DigiNow/Super Charger V2.5

From Unofficial Zero Manual
< DigiNow
Revision as of 05:54, 14 August 2018 by BrianTRice (talk | contribs)

Jump to: navigation, search

This refers to v2.5 of DigiNow's charger product, released in early 2018, following on V2.

This release revises the V2 controller to integrate better with the vehicle.
There are unconfirmed claims of revisions to the charging units themselves.
Reportedly, the charging units shipped as of 2018(?) support 4kW per unit when station voltage is high enough, up from 3.3kW in V2.

See DigiNow/Super Charger V2 for most details; 2.5 details are only published in various forum posts for now.

Features
  • The v2.5 control board can upgrade an existing v2 install.
  • v2.5 install defaults to a bellypan fitment (shipped to/from DigiNow) which replaces the onboard charger.
  • Uses the onboard charger's CANbus connection for these features:
    • It can initiate charging from a completely keyed-off motorcycle state.
    • Balances the Power Tank and Monolith.
    • Adjusts/limits charging on the fly based on BMS-reported voltages, capacities, and temperatures.
  • Removes 3.3kW maximum per-unit power limit from v2.0.
  • Removes the v2 limit on the number of chargers (3?).
    At higher voltage stations or plugs you may see up to 4kW per unit.
  • There is also a text-protocol-based Bluetooth LE (BLE) interface which offers some dynamic inspection and configuration abilities.
  • Can target a battery voltage limit where it will taper and then stop to target an SoC for better lifetime conditioning of the battery cells.
    Initially configured by DigiNow; changed via BLE console.
    i.e. stop at 80% (110.0V) every night or 60% (106.0V) when not riding for a month, versus a default of 100% (116.4V).
Video Guides
Installation
The installation method for 2.5 is into the bellypan replacing the onboard charger, and connecting to the bike with its connector.
This is how the DigiNow 2.5 control board listens to BMS and MBB messages and act on them appropriately.
The stock bellypan is not deep enough to enclose the units, so the cooling fans are smaller and the pan is reinstalled over the chargers with bolts and offsets.
A custom-engineered pan is in development by DoctorBass, to be released, which doubles as a heatsink.
Startup
  1. Connect the power source to a J inlet.
  2. Confirm startup sequence for the state:
    • Contactors (one or both installed batteries) should click shut if not already.
    • Instrument cluster engages charging green flashing indicator
    • Instrument cluster shows time to charge.
      Expect this to start as 00:00 and slowly converge from a very high number of hours to an expected value as power increases at the configured ramp rate.
  3. Listen for cooling fan engagement.
Monitoring
  1. Download a serial Bluetooth (LE) console emulator.
    Examples
    (Used below) Serial Bluetooth Terminal app for android
    HM10 Bluetooth Serial Pro app for iOS
  2. Open the app and select the Menu button in the top left corner, then Devices, then Bluetooth LE
  3. Plug in the charging system / motorcycle to a power source
  4. Press scan on the app on your phone
  5. You should see a device discovered which includes SCv2 in it's name, select that device, the left side of the menu item should turn green
  6. Press the menu button again, then Terminal
  7. Once in the Terminal View, press the connect button on the top right hand corner to the left of the trash can icon
  8. The terminal should indicate a successful connection and there will be CSV output approximately once a second
Event Example

For a ZF13.0 with 3.3 Power Tank and 1 DigiNow charger at 110V:

1032,1032,1032,957,10,3,104,26,130,20,20,21,3,9900,9900,0,50,3
Message Decoding
BMS info Charger info
Voltage Current Capacity Temperature Power
Vmin V0 V1 IT I0 I1 C0 C1 CT T1 T2 T3 N PT P O ∂P v
1032 1032 1032 957 10 3 104 26 130 20 20 21 3 9900 9900 0 50 3
Event Fields
Var Label Source Unit
Vmin Battery voltage used min(V0, V1) 0.1VDC
V0 Battery voltage BMS0 0.1VDC
V1 Battery voltage BMS1 0.1VDC
IT Target total charging current (Dynamic) 0.1ADC
I0 Battery current BMS0 1ADC
I1 Battery current BMS1 1ADC
C0 Battery capacity BMS0 1Ah
C1 Battery capacity BMS1 1Ah
CT Total battery capacity C0+C1 1Ah
T0 BMS0 Lowest Cell Temperature BMS0 1℃
T0 BMS0 Highest Cell Temperature BMS0 1℃
T1 BMS1 Lowest Cell Temperature BMS1 1℃
T1 BMS1 Highest Cell Temperature BMS1 1℃
N Number of chargers acknowledging Configuration 1 charger
PT Target total charging power Configuration 1W
P Requested total charging power (Dynamic) ≤PT 1W
O Capacity override flag Configuration 1=override
∂P Charging power ramp rate Configuration 1W/sec
v Control Board Firmware Version (Fixed)


Adjustment
  1. Use the steps above to begin monitoring the charger.
  2. Enter a CSV string corresponding to the following second-hand specification:
    Vlimit,Ilimit,N,Ptarget,O,∂P
    • Vlimit: target voltage
      in units of 0.1V, so 1164 = 116.4V
    • Ilimit: battery current limit
      Use the contactor C-rate limit ≈ sum of Ah-rating of all BMS units attached
    • N: number of chargers assumed!
      The controller broadcasts a message that all chargers should respond to, dividing the power target below by this number.
    • Ptarget: target total wattage across all listening chargers
    • O: 1C+ flag
      Always use 0 unless you've bypassed the contactor!
    • ∂P: power ramp rate (W/sec)
      This limits power level adjustments unless there's an emergent condition requiring fast ramp-down.
  3. Select or compose an appropriate CSV string for your setup.
  4. Input it in the entry at the bottom of the app
  5. Send it to the charger by pressing the arrow button to the right of the entry
  6. Observe either through the Zero app or some meter that the actual wattage is as desired.
Example CSV config messages
  • 1.3kW wall charging
    1164,104,2,1300,0,50
    This charges a 104Ah pack to 116.4V, assumes 2 charging units connected, distributes 1300W=1.3kW between them, no contactor bypass, and only changes power by 50W/sec
    The controller broadcasts a 650W message and assumes 2 chargers will implement it.
  • 6.6kW EV station charging
    1164,104,2,6600,0,50
    Per above, but targets 6600W=6.6kW across 2 chargers
    The controller broadcasts a 3300W=3.3kW message and assumes 2 chargers will implement it.
  • 9.9kW EV station charging (if you have 3 units):
    1164,104,3,9900,0,50
    Per above, but targets 9900W=9.9kW across 3 chargers
    The controller broadcasts a 3300W=3.3kW message and assumes 3 chargers will implement it.
References
EMF announcement of DigiNow SuperCharger v2.5
Facebook announcement of DigiNow SuperCharger v2.5
Third-party Google Doc incompletely documenting v2.5 by BrianTRice