Electric Motor Werks Mini-SmartCharge-12000 User manual

Brand: Electric Motor Werks

Model: Mini-SmartCharge-12000

Type: User manual

Mini-SmartCharge-12000

User Guide (as of September, 2016)

Overview

The Mini-SmartCharge-12000 is a constant power charger intended for electric motorcycles and

other Electric Vehicles with battery packs that operate entirely under 360V. The constant power

approach gives the user the ability to maximize the power potential of any charging station or

power outlet available. The Mini-SmartCharge will adjust the current draw from any station or

power outlet to match the desired charging power to the battery.

Because the Mini-SmartCharge-12000 is a third-party charger, you will need a basic

understanding of the interaction between the Mini-SmartCharge and the vehicle. For the

purposes of this document, we generally assume the vehicle is a Zero electric motorcycle from

model year 2013 onward for models: S, DS, SR, and DSR. Adapting this guide’s

recommendations to another platform is a specific matter, and this guide serves as an example

and basis of work.

The procedure for using the Mini-SmartCharge-12000 has a universal pattern, but different

sources of power will require different means of connection. The Mini-SmartCharge supports

Level 2 J1772 EVSE connections by default but may be used with an adapter for NEMA 14-50

or other AC outlets, or a direct AC connection. Input configuration may also consist of a DC

direct input.

To test the installation, use known working charging stations or power sources. When possible

during basic testing, use low power sources before high power sources to minimize risk.

Guidance

Because the Mini-SmartCharge-12000 is a third-party charger uniquely suited to small EV range

extension, take care to mind one’s available range when setting out and when planning to use a

charging station. Plan before arriving to allow for station failure; the ability to travel to the next

available station is key to minimizing travel risk. Even if this risk appears slight, we advise you

maintain a charge buffer to travel at least 15 miles to handle unanticipated failures.

Limits

Input Voltage Range (AC)

12V - 277V

Input Voltage Range (DC)

12V - 400V

Output Voltage Range (DC)

0 - 360V

Output Power Range

0 - 12kW

Output Current Range (DC)

0 - 70A

Max. Operating Temperature

Cutbacks at 65C; shutdown at 70C

The voltage range is programmable, so for other applications we can create custom firmware.

Zero 2013+ and Brammo configuration:

Minimum Voltage

70V

Maximum Voltage

118V under load; 116V resting

Maximum Charging Power

9.3kW (80A at 116V) or 1C rate

Zero 2011-2012 configuration:

Minimum Voltage

48V

Maximum Voltage

75V

Maximum Charging Power

1C rate

The charger when started will operate at a charging rate configured initially at 5kW which

applies on every starting sequence until overridden. This startup rate is configured separately

from a manually requested rate while operating.

1 Power limits may vary depending on output voltage based upon thermal testing of your specific

implementation.

2 Higher power available with further testing. To be made available via firmware update. Higher

power units available before testing complete with warranty waiver.

Operating Conditions

The Zero motorcycle battery will open internal contactors to disconnect itself from the

motorcycle in a number of conditions. To charge, the contactors must be closed; to ensure this,

you must either: (1) leave the motorcycle keyed on, (2) use the onboard charger separately with

a power source. The contactors make an audible “click” sound when closing and opening; only

initiate a Mini-SmartCharge-12000 session after the contactors close.

The Zero battery will open contactors for the following conditions.

Inactivity

If the motorcycle is keyed on and not otherwise set in charging mode, and then 30 minutes pass

without control input. Twisting the throttle is sufficient to reset this timer; otherwise restart

charging once it happens.

Voltage

Voltage is too low or too high outside its safe operating range. If voltage is too high, confirm with

the Zero mobile application and attempt to bring it back to normal range by discharging the

battery by operating the motor (fastest) or turning on all electrical loads.

Power

Incoming power exceeds a 1C rate continuously for a minute. A 1C rate charges the battery fully

in 1 hour. For a battery with 13 kWh max capacity, this value will be 13 kW. If the charge rate is

too high for the battery, downgrade the charge rate and restart.

Temperature

If temperature is outside safe operating bounds: 0F to 120F. The Zero battery normally emits

heat while its charging rate exceeds 4 kW, and it will cool if under that threshold. When riding

aggressively one might choose to start at a lower power charge to cool the battery from overly

aggressive riding or racing.

If temperature is out of safe range, do whatever is appropriate to bring the temperature back in

range.

Response

If the contactors open while charging, stop charging immediately and examine the motorcycle

for any error sequences or codes per the Zero owner’s manual. To restart charging, first

disconnect charging, turn the motorcycle off, wait 10 full seconds before turning the motorcycle

on again, and only restart once indications are normal.

Operation

Start Charging

WARNING: Failure to follow these steps may cause a damaging rush of

current. By reading past this point, you explicitly accept all responsibility for any

such damage, and hold Electric Motor Werks, Inc. harmless against litigation or

prosecution even if errors or omissions in this warning or the document itself

contribute in any way to damage.

To charge, the contactors must be closed as per the above operating conditions. To ensure this,

you must either: (1) leave the motorcycle keyed on, (2) use the onboard charger separately with

a power source. The contactors make an audible “click” sound when closing and opening; only

initiate a Mini-SmartCharge-12000 session after the contactors close.

Connect the station power source to the Mini-SmartCharge-12000 inlet. For J1772, initiate

charging mode in whatever way the station requires, then insert the station plug into the

Mini-SmartCharge inlet. For NEMA 14-50, insert the NEMA plug into the station receptacle and

then connect the J1772 adapter plug end into the Mini-SmartCharge inlet.

● Expect the Mini-SmartCharge-12000 cooling fans to turn on immediately and stay on for

as long as the Mini-SmartCharge-12000 has power. Do not operate the

Mini-SmartCharge-12000 without fans on at greater than 3kW.

● Once charging has commenced and the green charging light is flashing on your dash,

you may safely turn the key off and the bike will continue to charge.

● Expect the Zero motorcycle to report charging mode and time to full charge on the dash

display if the motorcycle is already in charging mode by the onboard charger.

● Confirm charging level in the Zero companion mobile app.

● Expect charging rates to be lower when the battery state of charge is low (below 20%

and somewhat while below 40%) and if the desired wattage needs over 95 Amps at the

current battery SOC.

● Expect the Mini-SmartCharge-12000 to reduce power once battery voltage dynamically

reaches 117 V. It will reduce power in relatively fine increments to keep voltage just

under 117 V until this is not possible and then charging will stop. The cooling fan unit will

keep running until the Mini-SmartCharge’s power source is disconnected. Battery

voltage should return to 116 V once charging stops.

Stop Charging

Disconnect the J1772 plug from the Mini-SmartCharge-12000 inlet. Then, return the plug to its

holster for a J1772 charging station, or collect your the NEMA 14-50 plug from the receptacle at

this point.

Restart Charging

Disconnect power as recommended in Stop Charging above.

Turn the motorcycle off and disconnect the onboard charger.

Wait several seconds to allow the motorcycle to reset its systems.

Turn the motorcycle on or connect the onboard charger to make it accept charging.

Connect power again as in Start Charging above once indications are normal.

Battery Theory of Operation

● Battery voltage will rise with its state of charge while charging from below 20% and then

stays relatively constant (easing from 100V to 104V) from 20% to 80% where it starts

rising again.

● A Zero battery will have a full charge when it has 116V while at rest. During a charging

session, the voltage will dynamically increase by 1V so expect 117V at the end of a full

charge until charging stops.

● Indications for the Zero battery state of charge while charging may have a significant

inaccuracy at times, and typically report lower than actual towards the upper end of the

range (80% - 100%). Turning the motorcycle off and letting the contactor open and

waiting for several seconds should restore charge accuracy.

● The battery will charge most efficiently between roughly 20% and 80% state of charge;

focus on using this band if time spent is more critical than range.

● The Zero battery will emit heat above a charging level of 4kW, and will naturally cool

below that threshold. Expect several degrees Fahrenheit rise when performing a full

charge near a 1C rate.

● Discharging a battery at a very high rate can also produce heat. If the battery

temperature is already high enough to cause concern about the next charging phase,

ride at relatively modest speeds to allow ventilation to cool it faster than discharge heats

it up. Use a battery temperature indication to help understand this.

● High ambient temperatures will make maintaining a safe battery temperature more

difficult. Shade and ventilation may help.

● When keying on, the battery needs to precharge the controller circuit before closing

contactors for electrical safety. After using the Mini-SmartCharge regularly, if contactors

do not close within a few seconds, precharge may not have behaved normally. Key the

motorcycle off and wait two seconds before keying it on again. Wait until hearing the

contactors close to use the throttle.

● Because the precharge circuit is connected to the motorcycle’s power conductors even

with the contactor open, it is vulnerable to damage if the Mini-SmartCharge output is

(re)connected before it has fully discharged. Maintain permanent connection between

the Mini-SmartCharge-12000 and the motorcycle, or wait at least 10 minutes after both

contactors open and the Mini-SmartCharge is de-energized to (re)connect the systems.

● When using the Mini-SmartCharge repeatedly at high power, over time the battery state

of charge may become inaccurate. Keying off for ten minutes or performing a BMS reset

should restore charge accuracy.

Charging Station Operation

Some general concepts are worth keeping in mind when using charging stations or high power

plugs:

● The power a station puts out is a product of current and voltage. A lower voltage station

may not be able to emit as much power as one with higher voltage.

● Station voltage may sag under load compared to its unloaded measurement. This effect

can make its load seem pronounced and cause the station to protect itself to observe its

limit settings.

● A station may advertise its rate at a certain level but be set to break the circuit at a lower

level, or the circuit may break because of a combined load between the plug you intend

to use and adjacent plugs. If a station’s circuit breaker trips, you will hear a loud “thunk”

and the Mini-SmartCharge-12000 will turn off. Reset the circuit breaker if possible, and

then restart charging at a lower level or distribute the load between circuits using another

charger. Otherwise, find another station until it is serviced.

● An EVSE / J1772 station has its own software to manage charging and may stop

charging for a variety of reasons that are difficult to anticipate. Monitoring charging

remotely helps detect these problems when available. Restart charging and observe its

behavior carefully.

● A DC power station would still require the Mini-SmartCharge-12000 or equivalent to work

with a battery, in order to make that power safely stay within the output voltage range

and charging limits.

Using Another Charger Simultaneously

The Mini-SmartCharge-12000 cannot naturally balance its input or output with another charging

device.

WARNING: A charger that is energized and then connected to a de-energized

charger may cause a damaging rush of current. By reading past this point, you

explicitly accept all responsibility for any such damage, death, or injury, and

hold Electric Motor Werks, Inc. harmless against litigation or prosecution even if

errors or omissions in this warning or the document itself contribute in any way

to damage, death, or injury.

Observe the following guidelines at all times:

● The Zero accessory charging port has a fuse to enforce a limit on power drawn through

it. This fuse is not customer serviceable so mind it carefully. Check your owner’s manual

for the particular value, but for 2015-2016 Zero motorcycles, input to that port is limited

at 7.6kW steady state. 2014 should allow 6kW and 2013 allows 3kW.

● All chargers used on a battery should be designed or set to operate in that battery’s

voltage range, and should reduce power to accommodate the end of charging safely.

● Keep the Mini-SmartCharge installed in a fixed configuration for its power input and

output. To reconfigure the Mini-SmartCharge, wait until the both



the Mini-SmartCharge

and



Zero motorcycle have been completely powered off with contactors open for at least

10 minutes to avoid crippling damage to power electronics



● Connect the Mini-SmartCharge and wait for contactors to close normally before initiating

any charging.

● Plan combining chargers and power sources so that the battery can accept the

combined charging rate.

● To connect another charger, always start charging with only the Mini-SmartCharge

connected, then take the other charger and connect its input to a power source but leave

its output disconnected.

● Wait several seconds to confirm operation of both the Mini-SmartCharge and the other

charger, then connect the other charger’s output to the Zero accessory charging port.

● You may disconnect either charger’s input in any order once connected, but only

reconnect while observing the above guidelines.

Electric Motor Werks Mini-SmartCharge-12000 User manual

Brand: Electric Motor Werks

Model: Mini-SmartCharge-12000

Type: User manual

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Electric Motor Werks Mini-SmartCharge-12000 User manual

Electric Motor Werks Mini-SmartCharge-12000 User manual

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