Electric Motor Werks Mini-SmartCharge-12000 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.

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Limits

Input Voltage Range (AC)

12V - 277V

Input Voltage Range (DC)

12V - 400V

Output Voltage Range (DC)

0 - 360V

Output Power Range

0 - 12kW

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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

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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.

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

implementation.

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

power units available before testing complete with warranty waiver.

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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.

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