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Author Topic: Charger Mount Option  (Read 440 times)

BrianTRice

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Charger Mount Option
« on: December 14, 2016, 06:53:05 AM »

I've struggled to install my Elcon PFC 2500 in a way that is easy to use and I'm comfortable with since I bought it a year ago.

Carrying it on the Zero luggage racks is okay for the charger because of its IP67 weatherproof rating. However, the Zero's luggage system should really not be taxed that way, and I've noticed what one charger can do over time, whether in a side case or a top case.

So, for a while now, I rolled it up in a towel and threw it and the cables into a waterproof duffle bag and strapped it to my rear seat and top case. I used a Givi top rack for the Maxia case for upper bracing. I had the rollover opening face forward so I can unload the cables and Elcon without undoing the straps.

This allowed me to carry it where the bike is rated to support a passenger, fill in the aerodynamic gap between my back and the tail case, and make the top rack a little sturdier by dampening the load it experiences going over bumps.

However, the duffle rollout took time and was wearing on my cable setup, and I had Hollywood Electrics inspect and fix some looseness that could have grown into a problem.

All of this to say that I scrounged for a Pelican case of the right size and I intend to mount it by giving it attachment points and using similar bracing as the duffle.

Here's my mockup on my old trusty 13DS:


And here's the charger layer out with cables inside how I intend to fasten it in:


With this setup, I should be able to quickly open the lid and connect the cables. At worst, I'll either set the case on the ground, make the charger quickly detachable, or use cable extensions to reach the bike inputs.

Anyway this seems like a good cheap way to use a charger with minimal wear and loading problems. And any improved charger should fit right in.

I'll update with further details shortly, including some CAD documents I made for layout.
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2016 Zero DSR, 2013 Zero DS, 2012 Suzuki DL-650 V-Strom Adv

BrianTRice

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Re: Charger Mount Option
« Reply #1 on: December 14, 2016, 07:01:07 AM »

I'll clarify that this is meant to match the face of the Givi Maxia 3 case I have on my DSR, not the small Monolock E340 case on my DS. :)
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BrianTRice

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Re: Charger Mount Option
« Reply #2 on: December 14, 2016, 07:10:13 AM »

Reference photos of my duffle setup:

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Ndm

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Re: Charger Mount Option
« Reply #3 on: December 14, 2016, 07:04:04 PM »

Hey Brian, if you don't mind losing the storage bag I cut the plastic portion out and have two ThunderStruck Motors tsm 2500's in the tank area, total 6200watts with onboard charger, plus a few inches of storage with the tank bag cut down
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giacomo

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Re: Charger Mount Option
« Reply #4 on: December 14, 2016, 09:16:32 PM »

Hey Brian, if you don't mind losing the storage bag I cut the plastic portion out and have two ThunderStruck Motors tsm 2500's in the tank area, total 6200watts with onboard charger, plus a few inches of storage with the tank bag cut down
Do you have your quick charger project documented somewhere? Thanks

Sent from my A0001 using Tapatalk

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Ndm

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Re: Charger Mount Option
« Reply #5 on: December 14, 2016, 09:32:48 PM »

I'm still finishing up with the permanent install, winter has come to Canada so I have indoor projects on the go, preliminary charges that I have done have been flawless as has the service from ThunderStruck Motors, I should add that up to four chargers are possible for a total of 10kw plus onboard, but since I have yet to find a j1772 with higher than one stall at 7.2 kW I'm good with two, all for under $2000 us programmed for farasis cells
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giacomo

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Re: Charger Mount Option
« Reply #6 on: December 14, 2016, 10:01:37 PM »

I'm still finishing up with the permanent install, winter has come to Canada so I have indoor projects on the go, preliminary charges that I have done have been flawless as has the service from ThunderStruck Motors, I should add that up to four chargers are possible for a total of 10kw plus onboard, but since I have yet to find a j1772 with higher than one stall at 7.2 kW I'm good with two, all for under $2000 us programmed for farasis cells
Thanks, did you program it yourself for the farasis cells?

Sent from my A0001 using Tapatalk

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BrianTRice

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Re: Charger Mount Option
« Reply #7 on: December 14, 2016, 10:30:29 PM »

Hey Brian, if you don't mind losing the storage bag I cut the plastic portion out and have two ThunderStruck Motors tsm 2500's in the tank area, total 6200watts with onboard charger, plus a few inches of storage with the tank bag cut down

My Supercharger is in the tank! The box/Elcon is the aux/backup charger. Or it will work for the DS around town, sort of.
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Ndm

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Re: Charger Mount Option
« Reply #8 on: December 14, 2016, 10:40:06 PM »

I guess if you're not permanently installing it on one bike the tank area is a no go, for my meanwell rsp 6kw setup I just used a military ammo box from a surplus store, the chargers came pre programmed from ThunderStruck, I might add the price I quoted was for four chargers, I got two with the j1772 control board for $1250 USD shipped (the chargers are can bus controlled and you must have the controller, although you can run it without j1772) sorry for hijacking the thread
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BrianTRice

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Re: Charger Mount Option
« Reply #9 on: December 16, 2016, 01:37:30 AM »

It's fine. I'm also leaving room for a power tank at some point.
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