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Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: ElektroExpat on December 19, 2020, 12:43:54 AM

Title: Charge Tank Design
Post by: ElektroExpat on December 19, 2020, 12:43:54 AM

Hello fellow forum friends,

I have a question regarding the Zero Charge Tank design. I found a an old video on the unofficial manual site of a Charge Tank being installed, shown with the tank plastic removed.
More recently, I have seen a picture of a Charge Tank sent by a dealer showing a different design, now without a massive visible heat sink.
Can anyone shed some light on the Charge Tank design? Is it 2.5kW vs. 6.5kW versions I am seeing? If the new unit doesn't have such a massive heat sink attached, how does it efficiently radiate heat from the charger?

Pictures have been attached for reference.
Thanks in advance for any help.

Title: Re: Charge Tank Design
Post by: JaimeC on December 19, 2020, 01:19:27 AM

Whenever I plug in my 6.6kWh Charge Tank to a J1772 EVSE, I can hear a fan powering up and spinning so that's how heat is dissipated in that one.  Maybe the older models didn't generate as much heat so passive cooling with the fins was enough?

Title: Re: Charge Tank Design
Post by: MVetter on December 19, 2020, 01:34:19 AM

I believe the large heat sink one is the 2.5 and the black one is the 6kW model.

Title: Re: Charge Tank Design
Post by: ElektroExpat on December 19, 2020, 02:20:57 AM

Yes, the black unit is a 6kW unit. I do not however know what the other unit is.

It raises the question if the new units have  enough heat sink/cooling capacity, when the black unit is compared with what I can only imagine to be an older 2.5kW unit with a large heat sink attached.

Thoughts?

Title: Re: Charge Tank Design
Post by: NervEasy on December 19, 2020, 02:59:08 AM

I have a 6kw unit in my Zero and I think the heatsink of that unit is in the middle, it weighs to much not to have a heatsink. It is really heavy. And I think it has 4 small fans that sound really angry when blowing at full tilt. Like a server, a big one.

So yeah some heatsinkingbis done in the middle, like a sandwich.

Title: Re: Charge Tank Design
Post by: TheRan on December 19, 2020, 03:36:27 AM

The 6/6.6kW unit might essentially be two sandwiched 3/3.3kW units, in which case having the heatsink in between them would be the simplest cooling solution.

Title: Re: Charge Tank Design
Post by: remmie on December 19, 2020, 03:39:32 AM

This is a picture of the 6 kw rapid charger install (= charge tank) for the SR/F

Behind the top grill you can see 2 of the 4 fans (the gold colored bits)
The same behind the bottom grill

Title: Re: Charge Tank Design
Post by: ElektroExpat on December 20, 2020, 03:26:52 AM

Thanks everyone for the feedback and pictures.
Does anyone happen to have a tank-removed picture of the 6kW charger installed on an S/SR/DS/DSR?

Title: Re: Charge Tank Design
Post by: UlsterZero on December 20, 2020, 10:38:49 PM

Attached is a picture taken when I installed the 6kW charger in my SR.  Although not visible in the picture the cooling fans are at the front of the charger, and there are vents in the front of the tank to allow air to flow into it.  The baffle at the back I believe is to ensure air flows through the charger rather than around it.

The fans do tend to get noisy when charging, especially when the charger starts to heat up.  The fans gradually slow down and get quieter as the battery nears 100%.