Rjf: /* Sevcon */ Manuals.

2008-12-04T07:02:58Z

Sevcon: Manuals.

Rjf: update to intro...

2008-07-03T09:23:29Z

update to intro...

Rjf: Moved from personal website.

2008-07-03T09:12:17Z

Moved from personal website.

New page

{{TOCright}}

Kawasaki EX-500 based EV conversion utilizing the stock transmission coupled to a ~$400 48v eTek motor capable peaking to ~300A.

== Other Bike Conversions ==
* http://www.evdeals.com/BidwellSecrets.htm

== Sevcon ==
The ~$320 Sevcon 4QD 24-48V controller, Type 633T43802, SW 1.50.03 has armature current limits of 330A @1min and 130A @1hour. The Sevcon PCPak software for a windows PC is used as the programming interface.
* 12.17 Digital Configuration = 15 ''footbrake @06, FS1@04, Seat@05''
* 12.18 Analogue Configuration = 3 ''0-5K throttle(10) and brake(11)''

=== Wiring ===
<div style="clear:right; float:right;">
{| width=400
||<pre>
Wiring for Sevcon 4QD 24-48V controller. ($320)
Armature Current 330A @1min, 130A @1hour

-ve +ve---~fuse~---/Key>--------|-----\
| *(01)--| \
|______./Forward>--------*(02) \
|Clutch| Reverse>--------?(03) \
|______./FS1-Bel>--------*(04) -ve \ +ve
|_______/Seat-Sw>--------*(05) | \ |
|_______/FootBrk>--------*(06) | \ |
|-> P. Steer Trigger <---(07) | | |
| *(08)--Contactor_1--| |
| Contactor_2 <---(09) | |
|-------~0-5K Throttle --*(10) | |
|-------~0-5K RegenBrk --*(11) | |
<-?-------12V Out-----?(12) !==|=========|==!
extra supression 1 <---(13) ! B+ B- !
extra supression 2 <---(14) ! SEVCON 4Q !
horn supression <---(15) ! M1 M2 !
program (16) !==|=========|==!
|__MOTOR__| </pre>
|}
</div>
* Ignition to main power(01), with 110/220vac grid charge interlock.
* Seat(05) to wrist strap kill switch. Set "Seat Delay"=0.1s
* Throttle(10) to new after market twist grip, will loose original run/stop and starter buttons.
* Forward(02) and FS1(04) to NC Clutch switch, open on clutch to "freewheel" for shifts and coasting. Set "decel delay"=1.8s, "neutral braking level"=1 for coasting.
* RegenBrk(11) original choke & FootBrk(06) to brake light switch per additional relay. Set "footbrake level" to regen preference for when footbrake is applied.
* Contactor drives(08,09) are rated at 3A peak (10s) and 1.5A continuous. Use Albright aux contactors to drive a contactor status light.
* Pin 12 is available for 100mA supply, typically used for (but not limited to) accelerator modules. 12V system with DC-DC converter (per Contactor_2 or Pin 12 signal). Drive a controller system status light.
* Pins 13,14 & 15 are general-purpose suppression connections, may be used to suppress spikes generated by contactors opening / closing.
* Left grip: Head Light, Tail Light, instrument lights, Brake Lamps, Blinkers. Modified Clutch and Choke.

{{PageBreak}}
=== Fault Codes ===
<div class="references-small" style="-moz-column-count:3; -webkit-column-count:3; column-count:3;">
'''Fault Finding - The Diagnostic LED next to the calibrator connectors'''
* ON -No fault, normal condition
* OFF -Internal controller fault
* 1 flash -Personality out of range
* 2 flashes -Illegal start condition (Traction)
* 3 flashes -MOSFET Short Circuit
* 4 flashes -Contactor fault or Motor Open Circuit
* 5 flashes -Not used
* 6 flashes -Accelerator wire off fault
* 7 flashes -Low or High battery voltage or BDI cutout operating
* 8 flashes -Over temperature or timed cutback
* 10 flashes -Power Up Autozero has not yet been completed

'''Table 10: Flash Fault Descriptions'''<br>
In addition to the LED indication a more detailed description of any faults detected may be found by using the calibrator. Menu item number 13.01 gives a code which corresponds to the following detected faults:
* ID -Flash -Fault Description
* 0 -On -System OK.
* 1 -8 -Thermal Cutback, power is reduced.
* 2 -8 -Timed Current Limit.
* 3 -6 -Accelerator Wire Off.
* 4 -6 -Accelerator Pressed at Power Up.
* 5 -2 -Belly Fault The Belly switch function has occurred.
* 6 -2 -Seat Fault Drive selected and no seat switch closed.
* 7 -10 -Autozero Not Taken.
* 8 -2 -FS1 Recycle, FS1 switch closed during a direction change.
* 9 -2 -SRO Fault, Direction selected for >2 seconds with FS1 open.
* 10 -2 -Two Direction Fault Two directions selected together.
* 11 -2 -Sequence Fault Direction or FS1 switch closed at power up.
* 12 -7 -Low Battery Fault Battery voltage is too low.
* 13 -7 -High Battery Fault Battery voltage is too high.
* 14 -7 -High Battery Fault with Line Contactor Open.
* 15 -1 -Configuration Range Fault, A personality is out of range.
* 16 -1 -Configuration CRC Fault, The personality CRC is incorrect.
* 17 -4 -Line Contactor Welded Fault, Line contactor is welded.
* 18 -4 -Line Contactor did not Close Fault Line contactor is open.
* 19 -3 -Lower MOSFETs Short Circuit on Q2/Q4 Armature MOSFETs detected.
* 20 - -Reserved for future use
* 21 -0 -MOSFETs did not pulse during power on, failsafe enabled.
* 22 -0 -MOSFETs pulsed during power on failsafe disabled.
* 23 -3 -Upper MOSFETs Short Circuit on Q1/Q3 Armature MOSFETs detected.
* 24 -0 -Contactor 2 did not pulse during power on failsafe enabled.
* 25 -0 -Contactor 2 pulsed during power on failsafe disabled.
* 26 -0 -Contactor 1 did not pulse during power on failsafe enabled.
* 27 -0 -Contactor 1 pulsed during power on failsafe disabled.
</div>

== Soneil.com Battery Chargers ==
* [http://soneil.com/Completesets/4804SR.pdf 4804SR] - 48v @ 2A (90~264vac) - 6.9*3.4*2.3" (174*86*57mm) - 1.1lbs (500g) - cc/cv 57.6v, float 55.2v
* [http://soneil.com/Completesets/4808SRF.pdf 4808SRF] - 48v @ 3.5A (115/230vac) - 6.9*3.7*1.9" (175*94*48mm) - 1.7lbs (750g) - cc/cv 57.6v, float 55.2v - EVP:$190
* [http://soneil.com/Completesets/SPEC1205SR(REV%2003).17-Jun-04.pdf 1205SR] - 12v @ 3A (90~264vac) - 4.7*2.9*1.6" (119*73*41mm) - 0.5lbs (220g) - cc/cv 14.4v(Factory Adjustable), float 13.8v - EVP:1206S/R:~$44
* [http://soneil.com/Completesets/1212SR.pdf 1212SR] - 12v @ 5A (115/230vac) - 6.9*3.7*1.9" (175*94*48mm) - 1.5lbs (700g) - cc/cv 14.4v, float 13.8v - EVP:$90
* [http://soneil.com/Completesets/SPEC1214S(Rev01).042904.pdf 1214S] - 12v @ 7A (90~132vac) - 6.8*3.4*2.0" (173*86*52mm) - 1.3lbs (600g) - cc/cv 14.7v, float 13.8v
* [http://soneil.com/Completesets/SPEC1214R(Rev00).092804.pdf 1214R] - 12v @ 7A (192~264vac) - ^ - ^ - ^
*8x 4808SRF ~$1520 (13.6lbs) (28A 3360W)
*4x 1205SR ~$176 ( 2.0lbs) (12A 1440W) (Equalization Charging)

{{PageBreak}}
== Honda EU saddle Gens ==
http://www.hondapowerequipment.com/gensup.asp
* Two like EU series generators can be linked in parallel to increase available wattage.
* EU1000i-$ 789.95 - 120V 1000W max. (8.3A) 900W rated (7.5A) B 15A 125V Duplex" 5-15P - 0.6 gal - 17.7 x 9.4 x 15.0" - 29.0lbs - 59db - 31ZT3610.pdf
* EU2000i-$1079.95 - 120V 2000W max. (16.7A) 1600W rated (13.3A) C 20A 125V Duplex" 5-15P or 5-20P - 1.1 gal - 20.1 x 11.4 x 16.7" - 46.3lbs - 59db - 31Z07610.pdf
* EU2000 (13.3A) (3*3.5A@48v = 10.5A 1260W 1.69HP) *2(21A 2520W 3.38HP) Under rating
* EU2000 (13.3A) (4*3.5A@48v = 14.0A 1680W 2.25HP) *2(28A 3360W 4.50HP) Over rating 0.7A (80W) each
* 2x EU2000 ~$2160 (92.6lbs)

== Gear Ratios ==
http://en.wikipedia.org/wiki/Kawasaki_Ninja_500R
Engine speed @ 60 mph, top gear: 4935 rpm redline: 11,000 rpm
power: 52 bhp (39 kW) @ 9500 rpm (103 hp/L)
torque: 30.86 lbf·ft (41.84 N·m) @ 8000 rpm
Primary Drive 23/61, 2.652
Final Drive 42/16 sprockets 2.625
Rear Wheel Size 120/90-16 63H
gear ratios (overall) 1)17.87 2)12.37 3)9.60 4)7.83 5)6.88 6)5.92
ratios (transmission) 1)36/14, 2.571 2)32/18, 1.78 3)29/21, 1.38 4)27/24, 1.12 5)25/26, 0.96 6)23/27, 0.85
max speed @ICE redline 1)44 mph 2)63 mph 3)82 mph 4)101 mph 5)118 mph 6)133 mph
max speed @Etek ~4000 RPM limit is slightly less than @ICE due to the lack of the Primary Drive.
Etek should produce slightly more torque at the rear wheel than the original ICE.

@@ Line 16: / Line 16: @@
 * 12.17 Digital  Configuration = 15 ''footbrake @06, FS1@04, Seat@05''
 * 12.18 Analogue Configuration = 3  ''0-5K throttle(10) and brake(11)''
 === Wiring ===

@@ Line 1: / Line 1: @@
 {{TOCright}}
-Kawasaki EX-500 based EV conversion utilizing the stock transmission coupled to a ~$400 48v eTek motor capable peaking to ~300A.
+I'm in the process of converting my Kawasaki EX-500 motorcycle from gas to electric with the intension of utilizing the stock transmission coupled to a ~$400 48v eTek motor and Sevcon 4QD 24-48V regen capable controller capable peaking to ~330A.  This was my first bike and I rode it to work for nearly an entire wet winter while repairing my VW Vanagon.  Eventually I stopped riding it but couldn't bring myself to part with it even though it's engine was seized and no longer ran.
 == Other Bike Conversions ==

User:Rjf/Electric Kawasaki - Revision history

Rjf: /* Sevcon */ Manuals.

Rjf: update to intro...

Rjf: Moved from personal website.