This page you are viewing is part of the SEVA Wiki Archive, Please visit the new Official Website!
NOTICE: Visit the Maillist page for help joining the new google groups email list, the old maillist is no more.
SEVA meetings are held every second Tuesday.


User:Rjf/Electric Kawasaki

From SeattleEVA
< User:Rjf
Revision as of 09:12, 3 July 2008 by Rjf (talk | contribs) (Moved from personal website.)
(diff) ← Older revision | Latest revision (diff) | Newer revision → (diff)
Jump to navigation Jump to search

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

Other Bike Conversions

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

 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__|
  • 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.


Fault Codes

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
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.

Soneil.com Battery Chargers

  • 4804SR - 48v @ 2A (90~264vac) - 6.9*3.4*2.3" (174*86*57mm) - 1.1lbs (500g) - cc/cv 57.6v, float 55.2v
  • 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
  • 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
  • 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
  • 1214S - 12v @ 7A (90~132vac) - 6.8*3.4*2.0" (173*86*52mm) - 1.3lbs (600g) - cc/cv 14.7v, float 13.8v
  • 1214R - 12v @ 7A (192~264vac) - ^ - ^ - ^
  • 8x 4808SRF ~$1520 (13.6lbs) (28A 3360W)
  • 4x 1205SR ~$176 ( 2.0lbs) (12A 1440W) (Equalization Charging)


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.
Retrieved from "https://www.seattleeva.org/mw/index.php?title=User:Rjf/Electric_Kawasaki&oldid=8077"