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General Category => Pics and Vids => Topic started by: Chicamungo on January 14, 2017, 12:32:03 PM

Title: Installed my SuperCharger V2!
Post by: Chicamungo on January 14, 2017, 12:32:03 PM
So I got the charger fully installed tonight and I took some pictures of the different steps. Sorry for some of the pictures being poor quality, I was using a headlamp while working in my garage, so there's a little blown out. I'll try and explain some of the less clear steps.

So here's everything from the box all laid out inside.
(http://i.imgur.com/L2YUgXq.jpg)

So this is with the com unit velcro'd to the bike and the j-hooks in place in the frame of the bike, getting the mounting bracket ready.
(http://i.imgur.com/KExJGF7.jpg)

Now the super charger is in place sitting in the bike power tank area.
(http://i.imgur.com/e4qkjkl.jpg)

The bracket is now in place and holding the charger tightly. Don't tighten it too much though, or you'll bend the bracket.
(http://i.imgur.com/I2M395B.jpg)

This is showing the connection to the auxiliary charging port under the seat. Hard to get a good shot of this, so it's blurry :(
(http://i.imgur.com/xTsmYuH.jpg)

This is the cables run up from the auxiliary port to the tank area. Note that you'll have to attach the connector yourself as it's so much easier to run the cables bare. It'll make sense when you receive your charger. (Note: don't plug in the port until after you put the connector on. Brandon informed me that that port holds voltage for a while after you first turn the bike off)
(http://i.imgur.com/tnOWISb.jpg)

Here's all of the connectors hooked up (for the most part). As far as I can tell, it's extremely intuitive as they're color coded and you physically can't hook up the wrong connector to another one, so you shouldn't be able to mess it up. I'm holding the hookup for the on board charger.
(http://i.imgur.com/De9FNHQ.jpg)

So on the right side of the charger, I ran the connector for the on board and zip tied it the front of the charger for now.
(http://i.imgur.com/SSChePU.jpg)

Alright this picture is awful and I apologize. This is just to the side of the horn, it's a little difficult to reach, but it hides the connector well and tucks it away.
(http://i.imgur.com/fPzqBMs.jpg)

Installing the j-plug inlet on the power tank plastics probably won't be something most of you are interested in, so here's the final product. But I installed it backwards. :(
(http://i.imgur.com/gN3i63n.jpg)

First charging session!
(http://i.imgur.com/xN0MPwh.jpg)

After ~15 minutes, not bad!
(http://i.imgur.com/uhQRxlq.jpg)

Info from the app right after connecting to the charging station. In the amount of time I was in the store for a few minutes, it eventually went up from 4kW charging to ~4.9kW charging. So don't be afraid that it doesn't hit the full charging level right away.
(http://i.imgur.com/4VPENJf.png)

And just one final pic of my bike in most of her glory!
(http://i.imgur.com/sZ8JLPM.jpg)

So that's about it! Now please be aware that what I've done may not be best practice. So I can't recommend you follow my steps. I'm just happy to give a little bit of insight in to what it all looks like! Brandon, if you see anything blatantly wrong, please let me know.

I'm happy to answer any questions about the install too, hope you all enjoyed it!
Title: Re: Installed my SuperCharger V2!
Post by: Shadow on January 14, 2017, 09:53:24 PM
Nice! Some questions:
Did you get a shipper tracking number before delivery?
The V1 had a WiFi and web browser control; Does the V2 base system provide a WiFi hotspot?
Are you happy with modifying the PowerTank cowl instead of a no-modification ChargeTank cowl?
Can you say the order date and what dealership?
Title: Re: Installed my SuperCharger V2!
Post by: Chicamungo on January 14, 2017, 11:04:16 PM
Nice! Some questions:
Did you get a shipper tracking number before delivery?
The V1 had a WiFi and web browser control; Does the V2 base system provide a WiFi hotspot?
Are you happy with modifying the PowerTank cowl instead of a no-modification ChargeTank cowl?
Can you say the order date and what dealership?

Yes, I received an e-mail from diginow that was basically an invoice requesting payment for shipping. It had the tracking number on there. It seems like that may not happen to everyone though. I spoke to Hollywood electrics about this, and apparently there was a little confusion as to who was collecting the shipping. In the end, I was refunded the shipping cost from Hollywood Electrics and just paid diginow directly. So I can't say that my experience will be the same for everyone else moving forward. I did have to sign for the package though. UPS said it was a 17.5lbs weight and it's also expensive. So it's probably good they make sure it's in your hands rather than on a porch.

Honestly, I didn't check last night. It was cold, I was excited, and I admittedly had a beer about 20 minutes before (had to ride to my favorite brewery to get my SoC lowered!). I haven't heard anything about it, at this point my gut says it's not installed on mine. But I am definitely not informed on this subject.

I'm actually surprised at how decent this looks. While modifying the tank, I was certain that I was going to get the charge tank cover once I receive the 2nd unit to charge at 6.6kW. But now I'm not so certain. I'm fine with how things are right now, or will be once I fix my inlet orientation.

I ordered on the very first morning the forum thread went up saying we could order, so I called Hollywood Electrics. So back in late June?
Title: Re: Installed my SuperCharger V2!
Post by: anton on January 19, 2017, 12:43:38 AM
Nice write-up! Waiting for mine to arrive 8)
Title: Re: Installed my SuperCharger V2!
Post by: nevetsyad on January 19, 2017, 09:13:28 AM
Very nice. I don't know how I missed this post until now. I hooked mine up externally for the time being. Does the onboard need to be plugged in from the outside, once it's installed? Like, we park, plug in a 1 foot cable into the female 110 port on the SC, then plug it into the external onboard charger port, then plug in the J1772?

Or, leave the bike keyed on, and plug just the SC in? We can turn it off once it starts charging via aux only, right?

Great photos, thank you for that!
Title: Re: Installed my SuperCharger V2!
Post by: Electric Cowboy on January 19, 2017, 10:19:59 AM
Nice job!

No wifi is intended in the v2 units for now. Maybe at a later date for people interested in metrics etc. We will provide a BTLE/BT connection, but based on feedback from the v1 not everyone loved the wifi.

You can use the SC by itself by plugging in a Jplug while the bike is on and then turning it off once you see the green charging light. At any time you can plug the onboard in from the connection we supply or any other outlet.

You can also do as you described with the bike off plug in the onboard to the provided outlet, or any other outlet, and then plug in the Jplug. This should still give the onboard time to fire up before the SC initiates charging thus starting the bike. If you do it this way, just make sure to check that the bike is infact charging.

Again, awesome post and photos! Enjoy faster charging!
Title: Re: Installed my SuperCharger V2!
Post by: dukecola on January 20, 2017, 07:27:48 AM
Thanks for the great write up. I've got a PT so will be charging with charger off bike or in top box. Nice to see the total weight of your UPS package was 17.5lbs, that means the charger and cables don't weigh too much. I already ride overweight 2 up so adding extra weight is an issue for me.  Was planning to cut back on the donuts but won't have to now. <evil grin>
Title: Re: Installed my SuperCharger V2!
Post by: Chicamungo on January 21, 2017, 12:14:43 AM
Thanks for the great write up. I've got a PT so will be charging with charger off bike or in top box. Nice to see the total weight of your UPS package was 17.5lbs, that means the charger and cables don't weigh too much. I already ride overweight 2 up so adding extra weight is an issue for me.  Was planning to cut back on the donuts but won't have to now. <evil grin>

Just be aware that this is only for the 3.3kW. You have to almost double it if you're going for 6.6kW. With that said, I sincerely hope that it won't cut in to your donut intake. I would never wish that upon anyone!
Title: Re: Installed my SuperCharger V2!
Post by: BrianTRice@gmail.com on January 21, 2017, 05:05:36 AM
Just be aware that this is only for the 3.3kW. You have to almost double it if you're going for 6.6kW. With that said, I sincerely hope that it won't cut in to your donut intake. I would never wish that upon anyone!

Do you mind if I use your photos on the wiki? I intend to write up a version of the instructions and link this thread, but it'll help to have permission to use the photos directly (with some resizing).

Thanks!
Title: Re: Installed my SuperCharger V2!
Post by: Chicamungo on January 21, 2017, 05:15:01 AM
Just be aware that this is only for the 3.3kW. You have to almost double it if you're going for 6.6kW. With that said, I sincerely hope that it won't cut in to your donut intake. I would never wish that upon anyone!

Do you mind if I use your photos on the wiki? I intend to write up a version of the instructions and link this thread, but it'll help to have permission to use the photos directly (with some resizing).

Thanks!

Feel free to use these pictures on the Wiki. If you want better quality ones to resize, let me know and I can send you the source pictures. These were resized on my computer and then uploaded to imgur. So I can't speak to their longevity towards being hosted.
Title: Re: Installed my SuperCharger V2!
Post by: nevetsyad on January 22, 2017, 08:03:22 PM
Mine is going to be external for a while, if you need any detailed pics of it before install. Just let me know.
Title: Re: Installed my SuperCharger V2!
Post by: BrianTRice@gmail.com on January 23, 2017, 10:30:43 AM
Mine is going to be external for a while, if you need any detailed pics of it before install. Just let me know.

More pictures can't hurt, thanks. It's fine to email me (this username at gmail), say.
Title: Re: Installed my SuperCharger V2!
Post by: Shadow on January 24, 2017, 01:09:23 PM
A package is shipping from DigiNow towards my general direction.

Time now to learn how to DSR in 10 feet of snow?
Title: Re: Installed my SuperCharger V2!
Post by: mrwilsn on January 24, 2017, 07:52:21 PM
A package is shipping from DigiNow towards my general direction.

Time now to learn how to DSR in 10 feet of snow?
Isn't that what those DS tyres are for?? Just get some studs like Aerostitch used on the FX 😉. How awesome would a video of a DSR on the slops be? Launch off some ski jumps? Amirite?

Congratulations! The wait will be worth it 😀 Enjoy!

Sent from my Nexus 6P using Tapatalk

Title: Re: Installed my SuperCharger V2!
Post by: NEW2elec on January 26, 2017, 09:21:38 PM
What's that little box thing on the left side handle bar?
Title: Re: Installed my SuperCharger V2!
Post by: mrwilsn on January 26, 2017, 11:27:52 PM
What's that little box thing on the left side handle bar?
I noticed in Chicamungo's pics that he has Oxford Heaterz heated grips installed.  I think you are talking about the control pad to adjust the temp which he has installed next to his left hand grip.

Sent from my SAMSUNG-SM-G930A using Tapatalk

Title: Re: Installed my SuperCharger V2!
Post by: protomech on January 27, 2017, 01:23:40 PM
Thanks for the great write up. I've got a PT so will be charging with charger off bike or in top box. Nice to see the total weight of your UPS package was 17.5lbs, that means the charger and cables don't weigh too much. I already ride overweight 2 up so adding extra weight is an issue for me.  Was planning to cut back on the donuts but won't have to now. <evil grin>

Just be aware that this is only for the 3.3kW. You have to almost double it if you're going for 6.6kW. With that said, I sincerely hope that it won't cut in to your donut intake. I would never wish that upon anyone!

The extra HK-J charger weighs about 8 pounds (going from the 3.3 to the 6.6).
Title: Re: Installed my SuperCharger V2!
Post by: Shadow on January 31, 2017, 08:55:14 PM
Mine arrived to the doorstep yesterday, a 3.3 kW base install with the modular J1772 plug system for L14-50 and Tesla HPWC compatible.

Unboxing: https://www.youtube.com/watch?v=HQRYhf2TrzA (https://www.youtube.com/watch?v=HQRYhf2TrzA)
Connections: https://www.youtube.com/watch?v=o7z9KTMh0W0 (https://www.youtube.com/watch?v=o7z9KTMh0W0)

There's 10ft+ of snow everywhere here. Maybe I will try to install this week but it won't be easy to get the bike ('16 Zero DSR) to and from its parking spot to the street for testing.
(https://image.ibb.co/fx4uov/IMG_20170125_181424.jpg)
Title: Re: Installed my SuperCharger V2!
Post by: NEW2elec on January 31, 2017, 10:54:19 PM
Great work on the videos Shadow.  I would love to see an in depth install video if your up for it.
Sorry about the snow, come down south its warm here :)
Title: Re: Installed my SuperCharger V2!
Post by: anton on February 01, 2017, 12:09:47 AM
As you can see on this photo (http://diginow.it/img/products/charger.jpg) there's gray Anderson connector in zip bag and the other side of AUX cable (cable that you plug into Zero AUX charger port, has brown Anderson connector and black/red wires) is just crimped.

I believe the reason for this is to make installation easier, as you can feed crimped connectors through bike's internals more easily than if you'd have grey Anderson connector installed  :)

So what you do is take that connector out of the bag and slide both wires into it, where they lock in place.

What I didn't realize however is that those crimped ends are not exactly symmetrical top/bottom. They have slight bend that helps locking them in place. I locked one of them upside down which meant it wasn't sticking out as far enough as it should've been and therefore SC didn't work in my previous test.

Once I fixed that, I was able to charge at 4.75 kW (Zero app reported it as 4.4 kW):

(http://i.imgur.com/tWFTdQi.png)

Brilliant!

Now I just have to wait for PowerTank plastic to arrive to finish my install :) Even though PowerTank plastic should be way easier to install, it's also $300 more expensive, so I figured I'll take cheaper approach for now.
Title: Re: Installed my SuperCharger V2!
Post by: Electric Cowboy on February 01, 2017, 01:24:57 AM
As you can see on this photo (http://diginow.it/img/products/charger.jpg) there's gray Anderson connector in zip bag and the other side of AUX cable (cable that you plug into Zero AUX charger port, has brown Anderson connector and black/red wires) is just crimped.

I believe the reason for this is to make installation easier, as you can feed crimped connectors through bike's internals more easily than if you'd have grey Anderson connector installed  :)

So what you do is take that connector out of the bag and slide both wires into it, where they lock in place.

What I didn't realize however is that those crimped ends are not exactly symmetrical top/bottom. They have slight bend that helps locking them in place. I locked one of them upside down which meant it wasn't sticking out as far enough as it should've been and therefore SC didn't work in my previous test.

Once I fixed that, I was able to charge at 4.75 kW (Zero app reported it as 4.4 kW):

(http://i.imgur.com/tWFTdQi.png)

Brilliant!

Now I just have to wait for PowerTank plastic to arrive to finish my install :) Even though PowerTank plastic should be way easier to install, it's also $300 more expensive, so I figured I'll take cheaper approach for now.
Awesome work on the video shadow! Anton I'm so glad you were able to figure that out!

So for the Tesla connector we have primarily tested it on destination Chargers. These are the public Chargers that Tesla sells to hotels and other businesses to expand their Network. I'd love to see a video with it charging at a home-based high-powered wall connector if anybody has time to get around to that.

I can only imagine how cold it is where you are, riding from Mexico to San Francisco right now, and it drops into the thirties to forties at night and that is freaking cold!
Mine arrived to the doorstep yesterday, a 3.3 kW base install with the modular J1772 plug system for L14-50 and Tesla HPWC compatible.

Unboxing: https://www.youtube.com/watch?v=HQRYhf2TrzA (https://www.youtube.com/watch?v=HQRYhf2TrzA)
Connections: https://www.youtube.com/watch?v=o7z9KTMh0W0 (https://www.youtube.com/watch?v=o7z9KTMh0W0)

There's 10ft+ of snow everywhere here. Maybe I will try to install this week but it won't be easy to get the bike ('16 Zero DSR) to and from its parking spot to the street for testing.
(https://image.ibb.co/fx4uov/IMG_20170125_181424.jpg)


Sent from my Nexus 6P using Tapatalk

Title: Re: Installed my SuperCharger V2!
Post by: Electric Cowboy on February 01, 2017, 01:34:01 AM
As you can see on this photo (http://diginow.it/img/products/charger.jpg) there's gray Anderson connector in zip bag and the other side of AUX cable (cable that you plug into Zero AUX charger port, has brown Anderson connector and black/red wires) is just crimped.

I believe the reason for this is to make installation easier, as you can feed crimped connectors through bike's internals more easily than if you'd have grey Anderson connector installed  :)

So what you do is take that connector out of the bag and slide both wires into it, where they lock in place.

What I didn't realize however is that those crimped ends are not exactly symmetrical top/bottom. They have slight bend that helps locking them in place. I locked one of them upside down which meant it wasn't sticking out as far enough as it should've been and therefore SC didn't work in my previous test.

Once I fixed that, I was able to charge at 4.75 kW (Zero app reported it as 4.4 kW):

(http://i.imgur.com/tWFTdQi.png)

Brilliant!

Now I just have to wait for PowerTank plastic to arrive to finish my install :) Even though PowerTank plastic should be way easier to install, it's also $300 more expensive, so I figured I'll take cheaper approach for now.
Awesome work on the video shadow! Anton I'm so glad you were able to figure that out!

So for the Tesla connector we have primarily tested it on destination Chargers. These are the public Chargers that Tesla sells to hotels and other businesses to expand their Network. I'd love to see a video with it charging at a home-based high-powered wall connector if anybody has time to get around to that.

I can only imagine how cold it is where you are, riding from Mexico to San Francisco right now, and it drops into the thirties to forties at night and that is freaking cold!
Mine arrived to the doorstep yesterday, a 3.3 kW base install with the modular J1772 plug system for L14-50 and Tesla HPWC compatible.

Unboxing: https://www.youtube.com/watch?v=HQRYhf2TrzA (https://www.youtube.com/watch?v=HQRYhf2TrzA)
Connections: https://www.youtube.com/watch?v=o7z9KTMh0W0 (https://www.youtube.com/watch?v=o7z9KTMh0W0)

There's 10ft+ of snow everywhere here. Maybe I will try to install this week but it won't be easy to get the bike ('16 Zero DSR) to and from its parking spot to the street for testing.
(https://image.ibb.co/fx4uov/IMG_20170125_181424.jpg)


Sent from my Nexus 6P using Tapatalk
Also just in case anybody was wondering the potting on both the control board and in the Tesla plug is a two-stage potting. The first stage is a more solid epoxy like sealant followed by a more flexible silicone type of potting. This gives us a firm fit which is secure and waterproof but flexible at the top where the cables come out.

Sent from my Nexus 6P using Tapatalk

Title: Re: Installed my SuperCharger V2!
Post by: anton on February 02, 2017, 12:13:29 PM
This is showing the connection to the auxiliary charging port under the seat. Hard to get a good shot of this, so it's blurry :(
(http://i.imgur.com/xTsmYuH.jpg)

@Chicamungo @Electric Cowboy Is it safe to assume that this AUX connector can stay plugged in while riding?
Title: Re: Installed my SuperCharger V2!
Post by: Electric Cowboy on February 02, 2017, 01:49:51 PM
This is showing the connection to the auxiliary charging port under the seat. Hard to get a good shot of this, so it's blurry :(
(http://i.imgur.com/xTsmYuH.jpg)

@Chicamungo @Electric Cowboy Is it safe to assume that this AUX connector can stay plugged in while riding?
Yep

Sent from my Nexus 6P using Tapatalk

Title: Re: Installed my SuperCharger V2!
Post by: Shadow on February 03, 2017, 06:16:14 AM
@Chicamungo @Electric Cowboy  Was mounting hardware included for the J-inlet?
Title: Re: Installed my SuperCharger V2!
Post by: anton on February 03, 2017, 06:17:31 AM
@Chicamungo @Electric Cowboy  Was mounting hardware included for the J-inlet?
Depends on what you mean by mounting hardware? Mine got fasteners and the inlet itself.
Title: Re: Installed my SuperCharger V2!
Post by: Chicamungo on February 03, 2017, 06:48:52 AM
@Chicamungo @Electric Cowboy  Was mounting hardware included for the J-inlet?

Kind of? The 4 screws on the inlet have washers underneath. So what I did was drill a couple of holes in my power tank cover and then run the screws through and threaded the washers underneath. So the entire inlet is being held up by those two screws. If you want some better pictures and/or descriptions of how I drilled holes in my cover, I can try to provide some.

It looks like all four are used if you have a charge tank cover though. I don't have one though, so I can't say for sure.
Title: Re: Installed my SuperCharger V2!
Post by: anton on February 03, 2017, 06:58:13 AM
So the entire inlet is being held up by those two screws. If you want some better pictures and/or descriptions of how I drilled holes in my cover, I can try to provide some.

Why only two and not four?
Title: Re: Installed my SuperCharger V2!
Post by: Shadow on February 03, 2017, 07:00:36 AM
Ah, yes I'm referring to the fasteners, see my unboxing video. Were they already on the inlet or maybe in some parts bag I missed?

@Chicamungo it would be helpful if you could write more about where to install the inlet, and any idea you have for mounting two inlets.  I talked to Brandon and two or possibly three of the 3.3kW modules can be mounted in the cowl area, there is no 6.6kW unit which I said I was expecting to add to the 3.3kW unit.  I will try to make a video for installation with your advice.
Title: Re: Installed my SuperCharger V2!
Post by: anton on February 03, 2017, 09:17:04 AM
Ah, yes I'm referring to the fasteners, see my unboxing video. Were they already on the inlet or maybe in some parts bag I missed?

In my case, fasteners and washers were already on the inlet.

I'll make photos of install too when my power tank cover arrives next week.
Title: Re: Installed my SuperCharger V2!
Post by: Chicamungo on February 03, 2017, 09:38:53 AM
So the entire inlet is being held up by those two screws. If you want some better pictures and/or descriptions of how I drilled holes in my cover, I can try to provide some.

Why only two and not four?

Mostly because I didn't want to drill a huge hole in the middle of my cover. Plus I wasn't sure if the cabling from the inlet would fit if it wasn't so far forward. So as evidenced in this picture
 (http://i.imgur.com/gN3i63n.jpg)

Only two could be attached to my cover. It's really solid and I haven't worried about it at all, even with a cable plugged in to it.

@Shadow I'll try and post a few pictures and write up a little bit this weekend. The pictures probably won't be that great though. I've had to remove my cover so many times recently because water issues on my heated grips and I'm really over taking them off. I'll try my best though!
Title: Re: Installed my SuperCharger V2!
Post by: anton on February 03, 2017, 09:48:36 AM
Mostly because I didn't want to drill a huge hole in the middle of my cover. Plus I wasn't sure if the cabling from the inlet would fit if it wasn't so far forward.

Only two could be attached to my cover. It's really solid and I haven't worried about it at all, even with a cable plugged in to it.[/quote]

Oh I see. So you just drilled a hole wide enough for cabling to fit through. Now that you've finished your install, were cables long enough after all? I was planning to drill a hole slightly further back on the cover so that inlet can sits flush, somewhere in this area:

(http://i.imgur.com/xduYyYk.jpg)
Title: Re: Installed my SuperCharger V2!
Post by: Chicamungo on February 03, 2017, 11:24:58 AM
Mostly because I didn't want to drill a huge hole in the middle of my cover. Plus I wasn't sure if the cabling from the inlet would fit if it wasn't so far forward.

Only two could be attached to my cover. It's really solid and I haven't worried about it at all, even with a cable plugged in to it.

Oh I see. So you just drilled a hole wide enough for cabling to fit through. Now that you've finished your install, were cables long enough after all? I was planning to drill a hole slightly further back on the cover so that inlet can sits flush, somewhere in this area:

(http://i.imgur.com/xduYyYk.jpg)
[/quote]

Pretty much. Sorry if I didn't explain it correctly. The cable is definitely long enough. But the problem is if there is enough clearance between the charger and the top of the cover to drill right through there. The charger (especially once bumped up to 6.6kW) takes a lot of the space, so I don't think you can actually fit it that far back.

Moving it this far forward makes it much easier to route the cable without stressing it too much.
Title: Re: Installed my SuperCharger V2!
Post by: anton on February 03, 2017, 11:58:02 AM
Pretty much. Sorry if I didn't explain it correctly. The cable is definitely long enough. But the problem is if there is enough clearance between the charger and the top of the cover to drill right through there. The charger (especially once bumped up to 6.6kW) takes a lot of the space, so I don't think you can actually fit it that far back.

I wish there was a photo / dimensions of Charge Tank vs Power Tank. 6.6 unit is supposed to fit with Charge Tank cover just fine but I wonder how much space there actually is.
Title: Re: Installed my SuperCharger V2!
Post by: Electric Cowboy on February 03, 2017, 03:10:12 PM
Pretty much. Sorry if I didn't explain it correctly. The cable is definitely long enough. But the problem is if there is enough clearance between the charger and the top of the cover to drill right through there. The charger (especially once bumped up to 6.6kW) takes a lot of the space, so I don't think you can actually fit it that far back.

I wish there was a photo / dimensions of Charge Tank vs Power Tank. 6.6 unit is supposed to fit with Charge Tank cover just fine but I wonder how much space there actually is.
The j inlet should be forward as in the photos not further back.

The is a lot of space. Charge tank and Power tank are same size, one just has a spot for a Jplug in it already.

Sent from my Nexus 6P using Tapatalk

Title: Re: Installed my SuperCharger V2!
Post by: Swiebo on February 09, 2017, 08:32:16 PM
It seems that the photos in the first post of this topic are gone. Can I find them somewhere else?

Grt,
Peter.
Title: Re: Installed my SuperCharger V2!
Post by: BrianTRice@gmail.com on February 10, 2017, 02:51:21 AM
It seems that the photos in the first post of this topic are gone. Can I find them somewhere else?

I can see them just fine, but I made sure to make private copies just in case.
Title: Re: Installed my SuperCharger V2!
Post by: Swiebo on February 10, 2017, 05:20:02 PM
My ISP was blocking the link to the photos, problem solved.

Grt,
Peter.
Title: Re: Installed my SuperCharger V2!
Post by: NEW2elec on February 11, 2017, 01:43:11 AM
I see the SC has a pretty big fan.  Does the covered "tank" let enough air in to keep the SC cool?
Title: Re: Installed my SuperCharger V2!
Post by: BrianTRice@gmail.com on February 11, 2017, 04:28:14 AM
I see the SC has a pretty big fan.  Does the covered "tank" let enough air in to keep the SC cool?

It really does. It's probably producing a lot less heat than the SCv1 at its full output and I've run SCv1 under the tank in hot weather acceptably well (although I put a shade up when I can). The air comes in between the plastics and the battery well enough.

I did make a tank plastic arrangement I can split up to open (honestly, how I found an unwelded power tank center piece I cannot really explain other than "that guy on the forum had one from a flea market find in San Jose"), which helps with airflow, but I mainly did it for testing and debugging access for the Supercharger.
Title: Re: Installed my SuperCharger V2!
Post by: Shadow on February 11, 2017, 10:54:45 AM
Removed the tank bag cowl, and while I'm at it why not install some high power charging electronics in the winter snow weather!
(http://i.imgur.com/zQ4A5pU.jpg)(http://i.imgur.com/khIWZaJ.jpg)
The J-hooks for SCv2 have a locknut need 11mm socket. The photos from @Chicamungo are super helpful. I was given some spacers which don't seem to go to anything, and also I'm missing the fasteners from the J1772 inlet so I'll have to ask for some to be sent out.  Maybe the spacers are for the second 3.3kW module I'm agreed to receive when the upgrade to two 3.3kW modules is ready for customers...

I noticed at least some sharp metal corners where wires for the SCv2 install run next to, and this might need some guarding. One of the heat shrink seals from the charger to a corrugated plastic conduit was sliding off and not really doing the job, might tack it down with glue.  I don't even have the J1772 inlet mounted yet so I just put this stuff in there and get it out of the house. It's a two-beer install. At the moment I have an all-weather cover over the bike until I get a cowl I like to mount the J1772 inlet to.

I'm wondering how the heck three modules are supposed to fit under a cowl in that space 3x3.3kW?  The connectors used at install time are bulky and that makes me wonder.. would we see a need to have two J1772 inlets mounted to the cowl?

Also since we have that edison plug from the power split assembly, is there a safe way to wire that to the internal charger directly?   I would presume the Chargetank does something like this?

@Chicamungo was velcro included or is that something you came up with?  I might have some around here...


**edit**  Do I need J1772 mounting fasteners if I will mate it to a Chargetank cowl?
Title: Re: Installed my SuperCharger V2!
Post by: Electric Cowboy on February 11, 2017, 08:09:42 PM
Absolutely do not rewire anything to the onboard charger directly. We did this on purpose, for safety reasons, so a kid doesn't electrocute them selves by sticking their fingers into your standard plug. Also so you don't short two out of phase plugs. So definitely don't do that... Trust me I thought about it. 😀 .

I think it would be a really smart idea not to rewire anything, as a side note 😋 ...

Bolts on the way just Incase. I believe the charge tank cover comes with its own bolts. It's a bit more difficult to install yourself than just the power tank, maybe like an hour or two extra just to use that tank. The tank itself requires you to remove the "helmet lock" this is why I use the power tank myself. But Hollywood Electrics does the charge tank cover install because it looks super clean.

We're working on the fit of three under the tank now. Lots of ways to do it.

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Title: Re: Installed my SuperCharger V2!
Post by: Chicamungo on February 12, 2017, 08:09:44 AM
Removed the tank bag cowl, and while I'm at it why not install some high power charging electronics in the winter snow weather!
(http://i.imgur.com/zQ4A5pU.jpg)(http://i.imgur.com/khIWZaJ.jpg)
The J-hooks for SCv2 have a locknut need 11mm socket. The photos from @Chicamungo are super helpful. I was given some spacers which don't seem to go to anything, and also I'm missing the fasteners from the J1772 inlet so I'll have to ask for some to be sent out.  Maybe the spacers are for the second 3.3kW module I'm agreed to receive when the upgrade to two 3.3kW modules is ready for customers...

I noticed at least some sharp metal corners where wires for the SCv2 install run next to, and this might need some guarding. One of the heat shrink seals from the charger to a corrugated plastic conduit was sliding off and not really doing the job, might tack it down with glue.  I don't even have the J1772 inlet mounted yet so I just put this stuff in there and get it out of the house. It's a two-beer install. At the moment I have an all-weather cover over the bike until I get a cowl I like to mount the J1772 inlet to.

I'm wondering how the heck three modules are supposed to fit under a cowl in that space 3x3.3kW?  The connectors used at install time are bulky and that makes me wonder.. would we see a need to have two J1772 inlets mounted to the cowl?

Also since we have that edison plug from the power split assembly, is there a safe way to wire that to the internal charger directly?   I would presume the Chargetank does something like this?

@Chicamungo was velcro included or is that something you came up with?  I might have some around here...


**edit**  Do I need J1772 mounting fasteners if I will mate it to a Chargetank cowl?

Shoot, I'm sorry for dropping the ball on explaining how I mounted it to my power tank. Do you still want some instructions on how I did that? Unfortunately I just looked and I can't get any good pictures without taking off my cover, which I don't feel like doing.

I already had the velcro myself. It's the kind with adhesive on either side of the velcro strips. But I also put dabs of super glue on the adhesive too just to make sure. I ended up moving my control unit from between the charger and that mysterious silver box, to just on top of the box. It allows the mounting bracket to hold in place better.

Unfortunately I have no experience with anything but the power tank, so I can't help beyond that.
Title: Re: Installed my SuperCharger V2!
Post by: Shadow on February 12, 2017, 10:58:26 AM
...I already had the velcro myself. It's the kind with adhesive on either side of the velcro strips. But I also put dabs of super glue on the adhesive too just to make sure. I ended up moving my control unit from between the charger and that mysterious silver box, to just on top of the box. It allows the mounting bracket to hold in place better.
Unfortunately I have no experience with anything but the power tank, so I can't help beyond that.

I've decided to sell the unmodified cowls I have and order a Chargetank cowl, which has its own challenges of removing the stock lock and extra cost over the Powertank cowl. I'll try to document the stock lock relocation and SCv2 install to the Chargetank cowl when it happens as best I can.

Good tip about the SCv2 control box.  It's okay about leaving your cowl on I know it's tricky to work on those fasteners, though I say my Chapman 1916 toolkit made easy work of it and readily suggest every Zero owner to have one. When / if you want to, it would be nice to see more detail about your Powertank cowl modification.
Title: Re: Installed my SuperCharger V2!
Post by: Chicamungo on February 12, 2017, 11:28:24 AM
...I already had the velcro myself. It's the kind with adhesive on either side of the velcro strips. But I also put dabs of super glue on the adhesive too just to make sure. I ended up moving my control unit from between the charger and that mysterious silver box, to just on top of the box. It allows the mounting bracket to hold in place better.
Unfortunately I have no experience with anything but the power tank, so I can't help beyond that.

I've decided to sell the unmodified cowls I have and order a Chargetank cowl, which has its own challenges of removing the stock lock and extra cost over the Powertank cowl. I'll try to document the stock lock relocation and SCv2 install to the Chargetank cowl when it happens as best I can.

Good tip about the SCv2 control box.  It's okay about leaving your cowl on I know it's tricky to work on those fasteners, though I say my Chapman 1916 toolkit made easy work of it and readily suggest every Zero owner to have one. When / if you want to, it would be nice to see more detail about your Powertank cowl modification.

I've gotten to the point where it's easy but it's just time consuming removing it! I've probably removed it 10+ times now because of all the issues I had with waterproofing my heated grips. Once I get my 6.6kW charger, I'll take pictures of my power tank cover and post those. Unless someone needs help right away, then I can try and give some tips then.

I actually did move my lock to the side too. It's very simple, my own advice besides what's in the wiki is make sure you don't drill in to the plastic casing that's under the passenger seat. I ended up slightly clipping it with my drill. I didn't even know anything critical was under there.
Title: Re: Installed my SuperCharger V2!
Post by: BrianTRice@gmail.com on February 13, 2017, 05:36:06 AM
I actually did move my lock to the side too. It's very simple, my own advice besides what's in the wiki is make sure you don't drill in to the plastic casing that's under the passenger seat. I ended up slightly clipping it with my drill. I didn't even know anything critical was under there.

Whoa. Yeah, good point. The wiki should definitely say that.
Title: Re: Installed my SuperCharger V2!
Post by: anton on February 19, 2017, 01:19:31 AM
@Chicamungo @Electric Cowboy What's the preferred way to route inlet wires back inside the bike when using power tank cover? Should I cut a bit of plastic on the side/center to feed the wire back or should I try fitting through the left/right part of the frame? There is some space there on both sides and connectors do fit through those spaces, but the wire might be pinched if you turn handlebars too far.
Title: Re: Installed my SuperCharger V2!
Post by: Shadow on February 19, 2017, 01:40:44 AM
I'll have DSR tankbag, powetank, and chargetank cowls in my hands soon. I was going to sell the extra cowls as-is.

If a buyer sends an inlet I'll mount it up, make an install video, and ship the completed install.
Title: Re: Installed my SuperCharger V2!
Post by: Chicamungo on February 19, 2017, 01:59:53 PM
@Chicamungo @Electric Cowboy What's the preferred way to route inlet wires back inside the bike when using power tank cover? Should I cut a bit of plastic on the side/center to feed the wire back or should I try fitting through the left/right part of the frame? There is some space there on both sides and connectors do fit through those spaces, but the wire might be pinched if you turn handlebars too far.
I ended up drilling a couple of holes using a 1 1/2" hole saw. I drilled it right in the front black area. One up high to give enough space for the inlet to fit there, and one near the bottom to actually route the cable through. You may be able to do it using only one hole, but I didn't plan ahead.

I would advise against running it to the side. The cable is too thick and you wouldn't want that damaged or to prevent your handlebars from fully turning.
Title: Re: Installed my SuperCharger V2!
Post by: mrwilsn on February 19, 2017, 06:13:16 PM
@Chicamungo @Electric Cowboy What's the preferred way to route inlet wires back inside the bike when using power tank cover? Should I cut a bit of plastic on the side/center to feed the wire back or should I try fitting through the left/right part of the frame? There is some space there on both sides and connectors do fit through those spaces, but the wire might be pinched if you turn handlebars too far.

If you are worried about turning your handle bars causing issues with your super charger install then something is wrong.

If you have a 2016 or older bike you should remove the tank bag lock.  Two screws and it comes right off.  Removing it keeps it from interfering with the J-plug wires.
(http://i1074.photobucket.com/albums/w410/TheMrwilsn/IMG_2376_zpsscvf0elf.jpg) (http://s1074.photobucket.com/user/TheMrwilsn/media/IMG_2376_zpsscvf0elf.jpg.html)

The wires to the J-plug should stay completely under the tank.  If you are considering routing in between the frame and the handle bars such that it would get pinched by the triple tree or making extra holes in the tank (other than to mount the J-plug)....don't.  This is a picture of my SCv1 which is bigger than the SCv2 3.3 module and the cable fits under the tank you just need to route it such that the cable goes around the corner of the SC on the front right side but above the corner of the SC on the front left side.
(http://i1074.photobucket.com/albums/w410/TheMrwilsn/IMG_2408_zpsiqip2nwc.jpg) (http://s1074.photobucket.com/user/TheMrwilsn/media/IMG_2408_zpsiqip2nwc.jpg.html)

If you are talking about the cables running from the SC down to the Anderson connector then it should also stay inside the bike.  Here you can see my cables (red black wires with a red connector) running below the frame and down to the Anderson connector. (Note that the J-plug cable is not routed correctly in this picture and the tank would not fit if I tried with this routing)
(http://i1074.photobucket.com/albums/w410/TheMrwilsn/IMG_2401_zpskszyxu0o.jpg) (http://s1074.photobucket.com/user/TheMrwilsn/media/IMG_2401_zpskszyxu0o.jpg.html)

I used a charge tank instead of power tank but in either case you should just have one hole in your tank....where the J-plug will be mounted.  Here is my charge tank install.
(http://i1074.photobucket.com/albums/w410/TheMrwilsn/IMG_2309_zpshainhkx2.jpg) (http://s1074.photobucket.com/user/TheMrwilsn/media/IMG_2309_zpshainhkx2.jpg.html)

Title: Re: Installed my SuperCharger V2!
Post by: Shadow on February 19, 2017, 08:49:23 PM
@mrwilsn nice clear pictures thanks for sharing!   Can you say, what tools are needed and what locations need to be taken apart to remove the helmet lock?
Title: Re: Installed my SuperCharger V2!
Post by: Electric Cowboy on February 19, 2017, 10:38:44 PM
Mr Wilson nailed it. Anton was asking about the wires going to the DC charging port on the bike. Those cables go through the frame. As in Mr Wilson a photo.

Depending on your year model they will go through one side or the other. You can tell by looking, where there is more room.

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Title: Re: Installed my SuperCharger V2!
Post by: BrianTRice@gmail.com on February 20, 2017, 03:23:21 AM
Thanks for the photos! I'm updating the wiki for this: http://zeromanual.com/index.php/Zero_Aftermarket#DigiNow_Super_Charger (http://zeromanual.com/index.php/Zero_Aftermarket#DigiNow_Super_Charger)
Title: Re: Installed my SuperCharger V2!
Post by: mrwilsn on February 21, 2017, 10:00:21 AM
@mrwilsn nice clear pictures thanks for sharing!   Can you say, what tools are needed and what locations need to be taken apart to remove the helmet lock?

The seat and the tank need to be removed to get at the tank bag lock on the 2016 and older bikes.  Tank bag lock doesn't exist for 2017 bikes due to the introduction of the lockable storage tank.

The seat has 2x 5mm allen head bolts (I think some bikes/years use Torx for the seat bolts but my 2014 Zero S and 2017 Zero SR use allen head).
(http://i1074.photobucket.com/albums/w410/TheMrwilsn/IMG_20170220_212306_zpstjh1idfq.jpg) (http://s1074.photobucket.com/user/TheMrwilsn/media/IMG_20170220_212306_zpstjh1idfq.jpg.html)

After removing the seat you have access to 2x 3mm allen head bolts on either side of the tank next to where it meets the seat.
(http://i1074.photobucket.com/albums/w410/TheMrwilsn/IMG_20170220_213020_zps6tkufrzp.jpg) (http://s1074.photobucket.com/user/TheMrwilsn/media/IMG_20170220_213020_zps6tkufrzp.jpg.html)

Then there are additional 2x 3mm allen head in the tank bag area.
(http://i1074.photobucket.com/albums/w410/TheMrwilsn/IMG_20170220_212739_zpsnrq5tef2.jpg) (http://s1074.photobucket.com/user/TheMrwilsn/media/IMG_20170220_212739_zpsnrq5tef2.jpg.html)

Next are 6x Phillips head (PH2) on the tank 'bat wings' (one screw on each side is hidding in the hole at the bottom of the black plastic on the front of the tank).
(http://i1074.photobucket.com/albums/w410/TheMrwilsn/IMG_20170220_212623_zpsaeekjnuq.jpg) (http://s1074.photobucket.com/user/TheMrwilsn/media/IMG_20170220_212623_zpsaeekjnuq.jpg.html)

At this point you can remove the tank.  Optionally you can remove additional 2x 3mm allen head to remove the black plastic at the front of the tank above the horn.
(http://i1074.photobucket.com/albums/w410/TheMrwilsn/IMG_20170220_213316_zpsf6svr9vc.jpg) (http://s1074.photobucket.com/user/TheMrwilsn/media/IMG_20170220_213316_zpsf6svr9vc.jpg.html)

You may need to snip some zip ties to move some wire bundles around to get access to the 2x 4mm allen head bolts holding the tank bag lock in place from the bottom.
(http://i1074.photobucket.com/albums/w410/TheMrwilsn/IMG_20170220_090243_zpsnfeaxv9r.jpg) (http://s1074.photobucket.com/user/TheMrwilsn/media/IMG_20170220_090243_zpsnfeaxv9r.jpg.html)
Title: Re: Installed my SuperCharger V2!
Post by: BrianTRice@gmail.com on February 21, 2017, 10:44:54 AM
@mrwilsn, may I use these photos and text on the wiki?
Title: Re: Installed my SuperCharger V2!
Post by: mrwilsn on February 21, 2017, 10:50:16 AM
No...mrwilsn proprietary

Haha...JK....You may use anything I post

Sent from my Nexus 6P using Tapatalk

Title: Re: Installed my SuperCharger V2!
Post by: BrianTRice@gmail.com on February 21, 2017, 10:53:59 AM
No...mrwilsn proprietary

Haha...JK....You may use anything I post

That's awesome; I appreciate it. :)
Title: Re: Installed my SuperCharger V2!
Post by: anton on February 21, 2017, 11:58:22 AM
@Chicamungo: Silly question, where are your brake lines on the right side? My 2016 SR has them but I can't see them on any of your photos. So far they've been the most painful thing to deal with.

(http://i.imgur.com/G0bt552.jpg)
Title: Re: Installed my SuperCharger V2!
Post by: Electric Cowboy on February 22, 2017, 12:48:31 AM
@anton wow you have a fair amount of extra line in there

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Title: Re: Installed my SuperCharger V2!
Post by: Chicamungo on February 22, 2017, 10:06:16 AM
@Chicamungo: Silly question, where are your brake lines on the right side? My 2016 SR has them but I can't see them on any of your photos. So far they've been the most painful thing to deal with.


(http://i.imgur.com/gN3i63n.jpg)

You can see in this shot where the brake line originates off of the right handlebar. But it follows the fork down to the brake on the wheel. It was never an issue for me. I didn't even realize that could be a problem! Sorry man, I didn't run in to this problem. Are all 2016 bikes run like that with their brake line?
Title: Re: Installed my SuperCharger V2!
Post by: anton on February 27, 2017, 07:01:53 AM
So I finally got around to put everything together. As I mentioned, brake lines on my 2016 SR were pain to deal with. I've no idea if that's specific to my particular bike or all 2016 SRs, hopefully someone can confirm this.

I've pretty much followed Chicamungo steps, with a few small changes/notes below.

BMS enclosure box (aluminium box with green circle on it) has bolts on each side. You need to position your SC controller closer to the middle of the this enclosure, otherwise these bolts prevent Velcro from holding box in place.

There's a little lip at the front of tank space underside, you should be able to slide SC all the way to it. Also, not pictured on this photo, but I zip-tied this outlet to the frame here so it sits behind the cowl and provides relatively easy access. This will do for now, but I'll get dust cover just in case.

(http://i.imgur.com/z6CqAjC.jpg)

This is how AUX cable is routed back inside. I wrapped wires in 3M Scotch Super 88 Vinyl Electrical Tape to be on the safe side too:

(http://i.imgur.com/VWvXGnT.jpg)

For whatever reason, my brake lines are pretty long. I didn't want to put SCv2 on top of them and they don't bend easily. So to put SCv2 in, I had to lift them up a bit, feed 3 wires from SCv2 itself under brake lines, then slide SCv2 unit itself in place, then let brake lines spring back to where they wanted to be. They apply some tension to the SCv2 mounting bracket, so I wrapped them and bracket itself in some vinyl tape to reduce possible wear. Probably unnecessary :)

(http://i.imgur.com/qzgHrxq.jpg)

Everything put together:

(http://i.imgur.com/YwYWCHl.jpg)

(http://i.imgur.com/zx1FAR5.jpg)

I didn't have to remove helmet lock as others suggested. I'll admit it's definitely easier to screw cover back in if there's more space in that area, but I don't think it's absolutely necessary.

Finally some photos of Power Tank cover. I used Dremel to make initial hole and then sort of grinded excess plastic away bit by bit. I wanted to position it as forward as possible as adviced by Brandon but I also wanted to have as small of opening as I can to limit element's exposure. Cover should open to the left :)

(http://i.imgur.com/CHSlXT1.jpg)

(http://i.imgur.com/rvJ1mTG.jpg)

(http://i.imgur.com/iyJTDQq.jpg)

(http://i.imgur.com/uf5dLOt.jpg)

(http://i.imgur.com/6Km8UE5.jpg)

(http://i.imgur.com/FYK6AyW.jpg)

(http://i.imgur.com/3kH1M02.jpg)