Gen2/Calex Charger/Connections

From Unofficial Zero Manual
Jump to: navigation, search
Calex Charger Connections
AC input is an IEC-60320 C13 inlet.
DC output is an Anderson SBS50-BRN, but it seems to be a narrower pin pitch with no center data pin set.
CANbus signal interface is a JAE MX23A18NF1 connector (applies to the Calex, not the Mean Wells!)
CAN signal pins per GWP data sheet
Pin Function
4 CAN ground
5 CAN +5V power
6 CAN Dominant Low
7 CAN Dominant High
10 ob_charger_attached_n [charger_attached]
11 ob_charger_attached_n [charger_attached]
12 charger_en_0 [charger_en_n]
13 ob_charger_ref_0 [charger_gnd_ref]
CANbus wiring
Adapted from an examination of the wiring on a 2014 SR: Onboard charger wiring for 2014 and 2015+ for the Calex.
When the onboard charger is plugged in and powered on the onboard charger pushes:
  • 5V and 48mA through the Charger attached Pin #11.
  • 5V and 26mA through the Charger enabled Pin #12.
The 5V ground reference is Pin #13 which is battery negative.
With this knowledge, another onboard charger solution can be wired to function as follows:
  1. Run a separate circuit that when triggered pushes 5V ~50mA through pin#11 (attached charger) with the other end of the 5V circuit connected to the battery negative pin #13.
  2. When this is triggered, the bike shows the battery state of charge % and charge time remaining, closes the contactor and allows charging - through the accessory charging port, the onboard charger port or via the Sevcon battery terminals for high power charging.
  3. Upon completion of charging, the 5V can be switched off and the charge level and time remaining switch off and the contactor opens just as with the onboard charger.
  4. The bike can be keyed on and ridden away as normal.
Using this method there is no need to leave the bike on when charging via the accessory charging port or the controller battery-side cables, or if you are using the accessory charging port without triggering the auxiliary pin on the accessory charging port's Anderson SBS75XBRN.
For 2015 onwards, the charger install uses additional wiring which may have a different approach using CAN signals, so it may require a different approach.