ElectricMotorcycleForum.com
Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: Doctorbass on August 30, 2023, 10:55:13 AM
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After I have blown one of my 4 3.3kW chargers last years after overheating i decided it is time for adding up cooling solution!
The charger pan with 9.9kW of chargers inside is pretty tight and have very little room for air cooling.
I have ordered an aluminum cold plate that i have installed on the bottom of the charger pan right in the middle to cover the area below all 3 chargers with it and also added thermal paste with epoxy seal around it to avoid rain to wash it all.
When I removed the broken cahrger unit I have by the same occasion cleaned everything, removing accumulated rock, sand and even insects and installed new fresh thermal paste to all 3 chargers.
The liquid cooling system is made of a 130 PSI 12V pump that is supplyed by the 12V from all the chargers fan 12v supply that are all paralleled with serie diodes on each. there is also a overflow tank and 1/4" flexible hoses and a 120mm radiator with 12v fan that i have dissassembled to waterproof the brushless circuit.
The difference of active cooling vs passive natural cooling is between 15 to 20Celsius which is enough to avoid the 90 Celsius that my broken charger had to deal with. The temperature i am mentioning is the highest measured using FLIR camera and high emissivity surface.
I used it now for 1 month and 4000km now and it is working like a charm!
Here is the video of a resumé of my 4000km trip last month where I explain briefely the modifications I made: ( you can autotranslate in English with the CC button) https://youtu.be/HRD66OCjMps?si=kZgiAnnO987_8fFq (https://youtu.be/HRD66OCjMps?si=kZgiAnnO987_8fFq)
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awesome job there! Make sure nothing dings your cooling radiator. One rock picked up off the road and you can have problems.
Aaron
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Well it's not really a problem if the radiator is broken. It's not a gas engine that'll overheat. The TCChargers have temperature protection, they'll simply turn off. (At least mine did).
As doctorbass had one die from heat, it seems they don't like the heat but they definitely don't die from one time charging on a broken radiator.
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The issue is dumping coolant right in front of your rear wheel.
Other than that small potential safety issue, nice job. I'm surprised such a small radiator managed to make such a big difference, assuming 90% efficiency that's dealing with 1kW of heat where as in a computer it'd be expected to deal with a CPU putting out like a tenth of that.
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Is that a custom metal pan? Did you DIY? If so, do you have any CAD files or anything I could use to send to a machine shop to custom make another?
I've been following your videos on youtube for a while. Glad to see you still have that old bike.
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Is that a custom metal pan? Did you DIY? If so, do you have any CAD files or anything I could use to send to a machine shop to custom make another?
I've been following your videos on youtube for a while. Glad to see you still have that old bike.
Hey my bike is not OLD !! ??? ;D
Yes it is my pan design. I worked hard on it to fit 3 chargers in a small space. I sold it to Diginow few years ago and have posted couple info here in teh past about it. Diginow own the rights outside Canada. You could ask Brandon and see if he want to share.
Doc
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Well it's not really a problem if the radiator is broken. It's not a gas engine that'll overheat. The TCChargers have temperature protection, they'll simply turn off. (At least mine did).
As doctorbass had one die from heat, it seems they don't like the heat but they definitely don't die from one time charging on a broken radiator.
Well I also believed that the built in temperature protection would protect them against overheating but apparently not!.. I found one of my unit not working after I came back from one hour shopping during a hot weather day and that I forgot to install the 55W 120mm suspended fan below the pan.
It happened couple times where I saw the temperature hitting 88Clsius over the 5 last years and everything worked well with the output power automaticly droped.
From about 75Celsius to 90 Celsius the power is derating but at 90 celsius it is prety toasty.. just enough to break the circuit inside apparently.
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Hey my bike is not OLD !! ??? ;D
I meant older, since I thought you got an energica.
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Hey my bike is not OLD !! ??? ;D
I meant older, since I thought you got an energica.
OK.. well I would love to try one one day as well and see if the expense really worth it compare to what i already invested on my 2017 SR.
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Slick setup! Where did you get that cold plate?
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Slick setup! Where did you get that cold plate?
I bought it from ebay. I wanted one that is slim but wide to cover all 3 Elcon and keep a good clearance to the ground.
I think the seller is still offering some.
Doc
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By any chance do you know the total weight of your chargers, and have you drilled and tapped additional holes in the frame to mount the pan? I'm currently working on adding a second charger under my bike and the plan was to use the mounting holes for the stock charger. I took the bellypan off earlier to take a look at the bolts and see what size they are and they're only M4 compared with M5 for the pan. Not only would it be less secure but it's also a pain finding hardware in the lengths needed so it's got me considering just mounting the second charger using the pan/pan mounting points instead.
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By any chance do you know the total weight of your chargers, and have you drilled and tapped additional holes in the frame to mount the pan? I'm currently working on adding a second charger under my bike and the plan was to use the mounting holes for the stock charger. I took the bellypan off earlier to take a look at the bolts and see what size they are and they're only M4 compared with M5 for the pan. Not only would it be less secure but it's also a pain finding hardware in the lengths needed so it's got me considering just mounting the second charger using the pan/pan mounting points instead.
The cold plate is bolted to the pan from the inside. I have taped holed in the cold plate. Then i have installed the charger back on the same original holes.
The pan is bolted on the 2017 SR frame in the existing threaded instert. The pan and 3 chargers weight about 60 pounds.
Doc
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Oh, I figured the chargers were mounted to the pan and that's what the additional holes in it were for. I suppose if I can get some spacers to reattach my pan under both of the chargers and have it pressing tight on them (how I assume yours is, since you have thermal contact) then that will give them some extra support. Strangely on my DS the rear most pan bolts are on an angle and the lip of the pan extends further back towards the footpegs. Because of this I won't be able to reuse them with some spacers, although I rounded off those bolts and had to grind the heads off anyway.
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Can you share a link to the ebay seller with the cold plate? I'm about to do a Diginow install (once this weather calm down)
Also, did you wire all 3 diginows to one charge port?
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Can you share a link to the ebay seller with the cold plate? I'm about to do a Diginow install (once these hurricanes calm down)
Also, did you wire all 3 diginows to one charge port?
It's been long time I have bought it. I have no more info.
Here is the schematic of the installation i have for the 4 chargers (3 in the pan and one on front of the monolith)
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Just as a sort of alternative viewpoint.
Cold plates can also be found in brewing supply shops / beer shops / bar restaurant supply shops.
They use them to keep the keg lines cold, Device would work fine here as well Id imagine.
Aaron