Vectux Charger Dead - Now what?

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Mik
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Vectux Charger Dead - Now what?

Just found that the original 2007 Vectux charger has given up the ghost. It charged the battery to 5\17th, not quite enough to make it back home after work, and then expired.
A faint smell of burned electronics is hanging around the fairings and nothing happens when the plug is connected to 240V.
The MC and motor operate as if the charger was not plugged in. Display is normal when the 2 connectors on the charger are connected. When disconnected, the fuel gauge display shows empty and the battery voltage "0".
When reconnected, the display goes back to normal, 6/17th, 141V etc (The Lairds charger software).

Sooo, I interpret this as a terminally failed charger with the Canbus communication circuits still intact, but most likely not repairable.
12 to 15 km of travel left before it's dead....

What are the options for a charger replacement?

I would like something programmable and permanently installed on-board.
It does not need to integrate with the display or the MC.

Any ideas? Or is it finally time to sell the Vectux in pieces?

betatester
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Re: Vectux Charger Dead - Now what?

Hi Mik,

may be I can help. From the German Vectrix Forum I know the guys, who assembled the original ESD Charger. Last time they offered some pieces to clear their stock for a reasonable price. So if you are interested let me know.

Greetings
Peter

The Laird
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Re: Vectux Charger Dead - Now what?

Hi Mik,

I am in the same boat. My repaired charger has died (although I haven't yet looked to see if it is a minor or major failure) and I am using a modified programme to take care of Fuel gauge and a modified Freddy (charging at 2.5Amps) to charge. Except that I can't charge away from home, it works well.

I have been considering building an onboard freddy charger for the bike with switched output currents, but that's still only an idea.

No need to sell it off just yet, miles of fun still to be had and never forget, these bikes were built at a cost of some $500,000-00 each (counting the bankruptcy figures/losses) so the bikes may yet prove to be quite valuable to future collectors :-)

E-mail me if you think that I can help.

Best wishes and Happy New Year to you and yours,

Sandy.

Aircon
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Re: Vectux Charger Dead - Now what?

these bikes were built at a cost of some $500,000-00 each (counting the bankruptcy figures/losses) so the bikes may yet prove to be quite valuable to future collectors :-)

hahahaha....post of the century.

CO2
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Re: Vectux Charger Dead - Now what?
these bikes were built at a cost of some $500,000-00 each (counting the bankruptcy figures/losses) so the bikes may yet prove to be quite valuable to future collectors :-)

hahahaha....post of the century.

I believe in 100.000usd each.

R
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Re: Vectux Charger Dead - Now what?

Taking into account how The Lairds has helped The vectrix Community, if Mr Mik feels it is ok, I suggest we raise funds toghether and give him an EDS replacement..

Mik
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Re: Vectux Charger Dead - Now what?

Hi everyone, thanks for your replies!

Peter, if you have contacts and can get a reasonably priced new ESD charger, then I think we should go with R's idea and buy one for The Laird. I pledge AU$100.- for it.
If The Laird had a new, undamaged ESD charger, he could possibly work out what goes wrong and if there is a preventative repair or modification that could make them more reliable.

I already have an offer for a practically free used ESD charger from a forum member in Australia who is working on a lithium conversion and does not need it any more. Not sure if he wants to be mentioned here, but thank you very much indeed!

I also have had contact from a commercial source who sell and repair Vectrix chargers and am waiting for a quote. Again, I leave the PM contacts private for now but am of course happy for the other forum members to "out themselves" here if they wish.

The Laird: Happy New Year to you, too! Hope you have fun! You are of course right, no need to give up so soon and get rid of the Vectix. I was feeling mightily unhappy yesterday when I found the charger dead during my lunch break. I was seriously contemplating selling all those rotten NHW10 Priuses and the Vectux and buying a diesel van that I can hand over to a greasy mechanic once a year to get fixed. Then, go surfing instead of endlessly having to fix vehicles that no-one else around here understands. Maybe an electric van with backup diesel generator....
However, after a good nights sleep, the prospect of some tinkering looks much more inviting. I'll take my "Universal Freddy" to work and charge the battery up (at around 3A), the ABCool is permanently installed, as are diode protected charge ports under the seat, part of the "Manual-BMS". Just will have to pay double parking fees for a day and arrange another lift to pick the Vectux up again. Most annoying because there are finally some waves and I want to surf...grrrr...
Building a dedicated DIY charger sounds like a nice project, particularly if you are involved to design it. Many Vectrix riders will eventually need some replacement charger.

Because I have already installed the ABCool (which powers the battery cooling impellers when I connect 240V) and safe charge point access under the seat, I think a power supply might be even better than a replacement ESD charger. Main problem I foresee is lack of cooling under the seat, but I imagine that I can divert some of the battery cooling exhaust air so that it travels through the under-seat are. That would add a safety feature in the sense that if the ABCool fails or the battery gets too hot, the overtemp protection of the power supply will shut down the charge process.

I found a power supply that looks suitable to me, maybe needs some padding underneath it to protect it from vibrations as it's not designed for vehicle use. It charges at up to 4A and up to 150VDC, with automatic switch-over between CC and CV mode. It's programmable with an added gizmo to connect it to Widows USB port and software is included. It would cost about AU$1300.- with the USB connector part. Unless I miss something, I think it would be an even better charger than ESD with The Lairds software, when set to charge at 4A to about 143V. Once 143V are reached, the charge current reduces and hold the battery at 143V indefinitely. That may not use much power, except for the ABCool, and could remain semi-permanently connected for winter storage. The scooter would always be filled to the required charge level. The ABCool might not even be needed, due to the slow charge rate and reducing current towards full battery. 4A during an 8hr shift will put around 32Ah into the battery - not a fast charge, but fast enough.
Here are links to the power supply, let me know if you think I'm barking up the wrong tree here...:
http://australia.rs-online.com/web/p/bench-power-supplies/4937934/
http://australia.rs-online.com/web/p/industrial-interface-converters/6565345/?origin=PSF_437625|acc
http://docs-asia.electrocomponents.com/webdocs/05bc/0900766b805bc6a7.pdf
http://docs-asia.electrocomponents.com/webdocs/04af/0900766b804af5db.pdf

This information may be used entirely at your own risk.

There is always a way if there is no other way!

The Laird
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Re: Vectux Charger Dead - Now what?

Hi Folks,

The generosity of some people never ceases to amaze me. 'R's suggestion in the preceding post is kind in the extreme, BUT I would gracefully decline the offer of another charger.

It seems that my latest failed charger is the 'hint' that I really should get to grips with the Runke programme and/or design a practical alternative to the unreliable ESD and the, as yet, uncontrollable Runke.

For the time being, I am able to continue using the bike, I have a working fuel gauge and everything except an onboard charge system. I really have no problem and, in a sense, no urgent need for a replacement charger.

I am touched by the suggestion and the thought of such generosity.

Best wishes,

The Laird / Sandy

kingcharles
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Re: Vectux Charger Dead - Now what?

Then we should donate The Laird a Runke charger? I am willing to chip in too, My 2007 ESD may not last much longer either...
Just let me know where to transfer the funds!

Once you go EV, Gas is history!

CO2
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Re: Vectux Charger Dead - Now what?

Then we should donate The Laird a Runke charger? I am willing to chip in too, My 2007 ESD may not last much longer either...
Just let me know where to transfer the funds!

Me too!

JimmyB
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Re: Vectux Charger Dead - Now what?
Then we should donate The Laird a Runke charger? I am willing to chip in too, My 2007 ESD may not last much longer either...
Just let me know where to transfer the funds!

Me too!

I'm in!

LithiumVectrix
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Re: Vectux Charger Dead - Now what?

My ESD charger failed 2 years ago. I fitted a charging socket near the trunk light switch and wired it straight to the battery with a 15 amp fuse. I use an external charger. The battery gauge show 0 bars all the time and I can tell how much charge I have by voltage. I charge at home in my garage. Since my bike has a 300 Km range, this is not a problem. I did a trip around Gippsland, Lakes area and took the charger with me in my top box, so I could charge where I was staying overnight.

R
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Re: Vectux Charger Dead - Now what?

Ok!
let it be a Runke, far more easier to find.
I can purchase one Runke charger for 498 Euros+ 21%VAT (104) + sending (50), totalling 650 euros

We're 5 in:
Mik
JimmyB
CO2
kingcharles
R

if more people goes in, we'll be able to purchase it!
ps: Somebody in portugal is buying plenty damaged runke chargers... FFM?

CO2
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Re: Vectux Charger Dead - Now what?

Where we can buy this?

Mik
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Re: Vectux Charger Dead - Now what?

What do you guys think about the Bench Power Supply solution?

...
...
I think a power supply might be even better than a replacement ESD charger. Main problem I foresee is lack of cooling under the seat, but I imagine that I can divert some of the battery cooling exhaust air so that it travels through the under-seat are. That would add a safety feature in the sense that if the ABCool fails or the battery gets too hot, the overtemp protection of the power supply will shut down the charge process.

I found a power supply that looks suitable to me, maybe needs some padding underneath it to protect it from vibrations as it's not designed for vehicle use. It charges at up to 4A and up to 150VDC, with automatic switch-over between CC and CV mode. It's programmable with an added gizmo to connect it to Widows USB port and software is included. It would cost about AU$1300.- with the USB connector part. Unless I miss something, I think it would be an even better charger than ESD with The Lairds software, when set to charge at 4A to about 143V. Once 143V are reached, the charge current reduces and hold the battery at 143V indefinitely. That may not use much power, except for the ABCool, and could remain semi-permanently connected for winter storage. The scooter would always be filled to the required charge level. The ABCool might not even be needed, due to the slow charge rate and reducing current towards full battery. 4A during an 8hr shift will put around 32Ah into the battery - not a fast charge, but fast enough.
Here are links to the power supply, let me know if you think I'm barking up the wrong tree here...:
http://australia.rs-online.com/web/p/bench-power-supplies/4937934/
http://australia.rs-online.com/web/p/industrial-interface-converters/6565345/?origin=PSF_437625|acc
http://docs-asia.electrocomponents.com/webdocs/05bc/0900766b805bc6a7.pdf
http://docs-asia.electrocomponents.com/webdocs/04af/0900766b804af5db.pdf

This information may be used entirely at your own risk.

There is always a way if there is no other way!

RuFuS
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Re: Vectux Charger Dead - Now what?

We could sell Vectrix chargers and controllers.

Check fuelfreemotos website:

http://fuelfreemotos.wordpress.com/pecas-vectrix/

Regards

CO2
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Re: Vectux Charger Dead - Now what?

Oh, so nice!

R
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Re: Vectux Charger Dead - Now what?

I'm not sure MIk, AU$1300 is a lot of money. For a fraction of this price you may get another Vectrix Charger. Rufus, thank you for your input, good to know you sell vectrix parts. How much for a Runke charger? Do you sell other Vectrix parts, like headlights, twist grip?

Frolle
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Re: Vectux Charger Dead - Now what?

I had thoughts about using Imax B8 charger instead of the built in one a while back.
http://visforvoltage.org/forum/12347-use-imax-b8-rc-chargers-instead-built-one-possible

I'm not that convinced that it is such a bad idea that the critics says.
Now I have got hold of both can-bus-adapter and SW so I had no need to proceed.

One thing I tested is that if the "start" button on the Imax-charger was constantly pressed (like after mounting a flip-switch) it would start the latest charge program. Convenient.
So my idea was something like this:

4x 12-18V 180W power supplies = USD 80
4x Imax B8 (150W) = USD 160

Some time and effort mounting wires at every 1/4 of the pack + the four temp-sensors supplied with the Imaxes.

This would give you a $240 solution where you can adjust the cut-of based on DeltaV, temperature, and power count.
The charge current would be just above 4A.

Plus a few more dollars to keep the fans spinning.

Adding some balance luxury with 2x LED-drivers will probably do your day.
http://visforvoltage.org/forum/12650-topping-charging-300ma-ebay-led-powe-supply

This is probably the solution I will fill up my trunk with the day my ESD-charger lets the magic smoke out.

/F

The Laird
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Re: Vectux Charger Dead - Now what?

Hi Folks,

I am struggling with this one. Your generosity is too much for me.

The situation is that I have one working bike, two faulty ESD chargers and one Runke charger of unknown condition.

I have been considering the options available since the last ESD failure. The options are, repair an ESD charger, purchase an ESD charger, Check, and repair if necessary, the Runke charger and then get back into the Runke programming project OR design and build a replacement charger whilst continuing to use the existing charger control software for the fuel gauge and other functions.

Right now what I really need is time to sort out which of the aforementioned options I should go for, keeping in mind the ESD failure problem and the lack of ESD replacements (I believe that it is no longer in production). I am also aware that, if the Runke programme modification proves to be too big a job, then we will all need a viable alternative.

With all of this in mind, what I really need is that time to sort out the best way ahead.

Again, I thank you all for your extreme generosity BUT I think that it will be in all of our interests if you will allow me time to determine the best way forward.

Please don't think me ungrateful, but I do need a little time.

Best wishes to you all,

Sandy.

RuFuS
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Re: Vectux Charger Dead - Now what?

Hi Folks,

I am struggling with this one. Your generosity is too much for me.

The situation is that I have one working bike, two faulty ESD chargers and one Runke charger of unknown condition.

I have been considering the options available since the last ESD failure. The options are, repair an ESD charger, purchase an ESD charger, Check, and repair if necessary, the Runke charger and then get back into the Runke programming project OR design and build a replacement charger whilst continuing to use the existing charger control software for the fuel gauge and other functions.

Right now what I really need is time to sort out which of the aforementioned options I should go for, keeping in mind the ESD failure problem and the lack of ESD replacements (I believe that it is no longer in production). I am also aware that, if the Runke programme modification proves to be too big a job, then we will all need a viable alternative.

With all of this in mind, what I really need is that time to sort out the best way ahead.

Again, I thank you all for your extreme generosity BUT I think that it will be in all of our interests if you will allow me time to determine the best way forward.

Please don't think me ungrateful, but I do need a little time.

Best wishes to you all,

Sandy.

Hi!

You can send us your faulty/damaged chargers. We can check if it's possible to fix them. We also make electronic modification on ESD charger to avoid failure.

Regards

R
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Re: Vectux Charger Dead - Now what?

Of Course, take all the time you need, The laird.
Frolle, I have Imax B8, it works Ok. You can store different charging patterns, and choose them depending on your needs. It is a good, cheap option.

Drew
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Re: Vectux Charger Dead - Now what?

Hi Folks,

I am struggling with this one. Your generosity is too much for me.

The situation is that I have one working bike, two faulty ESD chargers and one Runke charger of unknown condition.

I have been considering the options available since the last ESD failure. The options are, repair an ESD charger, purchase an ESD charger, Check, and repair if necessary, the Runke charger and then get back into the Runke programming project OR design and build a replacement charger whilst continuing to use the existing charger control software for the fuel gauge and other functions.

Right now what I really need is time to sort out which of the aforementioned options I should go for, keeping in mind the ESD failure problem and the lack of ESD replacements (I believe that it is no longer in production). I am also aware that, if the Runke programme modification proves to be too big a job, then we will all need a viable alternative.

With all of this in mind, what I really need is that time to sort out the best way ahead.

Again, I thank you all for your extreme generosity BUT I think that it will be in all of our interests if you will allow me time to determine the best way forward.

Please don't think me ungrateful, but I do need a little time.

Best wishes to you all,

Sandy.

Don't worry! I think it's just that those you've helped want to show their gratitude - myself included! I'm sure that given time and effort, you'll get there and as before the Vectrix community will be better off. We're all grateful for your efforts but first and foremost, we need to let you do as you see appropriate for your own needs, rather than be guided by us. You are after all, offering your various findings to us for free.

Keep you the excellent work Sandy - in your own time!

Very best wishes,

Drew

Drew

antiscab
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Re: Vectux Charger Dead - Now what?

its a shame both ESD chargers have failed

particularly disappointing The Laird's failed - Roman went to great lengths to harden that particular charger against failure including redesigning the start up power supply circuit

I have 2 x good ESD chargers and a good Runke charger in my shed

but the best solution (IMO) would be to install an Elcon charger - these can be had for AUS$650 delivered
I'm busy making a new cover for the 1500W units, with bolt down tabs that line up with the original Vectrix charger mounts

The CAN versions are also programable - meaning you can back the current off as far as you like

the failure rates on those chargers are low, and they are waterproof

did I mention they're cheap and available?

Daily Ride:
2007 Vectrix, modified with 42 x Thundersky 60Ah in July 2010. Done 194'000km

antiscab
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Re: Vectux Charger Dead - Now what?

actually - re the elcon/TC Chargers

you don't need the CAN version (and related CAN adapter) in order to vary the charge current

you can use a unit with the enable option, and vary the resistance between the enable and 5v pins

Daily Ride:
2007 Vectrix, modified with 42 x Thundersky 60Ah in July 2010. Done 194'000km

R
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Re: Vectux Charger Dead - Now what?

I've seen those chargers installed on the Zeros. Can they charge at 0.5 A?

Mik
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Re: Vectux Charger Dead - Now what?

The Elcon charger sounds interesting - cheaper than the bench power supply and more powerful, waterproof, vibration resistant etc.

How does the mounting direction under the front fairing agree with the Elcon charger? Will it need additional fans?

Regarding programming options: What exactly does the following mean: (from the FAQ section):

"What are the 10 selections I can make on my Elcon PFC charger?

Elcon PFC chargers can be programmed to provide 10 different Amp Hour selections (Battery Sizes), or 10 different Cell Count selections (Charge To Voltages), based on customer request at the time of purchase."

My question relates the the word "or" in the above sentence. I hope they really mean "and/or". And I don't understand why one would program "Amp Hours" anyway. What if you plug in when the battery is still half-full? Do they really mean "charge current" when they say "Amp Hour"?

Could one program something like this for the 10 options:

1) (= fast summer charge for NiMH 102 cells):
Start charge at 0.5A and increase to voltage dependent values below over 30seconds (soft start for generators etc).
If voltage is below 125V, charge at 0.5A until 125V.
If voltage is between 125V and 130V, charge at 3A.
If voltage is between 130V and 135V, charge at 6A.
If voltage is between 135V and 140V, charge at maximum amps.
If voltage is between 140V and 142V, charge at 6A.
If voltage is between 142V and 145V, charge at 1.5A.
If voltage is 145V, charge in CV mode.

2) (= gentle summer charge NiMH when not in a hurry):
Start charge at 0.5A and increase to voltage dependent values below over 30seconds (soft start for generators etc).
If voltage is below 125V, charge at 0.5A until 125V.
If voltage is between 125V and 130V, charge at 3A.
If voltage is between 130V and 135V, charge at 6A.
If voltage is between 135V and 140V, charge at 6A.
If voltage is between 140V and 142V, charge at 6A.
If voltage is between 142V and 145V, charge at 1.5A.
If voltage is 145V, charge in CV mode.

3) (= emergency charge from a weak source):
Start charge at 0.5A and increase to voltage dependent values below over 30seconds (soft start for generators etc).
If voltage is below 125V, charge at 0.5A until 125V.
If voltage is between 125V and 130V, charge at 3A.
If voltage is between 130V and 135V, charge at 3A.
If voltage is between 135V and 140V, charge at 3A.
If voltage is between 140V and 142V, charge at 3A.
If voltage is between 142V and 145V, charge at 1.5A.
If voltage is 145V, charge in CV mode.

4) An EQ charge algorythm

5) Similar to 1), but for cold weather.
6) Similar to 2), but for cold weather.
7) EQ charge cold weather.
8) Winter maintenance charge (maybe 1A to 140V, then change to CV mode.)
9) 12V lead-acid charge algorithm.
12) 24V lead-acid charge algorithm.

The above values are just approximate guesses and should be refined before ordering a charger.

If this sort of programming is possible, then I think we should start a new thread and develop optimal Elcon programming versions for various climate zones and scenarios, so that Vectrix riders can order a very useful replacement charger for NiMH batteries.

This information may be used entirely at your own risk.

There is always a way if there is no other way!

antiscab
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Re: Vectux Charger Dead - Now what?

I've seen those chargers installed on the Zeros. Can they charge at 0.5 A?

I've never tested to see what the minimum current is
0.5A would be for balancing nimh I'm guessing?

the other option is to work out some what to enable/disable the enable cicuit so the average ends up being 0.5A, if it can't actually go down that far

Daily Ride:
2007 Vectrix, modified with 42 x Thundersky 60Ah in July 2010. Done 194'000km

R
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Re: Vectux Charger Dead - Now what?

Hi antiscab,

0.5A would be for balancing nimh I'm guessing?

Not at all, would be for balancing my LI fe cells. The program provided by The Laird is currently charging to 3,45 V per cell, but the MiniBMS does not start to balance until the cells reach 3.55v, by dissipating energy on a 0,5 A resistor. with this firmware, the cells never get into balancing phase.
This program is fine, it avoids premature ageing of the cells due to hi voltage. However, because the internal resistance of my cells slightly differ from each other, sooner or later I'll be forced to balance the battery by charging at higher voltage, with an external charger...
antiscab
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Re: Vectux Charger Dead - Now what?

0.5A would be for balancing nimh I'm guessing?

Not at all, would be for balancing my LI fe cells.

Don't do that - its basically overcharging the battery (pretty much the same as putting it on float)

The major advantage is the TC charger can be wired directly to the miniBMS modules (with no master needed)

When any one cell reaches max voltage, the charger stops, when that cell falls back down below the miniBMS cut-off the charger re-starts.
This continues until the total battery voltage reaches the chargers CV voltage (which I normally set to 153.3v for the vectrix or 3.65v x 42)

basically you are balancing as fast as the balancers will go, without overcharging any one cell, nor holding a high voltage continuously.

Daily Ride:
2007 Vectrix, modified with 42 x Thundersky 60Ah in July 2010. Done 194'000km

Mik
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Re: Vectux Charger Dead - Now what?

I received an replacement charger last week, for very cheap, from a fellow Ozzi who wants to do a Lithium conversion including a new charger. Thank you very much!

I never had the charger out of the scooter, yet and find it amazing how heavy that charger is. I would not think it's a good idea to mount so much weight at the front of a bike. Wonder how much better it would ride without it, or mounted elsewhere.

Swapping it over is on the long (and growing!) to-do-list....

This information may be used entirely at your own risk.

There is always a way if there is no other way!

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