Type2 Mennekes to 3 230V Sockets

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About: Love 3D printing, 3D modelling, FabLabs, DIY and DIT, crazy about EV's!

For four years I am happily driving my electric motorbike now, the ZeroS.

And yes, charging time has become an important part in deciding to go somewhere by motorbike or taking the car or public transport...

Since my model is too old to add a charge tank, I've decided to create my own charge case :)

There are plenty charging stations in the Netherlands, where you can easily charge your vehicle with a Type2 connector. At home I charge with a regular domestic socket, but that is a pretty slow option when on the road. Plus there are not so many public power outlets...

Currently I can already use charging stations when I take an adapter with me, but since I'm only using 1 phase, it's still charging slowly.

So, let's use all 3 the phases available at the charging stations, by creating our own adapter!

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Step 1: Sourcing the Stuff

First of all I needed to add a topcase (that I still had) and a top box rack to my bike, so I can easily carry the charger. I won't focus on that now.

It took some time to find a company that was willing to sell me a Type2 connector that I could assemble myself. After contacting Laadkabelfabriek, we even had a nice brainstorm through e-mail about the possibilities :) So I sourced my Type2 from the 'Laadkabelfabriek' in the Netherlands. It is not a default part that you can order through the webshop, so just send them a mail :)

I decided to buy the version that comes with a key to start/stop charging. Ideally I would not need it, since most charging stations in the Netherlands start/stop either with a card or a push button. But just to be sure my cable will never be stuck into the charging station, I ordered this feature.

I found it hard to find these bare Type2 connectors... (Any advice for sourcing them is really welcome, please leave a comment)

Further more:

  • 2x IP44 sockets (at the local hardware store)
  • 2m. and 1m. cable 3x1,5mm2 (same local hardware store)
  • cable end sleeves for 1,5mm2 (hardwarestore)
  • cable with C13 connection (came with the charger so I used that one)
  • 3D printed insert for the cable gland (adjustable file is on Tinkercad)

Step 2: Preparing the Cables

Prepare your cables with cable end sleeves to ensure a good connection into the Wago terminal block.

I stripped ~10cm of the cable to enable some flexibility within the housing (which you will need!).

Add your sockets to the other side.

Step 3: Neatly Assemble the Connector

Put the cable gland around the cables before you start connecting them :)

Connect the cable for earthing (yellow and green) with the terminal block that has the yellow/green wire from the connector. Do the same for the blue cable.

This needs to be done for the 3 cables. So you will have a terminal block with 4 yellow/green wires for earthing and one terminal block with 4 blue wires.

The brown wires should be connected to the 3 seperate terminal blocks (the ones that only have 2 slots).

I don't know if it will matter, but I connected the C19 cable to L1, since this is the cable that connects directly to my bike.

Once you have all the wiring done, try to arrange everything neatly and slide the cable gland towards the connector housing. You should be able to close the housing without excessive forces! Re-arrange your wires when it does not close neatly!

Step 4: Result :)

Now your cable should look something like this.

I'm still figuring out what length is ideal for my application.

Bought an adapter to be more flexible between schuko and C13.

So currently I have one socket left, I could use that one to charge my phone or use any tool I can think of... What about connecting an electric BBQ?! :D I might buy a second charger to charge even faster!

To do/improve (mainly esthetic or practical improvements)

  • Rewire the connection from the charger to the motor
  • Connect charger securely to the top case
  • Buy a second charger...
  • Rewire the C13 connection on the bike so it's near the charger connection

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7 Discussions

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hagyl

Question 2 months ago on Introduction

Hi, Thanks for a nice Zero motorcycle modification idea. 1.Where do you plug in the second fast charger. My Zero S has only one connector for this. 2. can you use only two of the three phases on the type 2 plug (i.e. one for the normal charger, one for the fast charger) ??? 3. I'm having a hard time finding a type 2 plug in France. I guess you did too.
Thanks for your reply Hagyl

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Charlotte_Jhagyl

Reply 2 months ago

Hi Hagyl,
thank you!
1. To use 2 fast chargers, you will need to buy the Zero Y adapter. I never did, because I sold this setup after I installed a faster charger on my bike :)
2. No, you can use the 3 phases. In the instructable I use them all. But I made 2 schuko's and one C13 connection.
3. I did not buy it in France, but indeed had a hard time to find one. There is a link in the Instructable to a shop in the Netherlands (https://www.laadkabelfabriek.nl/product/verloop-type-2-naar-schuko-contrastekker-met-ontgrendeling/). If you contact the shop by mail, they will be very cooperative and will provide you the connector you need. (Tell Mark you're making the Instructable from Charlotte and he might know) (I noticed he made a neater solution: https://www.laadkabelfabriek.nl/product/adapter-type-2-naar-3x-schuko-totaal-11-kw/)

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GianniL3

1 year ago

where did you find printed circuit ? have you mad by yourself?

1 reply
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Charlotte_JGianniL3

Reply 1 year ago

It came with the type2 plug. There are instructions on the web how to make one yourself with a magnet.

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fred27

2 years ago

Nice write up. And nice to see another Zero rider on Instructable. (I recently got a FXS.)

1 reply
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Charlotte_Jfred27

Reply 1 year ago

I just recently noticed your reaction... Thumbs up!

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LaurentS22

1 year ago

Hello,

I contact you about the manufacture of a cable type 2 compatible all public terminals. I have a motorcycle zero S 2016 (13kw) and I would like to install a cable type 2 side terminal and on the other side 3 phases of 4mm² allowing me to charge in 2 x 20A and 1x16A (I have 2 fast chargers 3500 watt ) and the original (1500 w) charger is 8500 watts

is it possible to make that? 3 x 4mm² is enough for 3 chargers? and IEC c19 connector to 20A (12AWG)

thank

laurent