ElectricMotorcycleForum.com
Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: xmjsilverx on April 28, 2015, 07:24:58 AM
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I can't find anyone to build me a setup with 2 of the meanwell or tdk power supplies. I can do some basic electrical work but that work seems a little over my head. My question is what would stop me from buying an Elcon PFC-2500 and a j1772 inlet and wiring in a cable to power the on board charger off the j1772? I think I could do all this for less than $800 and it would cost me $1700 from hollywood electric. What would I need besides the parts below? Obviously I need a connector to attach it to the bike and I am unsure of what all connectors I need. Also do I need any type of pilot for the j1772 inlet? Anyone that has one of the elcons, I am also wondering if you have brought it with you in a backpack in case of a long trip? I would like something that fits in the OEM tank bag but I can't find anything besides the charge tank that will come out at some point at some price. I really don't want to put any other bags or boxes on the bike at this time.
http://evolveelectrics.com/chargers/elcon-hf/pfc-2500-charger/ (http://evolveelectrics.com/chargers/elcon-hf/pfc-2500-charger/)
http://emotorwerks.com/products/online-store/product/show/39-j1772-inlet-wire-1-meter (http://emotorwerks.com/products/online-store/product/show/39-j1772-inlet-wire-1-meter)
http://www.cablestogo.com/product/03129 (http://www.cablestogo.com/product/03129)
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You're not the only one who has baulked at paying USD1400 for a charger which is based on a USD600 charger. There are some smarts in the wiring of the Hollywood Electrics that I understand closes and opens the contactor to allow charging to start and stop. There are different ways of achieving this and the TC chargers also offer a CAN control which allows you to change the voltage and current ratings. I am working on an alternate solution using the TC chargers which should have a cost closer to $1,000 with more flexibility. When I have that setup I'll post more information.
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If you can find the post where I said how to close the contactors when I charge with my two series Mean Wells, on my e-trike, it describes how to do that.
Trikester
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Thanks Trikester.
I will be following your advice to implement that feature when I receive the 2 chargers.
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My previous post wasn't right here is a thread to the right information.
http://electricmotorcycleforum.com/boards/index.php?topic=4025.msg24955#msg24955 (http://electricmotorcycleforum.com/boards/index.php?topic=4025.msg24955#msg24955)
You will note the pins are indicated later if you need to confirm the connector like I did.
That reminds me ... I still haven't made that connector modification yet >__< lol
Not sure how many watts the resistor needs to be though :)
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Thanks for the info guys. I will do some more looking into it.
dgh853, are you planning to sell yours when you get it figured out? What wattage are you looking for?
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The TC chargers are the max 18A and 130V version. The CAN BUS control option will allow you to change the voltage to suit. I will set mine to 116V for my Zero SR. That will mean a max power consumption of about 116v x 18A x 0.93 = 2245W and actual charge rate of rate of 116v x 18A = 2.088 kWh per charger. I hadn't consider selling them, more likely to post the instructions on what I have done so others can do it themselves with no or minimal wiring. The only wiring I foresee is to wire the ancillary pins for the Anderson connector as noted above. BTW the $1000 was Australian dollars so about USD800 I think per charger. Getting a J1772 splitter is another story. Anyone know of other sources for one of these?
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Ok, thanks for getting back to me. I am still not sure I have gotten all of my questions answered. It sounds like I need an anderson connector to attach to the output of the charger. Is there already the other end of the connector on the bike or is that something I need to install as well? I don't see why I couldn't wire the nema cable in parallel with the j1772 so the j1772 would power both the nema and the elcon. My only question there is I know the j1772 comes with a pilot cable and I am not sure if that needs to be used or not. I will look into triksters post about closing the contactor.
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Yes, you need a brown Anderson connector on the charger that is the same as on the fast charge port. I think it is SBS75XBRN but you should double check on your bike. Yes, I believe you do need to handle the pilot signal. Try Googling for J1772 splitter for more information.
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xmjsilverx - what Zero do you own?
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I have a 2015 SR.
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The 100K resistor to close the contactor doesn't need to be more than 1/4 watt. I think I used a 1/2 W resistor just for more ruggedness in the harness.
Trikester
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When I want to use my DeltaQ charger, it will not start charging when the main cord is not connected or the key switch is off. Once I have connected the main cord or switched on the key switch, the DeltaQ starts charging and keeps charging even though the main cord will get disconnected and the key switch will get switched off. So there must be a signal from the DeltaQ that keeps the charge contactor on, I guess. But how will it start charging without the main cord or key switch?
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When the switch is turned on it sends voltage to the pin that i described where i used the 100K resistor on my external hookup. Once that circuit has closed the contactor the key can be turned off.
On my trike setup, I plug in my charger which I've wired to connect the resistor to the B+ line through the connector. But I don't put AC power to the charger input yet. I turn on the key which energizes the pin connected through the 100K res. Once I hear the contactor close I then turn off the key and connect charger AC quickly, before the contactor drops out again.
Trikester
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What's the reason that you have the AC disconnected before closing the contactor with the key switch? I can fully connect the DeltaQ before switch on the contact.
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Because if there is voltage from the charger present at the connector the contactor won't close. Your Delta Q keeps its output voltage off until the contactor closes. The Mean Well charger's output is energized as soon as I connect the AC.
Trikester