Difference between revisions of "Gen2/Accessory Charging Port"

Latest revision as of 00:07, 11 May 2020

The Gen2 platform includes a charging circuit terminated by a hard-mounted brown Anderson SBS-75X connector to support OEM and third-party additional chargers.

Input

Warning:

Only supply DC power to this port in the battery's normal range, or risk catastrophic damage to the battery.

All external chargers are switching power supplies that turn AC (or sometimes DC!) power at a wider range of voltages into DC that behaves well with Zero's battery technology and voltage range.

2012 Zero batteries operate in a lower voltage range than 2013+ Zero batteries; chargers for one range of years should never be used on another range of years.

To use

• Remove the rubber boot cover and plug in the charger(s).

  

  As delivered, the rubber boot cover will be secured with zip ties. Remove them first.

  2013 models do not include the rubber boot; it is a good idea to install one to protect the plug over time, though.

• Use the onboard charger in conjunction with the accessory charging port to keep the motorcycle in charging mode (allows keying off while charging among other things).
• Replace the rubber boot after unplugging the charger(s).

Location

Mounting (SDS Platform)

One or two small H2.5 Allen key socket head bolts run up through the connector's holes into a collared insert on a flanged edge of the board mounting plate.

Detaching (SDS Platform)

1. Remove the left lower plastic panel first for access.
2. Either:
   • Use a very low overhead / right-angle H2.5 Allen key wrench from the left side of the bike ahead of the vertical frame stanchion.
   • Pull the board mounting plate up by enough room to fit a right-angle Allen key underneath, between the connector and the motor fins, about an inch or two.

Enable Line

The Anderson SBS-75X connector has two signaling pins which the Gen2 employs in conjunction with a feature of the Zero Quick Charger to indicate charger presence.

The feature is not completely understood, but it operates this way:

• When the contactor is shut, if the enable line detects charger presence, the contactor will remain shut until or unless the enable signal is removed, or a safety limit is detected by the BMS requiring opening the contactor.
• The enable line has no effect if the contactor is open.

Implementing the feature has been performed in various ways.

• See the XMX off-bike charging article for enable pin wire-up or charging Y-cable fabrication for how to combine enable signals safely.
• One minimal implementation joins the two pins in a simple 100kΩ resistive circuit.

  Full pack voltage would supply 1mA current to such a circuit at most, so a high-current wire is not needed; just a solid circuit pinned appropriately for the connector with an inline resistor and weather+abrasion+strain-proofing).

  Warning:

  This implementation has not been officially vetted by Zero, and there may be unknown effects operating with such a circuit long-term

Removing the rubber boot

Only for when you are replacing the Anderson connector permanently with another type/shape of connector.

The rubber boot is held by a nylon "fir tree" plug.

Use a flat tool (screwdriver, nylon pry tool, etc) to wiggle between it and the mounting plate until loose.

After removing, you can install the rubber boot elsewhere using (for example) an M5 bolt and some washers.