From Unofficial Zero Manual
- 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!)
|5||CAN +5V power|
|6||CAN Dominant Low|
|7||CAN Dominant High|
- 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:
- 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.
- 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.
- 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.
- 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.