XMX Platform/Charging Off-Bike
From Unofficial Zero Manual
- Goal
- The XMX Platform FX/FXS models have removable power pack modules that can be charged while off the bike.
- NOTE: 2017 models do not have modular packs unless requested as an extra-cost option.
- Motivations
- Charging packs off the bike can be useful when the bike is parked where there is no power available.
- It can also be faster because the external chargers have higher wattage and can be combined using Y adapters.
- Swapping fully charged packs with a depleted ones is by far the fastest way to recharge an electric motorcycle; it can be done in minutes.
- Notes
- The power packs are easily removed but they weigh over 40 pounds (19 kg) each, so handling requires strength and care.
- To use two separately-charged packs together, it is best to charge them to the same voltage / SoC.
- The bike tries to use both packs equally at the same time.
- If one has a higher charge state, it will use it until it matches the lower-charged one and then use both together.
- That can reduce the bike performance at high speeds and torque demand since it can't use both packs when they are unbalanced.
- Cabling
- Connecting external chargers to the power packs requires the Power Pack Module Charging Adapter sold by Zero for $140 each.
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- Combining external chargers for one Power Pack module requires the Quick Charger Y Adapter sold by Zero for $250 each.
- Each Y cable joins 2 chargers. Joining 4 chargers requires 3 cables; two cables join each pair of chargers, and then the third cable joins the output of each Y cable.
- DIY OPTION: See the Y-Cable instructions to make one using Anderson connectors.
- Configurations
- A wide variety of charging connections can be used on and off the bike with various charging rates and AC power requirements.
- Here are the possibilities using various chargers combined with the onboard 650W Calex charger in some cases.
- The C-Rate is computed for a ZF3.3 Power Pack Module shipped on 2016-2017 models.
- Older models carrying a ZF2.8 will require multiplying this rate by 1.17.
| Chargers | Circuit Rating | |||||||
|---|---|---|---|---|---|---|---|---|
| External Model | Per-Unit Power | Rate | Packs | Onboard | External | Y-cables | @ 120V | @ 240V |
| N/A | 0 | 0.10C | 2 | ✓ | 0 | 0 | 15A | 10A |
| 0.20C | 1 | |||||||
| OEM Quick Charger | 1kW | |||||||
| 0.14C | 2 | ✗ | 1 | 1 if off bike | 15A | 10A | ||
| 0.24C | 2 | ✓ | 1 | 0 | ||||
| 0.28C | 1 | ✗ | 1 | 0 | ||||
| 0.28C | 2 | ✗ | 2 | 1 if on bike | 20A | 10A | ||
| 0.38C | 2 | ✓ | 2 | 1 | 25A | 15A | ||
| 0.55C | 1 | ✗ | 2 | 1 if on bike | 20A | 10A | ||
| 0.55C | 2 | ✗ | 4 | 3 | 50A | 25A | ||
| 0.65C | 2 | ✓ | 4 | 3 | 50A | 25A | ||
| 0.75C | 1 | ✓ | 2 | 1 | 25A | 15A | ||
| Elcon 2500 | 2.5kW | 0.44C | 2 | ✗ | 1 | 0 | – | 15A |
| 0.54C | 2 | ✓ | ||||||
| 0.87C | 1 | ✗ | ||||||
| DigiNow SuperCharger | 3.3kW | 0.58C | 2 | ✗ | 1 | 0 | – | 15A |
| 0.68C | 2 | ✓ | 20A | |||||
- Over-Rating Configurations
- 4 OEM Quick Chargers with one pack exceeds the 1C contactor limit.
- 1 DigiNow SuperCharger exceeds 1C for one Power Pack Module unless de-rated in the firmware below 3.3kW.
- Power Pack Discharge / Diagnostics Adapter
Single Brick off bike Pack SOC tester, close contactor A variation of the DIY charging adapter, this controls the enable signal for testing.
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- Zero FX Single Battery Block Hack video on YouTube
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Packs that are off the bike can be monitored to determine the state of charge by measuring the voltage:
- Use a DVM with probes as shown to get a reading between 90 and 117 volts.
- Then use these graphs to find the approximate charge level that the bike will report.
