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<onlyinclude>
This describes installing ''appropriately crimped and terminated'' cables onto the [[Gen2/Motor Controller|Sevcon controller]]'s DC terminals.
{{warning|This procedure, if performed imprecisely, can result in irreversible damage to your powertrain, fire, injury, and even death.}}
;Motivation
: The officially recommended charging inlet is the [[Accessory Charging Port]], which is fused to less than the 1C limit.
: In order to achieve 1C charging, some bypass is required for at least one charging subsystem.
: One may run one charging system through the port and one through the controller.
;Mechanism
: The Sevcon Gen4 controller has a series of terminals: M1, B-, M2, B+, M3.
: B+ and B- are battery side terminals used mostly for input power but also supply power back to the battery via regen.
;Requirements
: Planned route and matching cable length from the controller to the charger.
: See the Sevcon Gen4 product manual under '''Connecting power cables'''.
* Keep cable runs short
* Minimize current loops by keeping positive and negative cables as close together as possible.
* Route cables away from the LED if you intend to make this visible under normal operating conditions.
* Minimize bending and avoid touching the protective riser brackets around the terminals.
;Terminal Bolt Concerns
: Connect your power cables using the original bolts.
:* They are sized to clamp one ring lug thickness.
:* Use a longer bolt (of the same material!) if you are fastening more than one ring lug.
:* Minimum thread engagement = 10mm.
:* Maximum bolt penetration = 15mm.
: For the [[Power Tank]], longer terminal bolts (by 5mm likely) may be required to ensure the right amount of thread engagement.
:: {{disclaimer|'''TBD''' acquiring the right bolts (measurements and alloys)}}
;Materials
* Red and black cables (4AWG rated for 80A) crimped to M8 ring terminal lugs.
* [[Anderson_connector|Anderson SBS75X brown or red]] for charger connection, again the cables require '''impeccable professional crimping'''.
{{warning|An appropriate crimp tool and skills to use are not adequately specified online.
Power cable crimping should only be performed by a practiced and reviewed professional with specific experience in this application.}}
;Tools
* Torque wrench specifically suitable for ''low-torque'', ''precise'' specifications and socket.
* Small Philips-head screwdriver (PH1?).
{{warning|Controller terminal bolts are made of a soft conductive metal and should not be manipulated with any excess force.
* Cross-threading or any distortion or excess or imbalanced compression of the bolt threads may result in excess thermal stresses under power.
* Poor conduction between the bolt threads, head, and the terminals may result in excessive heat and fire while riding.
* Sevcon terminal bolts are made of an unspecified alloy, and do not have a known safe replacement.
*: Store-bought bolts of the same shape may result in excessive heating and fire while riding}}
;Steps
# [[De-Energize Controller|Perform a lockout on the powertrain]].
# [[Seat Removal|Remove the seat]].
# [[De-Energize Controller|Controller verified fully de-energized]].
#: {{warning|Proceeding without completely verification is highly dangerous and could result in injury or destructive damage to equipment.}}
# Record the existing cable layout via photograph to preserve after the operation.
#: {{disclaimer|Do not trust illustrations given here - internal cable layouts might vary for any reason.}}
# ''Gently'' loosen the bolts fastening the leads on B+ and B-.
#: {{warning|Ensure the breaking torque is limited by your tool to not much more than the specification (7-12 ft-lbs) to tighten the terminal bolts later.}}
# Place the cable leads over the terminals as follows:
#: <table class="wikitable"><tr><th>Color</th><th>Terminal</th></tr><tr><td>Red</td><td>B+</td></tr><tr><td>Black</td><td>B-</td></tr></table>
#: Form a stack from bottom to top of:
#:[[File:Controller charge connection lead stack.jpeg|thumb|none|200px|Charge connection terminal stack]]
## Monolith terminal. ''in background of photo''
## ''(Optional)'' Power Tank terminal.
## Charger terminal.
## ''(For B- Only)'' Ground reference terminal. ''photo note: this is incorrectly shown between/below the charger terminal''
## Washer.
## Terminal bolt.
# Ensure that the route for the battery leads is the same as before.
# Ensure that the route for the charger leads minimizes bending and does not contact the protective riser brackets around the terminals.
#: [[File:Controller charge connection routing.jpeg|thumb|none|400px|Controller charge connection routing (example)]]
# Gently but firmly re-tighten the bolts on B+ and B- to 7 Nm ± 1 Nm (6.2ft-lbs) per Sevcon (also recommended 7-12 ft-lbs).
# Confirm electrical connectivity from each terminal to the Anderson connector that terminates the other end of the charger cable leads.
## While still de-energized, re-confirm there is no DC voltage at the terminals.
## Verify low/no resistance from the bolt head at '''B-''' to the end of the '''black''' cable's lead inside the Anderson connector.
## Verify low/no resistance from the bolt head at '''B+''' to the end of the '''red''' cable's lead inside the Anderson connector.
# Prepare the working area for live testing:
## Remove any tools or stray materials from the surface of the controller.
## Route the new charging connection so that it rests away from any conductive elements, including the frame.
# Test live ''without'' the charger.
## Key the vehicle on.
##* ''Immediately'' key the vehicle off on any sign of an electrical fault.
##* Verify the contactor closes.
##* Verify that there are no reported errors, or only precharge warnings.
##* Check DC voltage across the red and black terminals in the Anderson connector housing; it should match expected battery voltage exactly.
# Test charging.
#: {{disclaimer|TBD Full safety procedure and checklist}}
# [[De-Energize Controller|Fully de-energize the controller]] again for maintenance close-out.
# Route the new charging connector to its intended destination.
#: Ensure that the new cabling cannot be chafed by the edge of the controller cover.
#: Ensure that the connector is securely positioned so that it will not strain the controller lug connections or the terminals within the connector housing.
#: Ensure that the connector is placed away from splash and dust weathering.
# Re-fasten the controller cover.
# Re-install the seat.
;References
* [http://electricmotorcycleforum.com/boards/index.php?topic=7111 made additional accessory charge port for Zero] was used to update this section.
*: {{disclaimer|This includes somewhat unresolved debate about appropriate electrical safeguards (fuse or breaker choice) for a connection like this.}}
</onlyinclude>
[[Category:High Voltage Procedure]]
This describes installing ''appropriately crimped and terminated'' cables onto the [[Gen2/Motor Controller|Sevcon controller]]'s DC terminals.
{{warning|This procedure, if performed imprecisely, can result in irreversible damage to your powertrain, fire, injury, and even death.}}
;Motivation
: The officially recommended charging inlet is the [[Accessory Charging Port]], which is fused to less than the 1C limit.
: In order to achieve 1C charging, some bypass is required for at least one charging subsystem.
: One may run one charging system through the port and one through the controller.
;Mechanism
: The Sevcon Gen4 controller has a series of terminals: M1, B-, M2, B+, M3.
: B+ and B- are battery side terminals used mostly for input power but also supply power back to the battery via regen.
;Requirements
: Planned route and matching cable length from the controller to the charger.
: See the Sevcon Gen4 product manual under '''Connecting power cables'''.
* Keep cable runs short
* Minimize current loops by keeping positive and negative cables as close together as possible.
* Route cables away from the LED if you intend to make this visible under normal operating conditions.
* Minimize bending and avoid touching the protective riser brackets around the terminals.
;Terminal Bolt Concerns
: Connect your power cables using the original bolts.
:* They are sized to clamp one ring lug thickness.
:* Use a longer bolt (of the same material!) if you are fastening more than one ring lug.
:* Minimum thread engagement = 10mm.
:* Maximum bolt penetration = 15mm.
: For the [[Power Tank]], longer terminal bolts (by 5mm likely) may be required to ensure the right amount of thread engagement.
:: {{disclaimer|'''TBD''' acquiring the right bolts (measurements and alloys)}}
;Materials
* Red and black cables (4AWG rated for 80A) crimped to M8 ring terminal lugs.
* [[Anderson_connector|Anderson SBS75X brown or red]] for charger connection, again the cables require '''impeccable professional crimping'''.
{{warning|An appropriate crimp tool and skills to use are not adequately specified online.
Power cable crimping should only be performed by a practiced and reviewed professional with specific experience in this application.}}
;Tools
* Torque wrench specifically suitable for ''low-torque'', ''precise'' specifications and socket.
* Small Philips-head screwdriver (PH1?).
{{warning|Controller terminal bolts are made of a soft conductive metal and should not be manipulated with any excess force.
* Cross-threading or any distortion or excess or imbalanced compression of the bolt threads may result in excess thermal stresses under power.
* Poor conduction between the bolt threads, head, and the terminals may result in excessive heat and fire while riding.
* Sevcon terminal bolts are made of an unspecified alloy, and do not have a known safe replacement.
*: Store-bought bolts of the same shape may result in excessive heating and fire while riding}}
;Steps
# [[De-Energize Controller|Perform a lockout on the powertrain]].
# [[Seat Removal|Remove the seat]].
# [[De-Energize Controller|Controller verified fully de-energized]].
#: {{warning|Proceeding without completely verification is highly dangerous and could result in injury or destructive damage to equipment.}}
# Record the existing cable layout via photograph to preserve after the operation.
#: {{disclaimer|Do not trust illustrations given here - internal cable layouts might vary for any reason.}}
# ''Gently'' loosen the bolts fastening the leads on B+ and B-.
#: {{warning|Ensure the breaking torque is limited by your tool to not much more than the specification (7-12 ft-lbs) to tighten the terminal bolts later.}}
# Place the cable leads over the terminals as follows:
#: <table class="wikitable"><tr><th>Color</th><th>Terminal</th></tr><tr><td>Red</td><td>B+</td></tr><tr><td>Black</td><td>B-</td></tr></table>
#: Form a stack from bottom to top of:
#:[[File:Controller charge connection lead stack.jpeg|thumb|none|200px|Charge connection terminal stack]]
## Monolith terminal. ''in background of photo''
## ''(Optional)'' Power Tank terminal.
## Charger terminal.
## ''(For B- Only)'' Ground reference terminal. ''photo note: this is incorrectly shown between/below the charger terminal''
## Washer.
## Terminal bolt.
# Ensure that the route for the battery leads is the same as before.
# Ensure that the route for the charger leads minimizes bending and does not contact the protective riser brackets around the terminals.
#: [[File:Controller charge connection routing.jpeg|thumb|none|400px|Controller charge connection routing (example)]]
# Gently but firmly re-tighten the bolts on B+ and B- to 7 Nm ± 1 Nm (6.2ft-lbs) per Sevcon (also recommended 7-12 ft-lbs).
# Confirm electrical connectivity from each terminal to the Anderson connector that terminates the other end of the charger cable leads.
## While still de-energized, re-confirm there is no DC voltage at the terminals.
## Verify low/no resistance from the bolt head at '''B-''' to the end of the '''black''' cable's lead inside the Anderson connector.
## Verify low/no resistance from the bolt head at '''B+''' to the end of the '''red''' cable's lead inside the Anderson connector.
# Prepare the working area for live testing:
## Remove any tools or stray materials from the surface of the controller.
## Route the new charging connection so that it rests away from any conductive elements, including the frame.
# Test live ''without'' the charger.
## Key the vehicle on.
##* ''Immediately'' key the vehicle off on any sign of an electrical fault.
##* Verify the contactor closes.
##* Verify that there are no reported errors, or only precharge warnings.
##* Check DC voltage across the red and black terminals in the Anderson connector housing; it should match expected battery voltage exactly.
# Test charging.
#: {{disclaimer|TBD Full safety procedure and checklist}}
# [[De-Energize Controller|Fully de-energize the controller]] again for maintenance close-out.
# Route the new charging connector to its intended destination.
#: Ensure that the new cabling cannot be chafed by the edge of the controller cover.
#: Ensure that the connector is securely positioned so that it will not strain the controller lug connections or the terminals within the connector housing.
#: Ensure that the connector is placed away from splash and dust weathering.
# Re-fasten the controller cover.
# Re-install the seat.
;References
* [http://electricmotorcycleforum.com/boards/index.php?topic=7111 made additional accessory charge port for Zero] was used to update this section.
*: {{disclaimer|This includes somewhat unresolved debate about appropriate electrical safeguards (fuse or breaker choice) for a connection like this.}}
</onlyinclude>
[[Category:High Voltage Procedure]]