Gen2/Fabricate Charger Y-Cable
From Unofficial Zero Manual
This describes how to fabricate a Y-Cable for joining chargers into the Accessory Charging Port.
- One can combine up to four Zero Quick Chargers to the 2014+ S platform models (up to 2 chargers prior to 2014).
- To connect more than one charger, at least one Y-Cable is required.
- This cable is available from Zero for $250, but can also be fabricated if you have the tools.
|3||Anderson Power Products SBS75X connectors, Brown||879-SBS75XBRN-BK||Color matters, since it also reflects the voltage and is keyed.|
|4||Anderson Power Products SBS50 #10 AWG connectors||879-1339G3-BK|
|6||Anderson Power Products SBS50 #6 AWG connectors||879-1339G2-BK|
|4||Anderson Power Products SBS75X aux socket connector||879-PM16S1416S32|
|2||Anderson Power Products SBS75X aux pin connector, standard sequence||879-PM16P1416S30|
- Choose one connector to be the common, to connect to the bike.
- The other two will connect to the Quick Chargers.
- Using an appropriate crimp tool, use the #6 AWG connectors to crimp two red #10 wires.
- Repeat with two black wires.
- Click the #6 connectors into the common SBS75X connector, observing the polarity marked on the connector.
- Crimp the #10 AWG connectors onto the other ends of the red and black wires.
- Click them into the other SBS75X connectors, again observing polarity.
- Use a #16 - #14 wire for the charge enable pins.
- Connect one end to a pin-connector, and insert into the recessed hole in the common connector.
- Connect the other end to two socket connectors, and insert into both not-recessed holes in a downstream connector.
- Stripping back the wire and using heat-shrink tubing may make for a better fit.
- Repeat using the other charge enable pin for the other connector.
- The seemingly-odd charger enable connections are due to the MBB only being able to drive two Delta-Q chargers per output, and allow a single Y-Cable design to be used as either the first or second in a fan-out.
- I made my cable the naive way with a single charger-enable pin to both connectors before I was told this.
- If someone has an official cable and can verify the wiring, that would be appreciated.
This drawing is made from an official cable.
- Charging Two Packs From One Charger
- A simple modification to the Y cable will allow two packs to be connected to one charger.
- This allows simultaneous charging of two packs off the bike.
- While two chargers could do this twice as fast, the AC power circuit for two chargers must be rated greater than 15 amps at 120V, often not available.
- I believe this modified Y connection is equivalent to the connection used when charging two packs on the bike.
- So the BMS in each pack controls its charging independently once both are enabled.
- I have tested it and it works. However, this configuration may be imperfect, use at your own risk.
- Connecting to a Pack Adapter vs Second Charger
- Here is a photo of the modified connector wiring with a pin added to allow connection to a pack adaptor instead of a second charger.
- The added Anderson pin PM16P1620S30 requires a special insertion tool. However it can be soldered to a heavy wire and supported in place with a tie wrap to the other wires as shown here.