Build Your Own Electric Vehicle You need this book if you want to build your own EV

Convert SLA to LiFePO4 in 2007 Zapino

15 replies [Last post]
Offline
Joined: 04/10/2012
Posts:
Points: 34

I am the proud owner of a 2007 Zapino. The range of the batteries is now only 8 miles round trip. I am at the point where I think I need to start saving up for new batteries. With the scooter being 5 years old its recent decrepitude corresponds with the owner’s manual. I called Jeff at Voltage Vehicles (anyone notice ZAP no longer answers their phone) and he said that an upgrade of the older model scooters is not being offered. I have been searching online for suitable LiFePO4 options with a BMS (Battery Management System) and have not found success. Has anyone out there already made this conversion? I am scared to spend a lot of money on batteries that I may inadvertently destroy with my poor shop skills. Any input is valuable. Thanks, Andrea

Comment viewing options

Select your preferred way to display the comments and click "Save settings" to activate your changes.
Offline
Joined: 12/22/2007
Posts:
Points: 211
Re: Convert SLA to LiFePO4 in 2007 Zapino

I work at Small Planet E-Vehicles.I have replaced batteries on a few Zapino's.
We have 2 more to do and also the smaller AER (4 batteries).

A few years ago a Calif company had a conversion. Including the BMS, it was
almost $2000. I was checking for that company but they appear to be out of
business..

The two affordable options are standard Lead/Acid batteries. We get them from
a Battery company here in Longmont, CO.

The other is Green Saver Silicone. Current price on their website is $79.

The job takes me 2 hours.

__________________

Robert Dudley
E-Scoot Tech

Offline
Joined: 04/10/2012
Posts:
Points: 34
Re: Convert SLA to LiFePO4 in 2007 Zapino

sgmdudley,

Do you have any you tube videos or straight forward instructions about changing out the old batteries with the new batteries? Someone in an older post gave the instructions on exposing the batteries so I can physically get to them, but I am a little worried about safety and proper installation. Any input you may have is appreciated.

Andrea

Offline
Joined: 12/22/2007
Posts:
Points: 211
Re: Convert SLA to LiFePO4 in 2007 Zapino

I posted the instructions for removing all the plastic pieces to get to the batteries
in a previous post.
.
There are five batteries in Series. This means there is a plus and minus cable connected
to every battery. In addition, there are two extra wires from the the 60VDC to 12VDC
converter. One wire to first battery in the string, 2nd wire to the last battery in the
string. Since the batteries are not installed in a logical layout due to space problems,
make a diagram of the batteries and the way the cables are connected. All battery bolts
are 10mm. Usually when you are dealing with only one battery as in a car, you always
remove the minus cable first. Do the same here. Find the plus and minus leads from the
controller and the circuit breaker. They go the the 1st and last batteries. They would
be the same ones as the DC converter. Remove the minus cables first, then the plus cables.
Now you can remove the rest of the cables. I used masking tape to label each end of each
cable to match the battery number and + or -. This is because the cables are all different
lengths. One all the cables have been removed, you can now remove the battery hold down
straps & brackets. Then just lift out all the batteries and install the new ones.

__________________

Robert Dudley
E-Scoot Tech

Offline
Joined: 12/22/2007
Posts:
Points: 211
Re: Convert SLA to LiFePO4 in 2007 Zapino

PS. You can wrap your 10mm wrench with electrical tape so only the ends are exposed to minimize
shorting the battery posts to the frame.

__________________

Robert Dudley
E-Scoot Tech

Offline
Joined: 04/10/2012
Posts:
Points: 34
Re: Convert SLA to LiFePO4 in 2007 Zapino

This is very helpful information. I am going to print this off and keep in with the owner's manual. I will follow the safety tip as well. Thanks again, Andrea

Offline
Joined: 12/22/2007
Posts:
Points: 211
Re: Convert SLA to LiFePO4 in 2007 Zapino

I just did a battery replacment yesterday on a Zapino.
.
Forgot that ZAP used double sided sticky tape to hold the batteries down.
Took two of us to break loose the two batteries that are side by side. In
the past when I replaced the batteries, I used alcohol to soften the sticky
tape. The only problem is the battery box has holes so the alcohol runs out.
I used duct tape to try to seal the holes to hold the alcohol in. Yesterday
we used a couple of large flat blade scewdrivers as pry bars. Used a block
of wood to pry against. The left side battery should come out first (left as
you are sitting on the scooter). The right side is under the frame a bit so
has to come out 2nd.

__________________

Robert Dudley
E-Scoot Tech

Offline
Joined: 04/10/2012
Posts:
Points: 34
Re: Convert SLA to LiFePO4 in 2007 Zapino

Sgmdudley,

I'm sure that my batteries will be really stuck down because of thier age. Thanks for the tip. It will likely save me time trying to figure out the quirks.

What battery suplier did you use? What brand of battery did you decide to replace the old ones with?

Thanks for sharing.

Andrea

Offline
Joined: 01/03/2011
Posts:
Points: 231
Re: Convert SLA to LiFePO4 in 2007 Zapino

If you are still interested in doing a lithium conversion, you can purchase a complete solution from: www.elitepowersolutions.com. They're not cheap, but you do get a matching set of cells, BMS, LCD SOC display, charger, etc.

I link to their 60V packages is: http://elitepowersolutions.com/products/index.php?cPath=27_45

__________________

Motorcycle: ZEV 6100, 77V, 40AH, 60+mph; Cycle Analyst, LED head lights, 3 Cell Log interfaces, TNC throttle and faster charger added. 6,800 miles so far.
Cost to date: $730, MSRP $6550 - $4120 tax credit - $1200 referrals + $500 mods -$1000 in gas savings.
Big EV Grin. :)

Offline
Joined: 12/22/2007
Posts:
Points: 211
Re: Convert SLA to LiFePO4 in 2007 Zapino

We used Werker AGM SLA WKA12-35C. Weight is 27.3 lbs, price $81 each.
You need 5. Purchased from a local "Batteries Plus".

__________________

Robert Dudley
E-Scoot Tech

Offline
Joined: 04/10/2012
Posts:
Points: 34
Re: Convert SLA to LiFePO4 in 2007 Zapino

DSC_0856.JPG

I just completed the changing the batteries. I opted to not do the LiFePO4 conversion secondary to cost and lack of information/other success stories. I used the werker brand batteries that were suggested by this forum. They work great! Thanks to everyone on this form that helped by providing information.

CHL lithium battery's picture
Offline
Joined: 02/23/2011
Posts:
Points: 305
Re: Convert SLA to LiFePO4 in 2007 Zapino

You may change into 20 cell of CHL battery 40AH LFP,Usd1450 including BMS and freight !

Range 120kms ...........

CHL lithium battery's picture
Offline
Joined: 02/23/2011
Posts:
Points: 305
Re: Convert SLA to LiFePO4 in 2007 Zapino

Voltage Reading_(09-04-00-01-26).jpg

Offline
Joined: 04/10/2012
Posts:
Points: 34
Losing Power while in motion intermittantly

I would be very appreciative for anyone's input regarding what may be wrong with my 2007 Zapino scooter. When I ride my scooter with the throttle turned I loose power and then it just comes back. I am usually not moving very fast 20/mi/hr or less. Once I was on a busy street and I could feel myself decelerate despite no change in my throttle or break postition and luckily the power returned so I did not become a traffic hazard. Another time I was moving 10mi/hr on a residential street and the power cut out and I coasted over to the curb and waited a few seconds, twisted the throttle again and behold the scooter was working again. The third time the power cut out and I glided to a 4 way stop and could not get the power to come back on. I tried truning the ignition on and off, then I opened the seat to flip the curcuit breaker, and finally I pushed the scooter through the intersection to the curb. I sat back in the seat for a few seconds and suddenly the scooter was back to its usual self and I made it home. I'm hesitant to get it out again before finding out what is wrong. Any ideas? So far I have ruled out a kickstand being floppy and any break issues. Thanks.

ookba's picture
Offline
Joined: 09/06/2013
Posts:
Points: 32
Re: Losing Power while in motion intermittantly

Andrea wrote:

I would be very appreciative for anyone's input regarding what may be wrong with my 2007 Zapino scooter. When I ride my scooter with the throttle turned I loose power and then it just comes back. I am usually not moving very fast 20/mi/hr or less. Once I was on a busy street and I could feel myself decelerate despite no change in my throttle or break postition and luckily the power returned so I did not become a traffic hazard. Another time I was moving 10mi/hr on a residential street and the power cut out and I coasted over to the curb and waited a few seconds, twisted the throttle again and behold the scooter was working again. The third time the power cut out and I glided to a 4 way stop and could not get the power to come back on. I tried truning the ignition on and off, then I opened the seat to flip the curcuit breaker, and finally I pushed the scooter through the intersection to the curb. I sat back in the seat for a few seconds and suddenly the scooter was back to its usual self and I made it home. I'm hesitant to get it out again before finding out what is wrong. Any ideas? So far I have ruled out a kickstand being floppy and any break issues. Thanks.

Sounds like you have a loose battery cable or ground somewhere. When you get the motor turning fast enough and creating enough load, it's asking for more current but your power source cannot provide it so it's cutting out. I'd check all the wiring to all batteries, breaker, motor, etc.

__________________

72V 54MPH 2008 Zoomin' Zapino

CC
Offline
Joined: 02/08/2014
Posts:
Points: 22
Re: Convert SLA to LiFePO4 in 2007 Zapino

Andrea I have a 2008 Zapino which had the same problem of losing power you described. Traced the problem to the interlock circuit. There are two cutout interlocks connected together - one for the kickstand and the other connected to the rear brake which activates when braking and resets when you release the throttle. The brake interlock has two very small wires that pass through the hub along with the motor wiring. The wires take a sharp bend coming out of the hub. Turned out the two small wires were shorted out at the bend so I found the connector for them and simply unplugged it. All is fine now. I also did a successful conversion to Lithium Iron Phosphate batteries. Source was Electric Vehicle Enterprises out of Palm Springs CA. Contact Bill Schlanger 928-600-3925. Bought 20 cells at $37 each, 20 balancers at $8.95 each and a 15 amp charger specifically designed for Lithium batteries. Did a lot of research on the best cells and determined GB Systems were my best bet. Did require some scooter mods to fit everything in, but it works fine.

__________________

Charles A Case

Comment viewing options

Select your preferred way to display the comments and click "Save settings" to activate your changes.

Short URL

Customize This