Auteur Sujet: Building a fast and configurable off board charger for a Zero electric motorbike  (Lu 867 fois)

Hors ligne Gérard Tayeb

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I have explained elsewhere what I am expecting for my Zero Motorcycles FXS 2016
- fast charger (about 3.3kW)
- that I can use only when I need it, i.e. not fixed to the bike, but transportable in the top case or elsewhere
- that plugs easily to the input current source on one side, and to the bike on the other side
- not too heavy (5 kgs) nor bulky
- that I can use alone, or with the inboard charger of the bike
- that can be used on a domestic plug 220V/16A
- that can be used on a weak domestic plug 220V/10A for instance, or less (configurable "on the road")
- that can be used on Mennekes Type 2 plugs (charging stations)
- that can charge to full charge (100%) or less (80% for instance), and configurable "on the road"
- waterproof and insensitive to vibrations

After looking around for some time, it appears that nothing that matches these criteria seems to be available at the present time.
But it could be possible to build it from these two main components:

1) The TC Charger HK-J. It is the 3.3kW model 96V32A, with CAN-bus, cooled with a fan. I chose to buy it from Otten, where I got very kind advices and support, and where I could get it with all its wiring and connectors adapted to my wishes.

2) The ThunderStruck EVCC-Basic Controller.
At page 6 of their manual, you can see that it can store 4 user-configurable settings and can easily switch from one to another (it only needs a contactor with 4 positions, addressing 4 different resistances).
It could be used for instance to switch between 4 settings like these ones (or any other since you can define for each of them a lot of parameters):
     | Full power| Reduced power|
     Full final voltage 116.2V (SOC 100%)| setting 1| setting 2|
     Reduced final voltage 109V (SOC 80%)| setting 3| setting 4|



Hors ligne Gérard Tayeb

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All the units (TC Charger, Elcon, Diginow) are based on the same unit, and generally have the same CAN addresses. The one I get from Otten should have a receiving CAN ID 0x1806E5F4, and transmitting one 0x18FF50E5. These are the addresses used in the EVCC Thunderstruck Controller, as said in the manual. Perfect!

I have ordered the EVCC-Basic Thunderstruck Controller. They asked me if I want them to program it before sending. I was initially thinking to program it myself, but since they proposed to do it, I asked them to program 4 different charging templates:
1) full power (should be 3.3kW and about 32A), max final voltage 116.2V
2) full power (should be 3.3kW and about 32A), max final voltage 109V
3) reduced power (20A), max final voltage 116.2V
4) reduced power (20A), max final voltage 109V
I will be able to change these programs later, but as it, I should receive everything almost "plug and play". I will just have to make the wiring according to the online manual, using a commutator and some resistors to select the 4 programs, and that's should be all!
« Modifié: 2018, juil., 13, 08:29:40 par Gérard Tayeb »

Hors ligne Gérard Tayeb

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I have finally found a solution that matches all my wishes  :)
- fast charger (3.3kW when used at the maximum power)
- that I can use only when I need it, i.e. not fixed to the bike, but transportable in the top case or elsewhere
- that plugs easily to the input current source on one side, and to the bike on the other side
- not too heavy (5.44 kgs with connectors and a 1 meter long Anderson cable), nor bulky
- that I can use alone, or with the inboard charger of the bike
- that can be used on a domestic plug 220V/16A
- that can be used on a weak domestic plug 220V/10A for instance, or less (configurable "on the road")
- that can be used on Mennekes Type 2 plugs (charging stations)
- that can charge to full charge (100%) or less (80% for instance), and configurable "on the road"
- waterproof and insensitive to vibrations

After examining many solutions, I have decided to buy my charger from Otten (Germany), where I got very kind advices and support, and where I could get the charger with all its wiring and connectors adapted to my wishes.
Otten proposed me two solutions:
  • A 3.3 kW charger "ready for use". You plug it on 220V/16A domestic plug on one side, and on the Anderson (brown) connector on the other side. You can use it with the charger of your bike at the same time
  • The same charger, but controlled by CAN-bus
Both chargers are waterproof, shock-proof (in fact they are the same as Diginow, Elcon, TC Charger HK-J,...) and Otten sells both at the same price 699€, that is quite interesting  ;)
I decided to opt for the second option, since the CAN-operated charger can be controlled and programmed externally, which offers more possibilities.
Some people use Arduino's to control their chargers (you can for instance find information on Lennart's Github, but since I have not used Arduino's myself before, I chose another option.

I am controlling the CAN-bus charger using the ThunderStruck EVCC-Basic Controller. They provide a detailed PDF manual with many useful instructions about the way to wire it and to configure it. At page 6 of their manual, you can see that it can store 4 user-configurable settings and can easily switch from one to another (it only needs a contactor with 4 positions, addressing 4 different resistances). Thunderstruck support was very nice, and I was surprised to be asked, at the time I was buying it: "How would you like that we configure your controller?"  :). I asked for:
- mode 1: 116.2V and 32A (full charge, draws 16A on the 220V plug)
- mode 2: 116.2V and 20A (full charge, draws 10A on the 220V plug)
- mode 3: 109V and 32A (about 80% charge, draws 16A on the 220V plug)
- mode 4: 109V and 20A (about 80% charge, draws 10A on the 220V plug)
And it works as is. Perhaps I will make more fine settings later, but these 4 are already pretty nice.
Note that the controller needs a 12V feeding, that is supplied by the charger itself. The 4 wires between the charger and the controller are: Ground, +12V, CAN-L, CAN-H.

Here are some pictures. I still have to get a 4 positions commutator (instead of my ugly piece of plexiglass with 4 plugs), and a box to put everything inside.

Hors ligne Gérard Tayeb

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Pour répondre à des questions qu'on vient de me poser, je joins le schéma de câblage de mon adaptateur de prise "Mennekes Type 2" vers 3 prises de 220V.
Le fichier contient 2 pages. La première était mon idée de départ (tout mettre sur une seule phase). Puis je me suis dit qu'il valait mieux profiter des 3 phases, ce qui correspond à la deuxième page. Il semble que quasiment toutes les stations qui utilisent les prises de Type 2 sont en triphasé, et de toutes manières "qui peut le plus peut le moins!".
Certaines stations de charge peuvent bloquer la prise. Pour la libérer il faut ouvrir l'interrupteur entre CP et PE. Au départ j'ai utilisé un connecteur provisoire (qu'on voit sur les photos). Je viens d'acheter un interrupteur à clé que je vais installer à la place.

J'ai acheté le matériel ici:
https://fr.aliexpress.com/item/Duosida-Dostar-EV-PLUG-32A-IEC-62196-2-European-standard-Type-2-male-connector-for-electric/32812965439.html
https://fr.aliexpress.com/item/Key-Switch-ON-OFF-Lock-Switch-KS-01/32490689557.html

Autres infos:
https://en.wikipedia.org/wiki/Type_2_connector
Attention, si vous démontez la prise sans précaution, vous vous retrouvez avec 2 broches de longueurs différentes pour PP et CP. Pour la remonter, il faut savoir que la broche la plus longue est PP.

http://evbitz.uk/EVBitz.uk/EPC_Wir_Diags_%26_Description.html
https://www.evchargeking.com/fr/t/charginginfo
http://electricmotorcycleforum.com/boards/index.php?topic=8248.0

« Modifié: 2018, sept., 01, 19:13:51 par Gérard Tayeb »

Hors ligne Gérard Tayeb

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J'ajoute quelques précisions postées par ailleurs:

Vidéo montrant le connecteur Anderson, et qu'il n'est pas nécessaire de découper le cache en caoutchouc sur une FXS:
https://www.youtube.com/watch?v=5VZz5fbscx0

Une réponse sur les chargeurs dans cette discussion:
https://www.facebook.com/groups/zmcowners/permalink/1867283203340879/

Hors ligne Gérard Tayeb

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J'avais aussi lancé une discussion sur http://electricmotorcycleforum.com/boards/index.php?topic=8087 où on peut trouver quelques autres détails.