trikester

[Doctorbass]

There is some great cheap ADJUSTABLE current and voltage power supply similar to the meanwell.

they are sold about 120$ and are availlable up to 600W of power and up to 84V wich is an excellent solution,

but they dont have the PFC wich usually incresse the efficiency ( power supply or charger that have the PFC cost higher price)

http://www.ebay.com/itm/600W-72V-8-3A-Switching-Power-Supply-With-Current-Control-Charger-LED-CCTV-US3-/190870024956?pt=LH_DefaultDomain_0&hash=item2c70bd72fc#ht_2399wt_1163

This might be the solution for cheap powerfull charger

[Doctorbass]

The PFC5000 from ELCON coat about 1500$ and is very big.

I have found another option that Is more compact and is god if you don’t want to permanently install it on the zero ( it is not sealed IP66)

The RSP-2000 power supply serie from Meanwell are one of the most compact charging option I have seen.

If you take two RSP-2000-48V  in parallel and connect one RSP-2000-24V in serie you get a 75V 80A.  The charger the size of a box for shoes! And is rated 6000W but can do 7.5kW no problem!

This become a really interesting 1200$ solution for 7500W of charging power that is really compact!!

Install a J1772 plug on it and the EVSE and you are ready for fast charging everywhere you have these plug!
Doc

[protomech]

Hm.. that's a good idea. If you go this route.. please document, very interested : )

Only problem I can see is then any one of those supplies failing will halt the charging process.

electricmotorwerks has an open-source 12 kW charger for $2000 assembled or $1000 kit. DC output up to 70A (5 kW) base, can be modified up to 150A (~11 kW). There's a water cooled design and an air-cooled design. It's perhaps twice as big as the Delta-Q charger.
http://www.emotorwerks.com/tech/electronics

They also have an EVSE on kickstarter now. Probably worth putting in its own thread.
http://www.kickstarter.com/projects/emw/emw-juicebox-an-open-source-level-2-ev-charging-st

[Doctorbass]

Hm.. that's a good idea. If you go this route.. please document, very interested : )

Only problem I can see is then any one of those supplies failing will halt the charging process.

electricmotorwerks has an open-source 12 kW charger for $2000 assembled or $1000 kit. DC output up to 70A (5 kW) base, can be modified up to 150A (~11 kW). There's a water cooled design and an air-cooled design. It's perhaps twice as big as the Delta-Q charger.
http://www.emotorwerks.com/tech/electronics

They also have an EVSE on kickstarter now. Probably worth putting in its own thread.
http://www.kickstarter.com/projects/emw/emw-juicebox-an-open-source-level-2-ev-charging-st

On all the zero motorcycles, the charger have a trigger wire ( white) that the MBB switch to ground to activate the cahrge current on the deltaQ. This wire signal is also controled by the BMS HVC limit.

so the zero have a wire that control the charge ON or OFF. and this wire can be connected to the Enable pin of these MEANWELL power supply.

I also have saw these 1000$ kit, but if you buy the kit you dont have any cooling system and enclosure and few other parts. The total price still come to about 1500$ from my calculations, but i agree that this is a very flexible solution too

Doc

[BSDThw]

Woh

up to 600W of power and up to 84V wich is an excellent solution,

but they dont have the PFC wich usually incresse the efficiency

As much as I know every supply in Europa having more than 100W need a PFC, therefore I am really staggered you can use 600W without PFC!

I have reread the thread as Terry has explain little of his charging (it was at his very beginning with modification) He mentions you need to mod (open) the battery box if you use more as 40A at the quick charge input (30A fuse => 40A fuse) but the wire... is to small.

He never answered to me what he had really done. To feed the current at the battery to Sevcon cable would be possible but you need to switch the main relay.
Ignition on seams to switch of the charger at the quick charge plug ( the trigger wire ). To switch the 24V relay would be a way but you run part of the Sevcon ... and to park my bike half in ON position when I go shopping  I  don't like the idea.

I still hang on the idea to reuse some parts of my developing projects to build a 5-6KW charger. So I always think how things will work together.
 

[Doctorbass]

Woh

up to 600W of power and up to 84V wich is an excellent solution,

but they dont have the PFC wich usually incresse the efficiency

As much as I know every supply in Europa having more than 100W need a PFC, therefore I am really staggered you can use 600W without PFC!

I have reread the thread as Terry has explain little of his charging (it was at his very beginning with modification) He mentions you need to mod (open) the battery box if you use more as 40A at the quick charge input (30A fuse => 40A fuse) but the wire... is to small.

He never answered to me what he had really done. To feed the current at the battery to Sevcon cable would be possible but you need to switch the main relay.
Ignition on seams to switch of the charger at the quick charge plug ( the trigger wire ). To switch the 24V relay would be a way but you run part of the Sevcon ... and to park my bike half in ON position when I go shopping  I  don't like the idea.

I still hang on the idea to reuse some parts of my developing projects to build a 5-6KW charger. So I always think how things will work together.

Yes here in america it is not all power supply or charger that have the PFC some even have as low as 0.17 power factor, like the cellphone charger!!

for the zf9 battery i know that there is only two port with 10 gauge wires and 30A fuse so max of 50A continuous could be acheived... but as well i will open thebattery and add some high amp connector. ( these connector are probably like on the 2011 model wich mean these port are probably connected BEFORE the contactor. The protection signal that control the charge activation from the BMS is usually a simple wire that is referenced form the gnd according to the schematics. these signal are in the middle of  the green Anderson connectors.

With a simple relay and npn transistor  i will be able to use this signal to control a signal relay that will trigger the meanwell output current. So once one or more cell bank reach 4.15V, the current will fall to zero for some delay to leave the bleed resistor of the BMS to balance the cells. And once all the cells will be full and balanced the BMS signal will stop activating the meanwell output

BTW these little 2000W power supply are some of the highest power density in teh market with 21.7w per cu inch!

Doc

[GdB]

Could this be useful tech our Zero's?

"Radically smaller, more efficient and perhaps faster EV charger may be on its way"
https://newatlas.com/medium-voltage-fast-charger/56646/

[GdB]

EDIT:
The 799 € Pulsar is AC (not DC)  : (

The wallbox DC model available in 2019 will probably be a lot more expensive and more bulky!  : (

They have this DC model for sale  now for $9995
https://www.evchargesolutions.com/Delta-EV-DC-Quick-Charger-Wallbox-p/deltadcfcsingle.htm
Output voltage range: 200-500Vdc (SAE Combo); 50-500Vdc (CHAdeMO)

https://cleantechnica.com/2018/10/18/wallbox-rolls-out-the-first-ever-residential-dc-fast-charger-adds-ai-voice-control/