Battery Theory of Operation
● Battery voltage will rise with its state of charge while charging from below 20% and then
stays relatively constant (easing from 100V to 104V) from 20% to 80% where it starts
rising again.
● A Zero battery will have a full charge when it has 116V while at rest. During a charging
session, the voltage will dynamically increase by 1V so expect 117V at the end of a full
charge until charging stops.
● Indications for the Zero battery state of charge while charging may have a significant
inaccuracy at times, and typically report lower than actual towards the upper end of the
range (80% - 100%). Turning the motorcycle off and letting the contactor open and
waiting for several seconds should restore charge accuracy.
● The battery will charge most efficiently between roughly 20% and 80% state of charge;
focus on using this band if time spent is more critical than range.
● The Zero battery will emit heat above a charging level of 4kW, and will naturally cool
below that threshold. Expect several degrees Fahrenheit rise when performing a full
charge near a 1C rate.
● Discharging a battery at a very high rate can also produce heat. If the battery
temperature is already high enough to cause concern about the next charging phase,
ride at relatively modest speeds to allow ventilation to cool it faster than discharge heats
it up. Use a battery temperature indication to help understand this.
● High ambient temperatures will make maintaining a safe battery temperature more
difficult. Shade and ventilation may help.
● When keying on, the battery needs to precharge the controller circuit before closing
contactors for electrical safety. After using the Mini-SmartCharge regularly, if contactors
do not close within a few seconds, precharge may not have behaved normally. Key the
motorcycle off and wait two seconds before keying it on again. Wait until hearing the
contactors close to use the throttle.
● Because the precharge circuit is connected to the motorcycle’s power conductors even
with the contactor open, it is vulnerable to damage if the Mini-SmartCharge output is
(re)connected before it has fully discharged. Maintain permanent connection between
the Mini-SmartCharge-12000 and the motorcycle, or wait at least 10 minutes after both
contactors open and the Mini-SmartCharge is de-energized to (re)connect the systems.
● When using the Mini-SmartCharge repeatedly at high power, over time the battery state
of charge may become inaccurate. Keying off for ten minutes or performing a BMS reset
should restore charge accuracy.
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