DigiNow/Super Charger V2.5
From Unofficial Zero Manual
- 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.
- 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:
- 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
- 9.9kW charger SKID PAN final version unit for Zero Motorcycles by DoctorBass on YouTube:
- 10kw Zero charger project almost finished!! by DoctorBass on YouTube:
- Zero Modding Updates + Pluggin in a DigiNow Supercharger at Home by NewZeroland on YouTube:
- 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.
- Connect the power source to a J inlet.
- 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
00:00and slowly converge from a very high number of hours to an expected value as power increases at the configured ramp rate.
- Expect this to start as
- Listen for cooling fan engagement.
- Download a serial Bluetooth (LE) console emulator.
- Open the app and select the Menu button in the top left corner, then Devices, then Bluetooth LE
- Plug in the charging system / motorcycle to a power source
- Press scan on the app on your phone
- 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
- Press the menu button again, then Terminal
- Once in the Terminal View, press the connect button on the top right hand corner to the left of the trash can icon
- 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:
|BMS info||Charger info|
||Battery voltage used||min(V0, V1)||0.1VDC|
||Target total charging current||(Dynamic)||0.1ADC|
||Total battery capacity||C0+C1||1Ah|
||BMS0 Lowest Cell Temperature||BMS0||1℃|
||BMS0 Highest Cell Temperature||BMS0||1℃|
||BMS1 Lowest Cell Temperature||BMS1||1℃|
||BMS1 Highest Cell Temperature||BMS1||1℃|
||Number of chargers acknowledging||Configuration||1 charger|
||Target total charging power||Configuration||1W|
||Requested total charging power||(Dynamic) ≤PT||1W|
||Capacity override flag||Configuration||1=override|
||Charging power ramp rate||Configuration||1W/sec|
||Control Board Firmware Version||(Fixed)|
- Use the steps above to begin monitoring the charger.
- Enter a CSV string corresponding to the following second-hand specification:
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.
- Select or compose an appropriate CSV string for your setup.
- Input it in the entry at the bottom of the app
- Send it to the charger by pressing the arrow button to the right of the entry
- Observe either through the Zero app or some meter that the actual wattage is as desired.
- Example CSV config messages
- 1.3kW wall charging
- 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
- 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):
- 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.