Doc Diy 6.6kW Zero 1hour COMPACT charger !

[Doctorbass]

Here is the link: http://electricmotorcycleforum.com/boards/index.php?topic=3085.0

Here is some interesting data:

TESTED results11 august 2013)

Efficiency measured: 92.5% ( 6980W AC 6460W DC out)
Current consumption ( at max output power): 30.5A AC
Max power output ( mean at end of charge) 6.60kW
Voltage output: 74.0V ( adjustable from 29 to 76.8VDC)
Current output: 91A (0.75C charging rate)
Weight ( including connectors and harness): 13.4lbs
Dimensions: L 13.2" x W 5" x D 5"
Max temp ( case): 43 celsius

Zero ZF9 battery temp at end of charge ( internal OEM temp sensor): 32 celsius
Zero ZF9 Battery measured capacity (with 2 bar flashing on the gauge): 6600Wh



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Some pictures for you guys:

( The update of my AC electrical network in my garage ( my 60A 240V sub pannel and the 40A 240V plug for charging my zero!)
Some picture of teh cahrger and also comparing the size of the original zero 1kW charger)
and finally the Cycle Analyst i installed on it and showing the reverse current charging the battery at 90Amp ! and 6.6kW

Doc

 

[hillzofvalp]

good to see this. I'm putting two of the 48V meanwells in series for 28S A123 for my small 2.5kWh pack. i think 1C charge will be quite enough for my usage.

the nice thing is that they only weigh about 5lbs a piece.. and fit nicely inside the bike..

I want to make a switch externally for 120 to 240VAC switching.. Do the meanwells automatically limit current based upon your AC Voltage setting? Aka 1500W for 120 and unlimited for 240?

edit: BY THE WAY, you probably have not only mine, but pretty much everyone's dream garage... 240VAC.. *sigh*

 

[bowlofsalad]

Someone is a far bigger fan of back to the future than I had thought. : P

Is weatherproofing a concern? You said the black charger was waterproof, I would guess that some of the reason that there is a much better weight/volume ratio for for the meanwell power supplies relate to their heat sink design combined with very fast fans. Is the other charger fanless?

I am curious about the cost comparison for each charger. I am not saying that considering 1 hour to 9 hour charge time isn't worth it even for something close to the cost of the bike itself, but cost is still a critical component for many people. Are there many level 2 chargers in your area or region?

@hillzofvalp Setting up 240vac in a garage is extremely easy, 2 or double pole breakers, look into them. Just about anyone can make this happen easily. I think the USAs obsession with 120v is ridiculous.

 

[hillzofvalp]

I know it's easy.. but I don't have a garage yet

The delta qs are passive cooled.. .huge sinks.

 

[Doctorbass]

good to see this. I'm putting two of the 48V meanwells in series for 28S A123 for my small 2.5kWh pack. i think 1C charge will be quite enough for my usage.

the nice thing is that they only weigh about 5lbs a piece.. and fit nicely inside the bike..

I want to make a switch externally for 120 to 240VAC switching.. Do the meanwells automatically limit current based upon your AC Voltage setting? Aka 1500W for 120 and unlimited for 240?

edit: BY THE WAY, you probably have not only mine, but pretty much everyone's dream garage... 240VAC.. *sigh*

Yes, i also have the RSP-1000-48, but i sold them this weekend. I was using them for 30s charging LiPo after i added some DC-Dc in serie to boost the voltage a bit.

The output power of the RSP is based on 3 things; the max 125% curent limiting of rated current, the AC input voltage. from 180 to 240V AC you get full power and at 120v it is derated a bit ( read the spec sheet you will see the graph)

Doc

 

[Doctorbass]

Someone is a far bigger fan of back to the future than I had thought. : P

Is weatherproofing a concern? You said the black charger was waterproof, I would guess that some of the reason that there is a much better weight/volume ratio for for the meanwell power supplies relate to their heat sink design combined with very fast fans. Is the other charger fanless?

I am curious about the cost comparison for each charger. I am not saying that considering 1 hour to 9 hour charge time isn't worth it even for something close to the cost of the bike itself, but cost is still a critical component for many people. Are there many level 2 chargers in your area or region?

@hillzofvalp Setting up 240vac in a garage is extremely easy, 2 or double pole breakers, look into them. Just about anyone can make this happen easily. I think the USAs obsession with 120v is ridiculous.

The DeltaQ 1kW is waterproof but i dont care with waterproof, i will not have the cahrger permanenently installed on teh motorcycle, i want it just portable so i can cary it on a bag on the top of the "gas tank". The air flow from these 6 little 40mm fans is pretty impressive!

The cost of a deltaQ is 500$ and the cost of this charger is 1300$ and it is 300$ les than a Elcon PFC5000 30pounds charger!

In teh Quebec province we have about 280 level II charge stations and it,s growing !! We have also a company called Addenergie that build most of them.

I also got my ordered J1772 plug and signal pilot circuit so i,ll be able to connect it on these stations

My plan is to have the max charging power that the basic level II charge station can do ( about 30A 240V and to also have couples adapter like the Oven NEMA 14-50 that we can find also in some RV camping service.

Electricity here is CLEAN and 97$ from hydro plan and is at 7 cent per kWh. We pretty have the best setup of Hydroelectricity here.

Doc

 

[hillzofvalp]

What is the difference between SE and RSP series?

 

[Danny Mayes]

Hey Doc,

Cool charger but, Thread hijack - are they little rear horn loaded monitors on the shelf behind you???

 

[Doctorbass]

What is the difference between SE and RSP series?

The SE serie are not as compact as the RSP is and i think they dont hav ethe Power factor corrector ( PFC) feature like the RSP does.

Doc

 

[Doctorbass]

Hey Doc,

Cool charger but, Thread hijack - are they little rear horn loaded monitors on the shelf behind you???

Yes these are my very first Horn Loaded full range speakers. I have used some modified 4" full range speakers with it The vocal low midrange is very precise. The big black wooden box you can also see behind my desk chair is a 12" horn loaded subwoofer. The desing is not mine but it's called "THE PUNISHER" it go as low as 45 Hz and have decent peak at 65Hz for great bass punch response. I also played with horn loaded/ 4th order bandpass subwoofer few years ago for some high SPL car audio competitions..

Doc

 

[Ypedal]

So that's why my lights were dimming one province over...

Well done Doc !.. that's freaking awesome !..

so 7000w / 7 cents per kwh, 1 hr charge , 70 cents per charge ? for 100 ( 90.. ) km range ... compare that to a typical 4 cyl car, is aprox 3~5$ in gasoline. ( i likely messed up that quick math.. but i'm close .. i think )

very nice. 8)

 

[Ariane]

Hi Doc,

Well done indeed, I need a 2.2 KW, 152 Volt compact charger for summer 2014 with my new project ebike can be fun to recharge both ebikes with the same "electric fueling station" like St-Hubert restaurant and they are easy to find.

Good work my friend, I have a nice day!
Black Arrow

 

[Tommy L]

I'm glad to see that you continue to find solutions!


Tommy L sends.....

 

[grindz145]

Wow yeah, that pack heated up nicely eh? 32C?

I know that the documentation that the dealers get recommend 1/2C max charge rate. 1C should be no big deal though.

It would be cool to come up with something that would monitor the voltage and terminate the charge...

 

[hillzofvalp]

I don't think cell level HVC is needed here.. Just set meanwell to 95% SOC.. for LiFe I would set it to around 3.45V. But like doc said in his other thread, it's not difficult to have bms trigger the meanwell through the 5V power on sense pins

 

[Doctorbass]

Wow yeah, that pack heated up nicely eh? 32C?

I know that the documentation that the dealers get recommend 1/2C max charge rate. 1C should be no big deal though.

It would be cool to come up with something that would monitor the voltage and terminate the charge...

Someone we know well here on E-S confirmed to me that these can be cahrged at 1C no prob ( they tested them.. so i guess that instead of having 300 000km , this battery might last 200 000km... lol

Doc

 

[Ypedal]

how many kms do you have on the bike now ?

 

[Doctorbass]

how many kms do you have on the bike now ?

I have aboout 3700km on it. Dont forget that i upgraded for a Zero S 2012 I sold the DS 2011.


Doc

 

[Danny Mayes]

Yes these are my very first Horn Loaded full range speakers. I have used some modified 4" full range speakers with it The vocal low midrange is very precise. The big black wooden box you can also see behind my desk chair is a 12" horn loaded subwoofer. The desing is not mine but it's called "THE PUNISHER" it go as low as 45 Hz and have decent peak at 65Hz for great bass punch response. I also played with horn loaded/ 4th order bandpass subwoofer few years ago for some high SPL car audio competitions..

Doc

hehehe, horn loaded speakers are like ebikes, one good experience and there is no return! I have owned many full rangers in my time and built a number of horns, they go together so well!

 

[hillzofvalp]

I don't realyl need PFC at charging stations right? and at home it's not that big of a deal for 5kWh per day max at 2.5kW

 

[Doctorbass]

I don't realyl need PFC at charging stations right? and at home it's not that big of a deal for 5kWh per day max at 2.5kW

The PFC is not a matter of saving money on the electricity bill, it's also a matter of charger efficiency!.. the PFC usually increasy by 10 to 40% the efficiency. These usually are above 90% efficiency :wink:


Also without PFC it would draw more current on the AC. Without PFC i would need to use 8 gauge on the AC input instead of 10 gauge. in other words, the PFC feature:
- Reduce the charger size
- Reduce the AC current requirement
- Is more efficient !


Doc

 

[grindz145]

And LESS HEAT to get rid of!

 

[hillzofvalp]

I thought PFC was more to condition the power or something to not put stress on the grid. the SE-1000-48 psu is rated for 89% efficiency

http://www.meanwell.com/search/se-1000/SE-1000-spec.pdf

edit: so you're really talking a gain of about 4% in efficiency (or 10-40% of that 11% gap from 89% to 100% efficient.)

 

[Sigmacom]

Doc - I'm still working on my current-limit-adjustable RSP 2000 I PM'd you about. I see what looks like a couple of Shottky diodes on the output of those power supplies - could you take a close up picture to show me exactly how you have mounted them on the output terminals?

 

[Ariane]

I thought PFC was more to condition the power or something to not put stress on the grid. the SE-1000-48 psu is rated for 89% efficiency

http://www.meanwell.com/search/se-1000/SE-1000-spec.pdf

edit: so you're really talking a gain of about 4% in efficiency (or 10-40% of that 11% gap from 89% to 100% efficient.)

The RSP-2000 is rated at 92 % efficiency, this power supply is lighter, more compact, weight less and we a single unit this power supply output twice the power of single SE-1000 in a lighter packaging, this exactly what Doctorbass said, with less heat in the process.

This is a good thing when you want to transport this power supply on an ebike or electric motorcycle.

Has for 10-40 % difference you talk about Doctorbass talks about chargers like BMS battery and others. If fact the EMC-1000 for instance is not a "900 watts charger" this version is able to output 72 Volt at 10 Amps. This charger can charger my battery pack at “only” 720 Watts and know it because I use two of them connected in series.

Good day!
Black Arrow