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Battery and Charging

Battery, adding to, replacing, maintaining and charging.

1 - Add

Add additional batteries

I will be looking at the manufacturer add on batteries, and my own soon.

Manufacturer Battery Type

In my 5kw model - Ternary Lithium Battery, 72 volts, 80 Ah, 30kg

Where to get new batteries

Manufacturer

Wondering if you can buy the 10kW version battery, which I think is 120 Ah instead of 80, but should fit in the same space? Look into it.

Online

Expensive. I found almost all 50Ah + size batteries were over $2000. I found one 72V, 70Ah with a 10A charger for $1000 via China. This would double my range.

DIY

Not looked into prices yet. I’ve built batteries before, but never this large.

Location of Mounting

Existing Battery Pack

I suspect, considering the 8kW and 10kW bikes have larger batteries, there is space here. Look at that in the box.

Rear Seat

This is a nice easy location to use, either inside, below, to the sides or on top.

Side car

You could have sidecar, and carry camping stuff, etc

Rear Trailer

Better alternative to sidecar, I think they are easier/safer to use, and certainly cheaper. Should not be that hard to wire in the lights, and an extended battery cord.

2 - Charging

Charging

Stock Charger

The stock charger is good, it charges at about 80 volts, 15 Amps. So a little over 1000 watts.

  • Specification (written on it)
    • Model C1200 battery charger
    • Input: 200-240 vAC, 50/60Hz, 15A
      • NOTE: It has a 10Amp plug, and only drawers about 1200 watts, so that 15 amps above is WRONG
    • Output: 84V, 15A
    • Battery: For Li-Ion Battery
  • Other notes
    • LED Red = Charging
    • LED Green = Fully charged
      • NOTE: Blinks when not connected

Top of charger

Connector

Faster Charge

Since we have 240 volt, 10Amps = 2400 watts, available in Australia, we should be able to build a charger that delivers in excess of 25 amps.

There are some 25A and even 50A chargers available with full automation and 4 stage controllers and more feedback. Obviously 50 amp chargers need bigger houe plugs (17 amps). Australia can have installed 10, 15, 20, 25 and 32 amp single phase plugs. For now I will concentrate on 10 amp chargers, which should produce about 25 amps into the battery.

Manufacturer Fast Charger

There is a 25 Amp Fast Charge set that is designed to be used at electric car fast charge locations. It looks interesting and has the correct connectors etc. I don’t yet know anything about these ports, do they need some form of communication, like USB-C to set the voltage etc. On the web site there is a picture of the cables but also a box. I’m wondering if that box is going inside the unit

Understanding

EV Level 1,2,3 chargers

Level 3 chargers run at 480 volts, 100 amps. 48,000 watts, or more than 10 15 amp power plugs. So not in any way practical in home use.

Level 2 chargers,

https://www.lifewire.com/every-ev-charging-standard-and-connector-type-explained-5201160

Volts

The volts of the charger will say either 72 or 84. The batteries are 72 volt lithium, but need to be charged to 84 volts. Therefore chargers will sometimes say 72, sometimes say 84.

Solar

In the post is a Solar MPPT 72V Lithium charger. It is only a 600W charger, so max about 7Amps - but if I can get it working ok, it will be free charging. About 8+ hours is my estimate.

Mounted and Waterproof

The stock charger is not water proof and should not be mounted on the bike. I have purchased a seat bag (waiting) to put it in for normal use, and for shopping.

Braaap are going to release a fast charger (25A I think) designed to be mounted and to allow you to use commercial charging stations.

Untested list

Here is a list of other chargers you could buy online. I have not reviewed or tested any of these. You need at least IP65/IP66 (IP67 is for immersion in water for 30 minutes, and not necessary) for water resistence (generally this means splash proof). Technically 64 should be enough. You need a 72V charger. The battery has the main BMS (battery management system) for balance charging, but you still need to make sure your external charger has the right cut off.

Also the stock wiring in the bike is a little thing for 25A or 30A charger, even though the Anderson plug used can do up to 50A.

For reference, here are a few searches:

An example charger, with cables, indicator and rated IP66

3 - Mount

Mounting the charger onto the bike.

Locations

  • Specific space side of bike
  • Rear seat

Weight

Wire routing

4 - Plug

Charging Plug

2022 as provided - In rear seat

Uses a Anderson Plug (TODO Model, rating etc). It has a large connection inside the motorbike, assuming down to the battery. It is always live.

I’m assuming that this is rated to at least 25 Amps for the fast charger.

This is a very high quality plug with plenty of amps. The stock charger, has a much smaller lead (due to it only being 15 amps).

2022 as provided - External plug

The manufacturer has removed the plug from the charger, but it is still on the bike.

It is actually a IEC C13, also known as a kettle cord. It is common in Australian kettles and most computer equipment.

https://en.wikipedia.org/wiki/IEC_60320#/media/File:IEC_60320_C13.svg

I can’t find out information on if it is legal to use. I’m guessing yes, since we control what does plug into 240 volts, not the other way around.

These plugs are rated to 15 amps though.

Scott’s EC13

Use an EC13 and connect it in parallel on the charger, to allow an alternative plug. I will need to monitor current and temperature to make sure this is safe. Pretty confident it will be.

My plan would then be cover it in red heat shrink, and a plastic large label to identify that it is 72 (or technically 84) volts.

Scott’s Internal Charger

Manufacturer has provided a spot to mount the charger. In reality there is some holes, but I can’t see any way to put screws in, until I pull the bike apart.

Howevev, if I do connect that onto the side, route the DC cable back up to the existing Anderson connector, then I could replace that EC13 socket with a 3 pin (ie, including earth) to the charger. Then I only need to plug in a standard 240 volt kettle cord, which is easy to carry.

See Mount

2022 Manufacturer Fast Charger

Apparently the fast charger will fit into the fuel tank slot to allow simple plug into to Level 2 chargers out in the real world. I have looked at the tank, and it seems quite constricted. Maybe it is possible, or maybe they plan on replacing the tank.

Maybe there is other things I can use in that spot, as it is nicer than removing the rear seat.

New Anderson Plug

I’m considering a new Anderson Plug to replace the EC13.

The one I found looks like it will be easy to install and replace the existing one. Internally I can use some good quality UV/Water proof heat shrink on the wires, which will vastly improve what is there.

Externally though, I could not find a panel mount anderson plug that has a cover. I’m going to hack away at that today to see if I can make a rubber cover that pulls into place.

5 - Replace

Replace main battery