Elcon PFC 5000 Battery Charger

PFC 5000 Battery Charger

This page illustrates how to use the battery charger. You will need PCAN view software from https://www.peak-system.com/Software-APIs.305.0.html?&L=1 and the hardware adapter.

Quick Charging Information

If you just want to know what to send via CAN:

Using CAN at (250kbits/s) with extended frame CAN ID

For 410V: Header: (Extended Frame) : 1806E7F4 Data: 10 04 00 8C 00 00 00 00
For 356V: Header: (Extended Frame) : 1806E7F4 Data: 0D E8 00 8C 00 00 00 00

When the charger is awaiting communication, the LED will blink green.

When the charger is communicating via CAN, it will

Blink red and green if the battery pack is not present, or it is out of range
Blink red if it is successfully charging

The charging cord should be connected from the battery charger to the charging connector. Connect Pins 13 (CHARGE_OUT) and 14 (CHARGE_IN) of the HVPH to close the charging contactor.

Read the rest of the page for more information

Charger Model: TCCH-312-14

Serial Number: SN170705415

Numbers below SN: 312-7*2

A link to the charger is below

http://www.elconchargers.com/catalog/item/7344653/7638130.htm

A link to the user manual is below.

http://www.thunderstruck-ev.com/Manuals/PFC5000.pdf

Set up Bike to Charge

The charging cord should be connected from the battery charger to the charging connector. Connect Pins 13 (CHARGE_OUT) and 14 (CHARGE_IN) of the HVPH to close the charging contactor.

How to use CAN to charge battery pack with PCAN view

The PCAN software from https://www.peak-system.com/Downloads.76.0.html?&L=1 was used with the hardware adapter. Click here: PCAN Software or Click on "Device driver setup for Windows" on the page.

It uses a 24MHz clock rate and a 250Kbps bit rate and 29-bit extended frame CAN ID.
Pin 1 of the adapter must be connected to CAN-Lo from your BMS and pin 2 to CAN-Hi. If your BMS does not already have a 120 ohm termination resistor across CAN-Lo and CAN-Hi, you will need to add one.
The charger expects to receive every second a message from the BMS with CAN ID 1806E7F4 and 8-byte data with the voltage and current requested.
If the charger doesn't receive a valid CAN message in 5 seconds, it stops charging until it receives a valid CAN message. The charger sends out every second a CAN status message with voltage, current and status information.
- For example, to charge to 410V, use 410x10 = 4100(decimal) = 0x1004(hex). That would be the 4 most signifacant bits sent. To charge at 14A, use 14x10 = 140 = 0x008C for the next 4 bits. The Picture below shows the setup that successfully charged the bike.
- So in summary, typically you want to send (250kbits/s)
  - For 410V: Header: (Extended Frame) : 1806E7F4 Data: 10 04 00 8C 00 00 00 00
  - For 356V: Header: (Extended Frame) : 1806E7F4 Data: 0D E8 00 8C 00 00 00 00

When the charger is awaiting communication, the LED will blink green.

When the charger is communicating via CAN, it will

Blink red and green if the battery pack is not present, or it is out of range
Blink red if it is successfully charging

The max charge rate of the charger is 4800 Watts. Make sure the charge rate is not over that by converting the return values from hex to decimal and multiplying them.

Installation & Safety Instructions

1. Preferably the charger should be installed in the vertical position with radiator fins vertical. A space of 10cm above ground should be open to ensure airflow. Never install in the vertical position with fins facing down.
2. Ensure all heat dissipating parts are not obstructed to avoid overheating. Do not put the battery charger near any heat sources. Make sure that free space around the charger is enough to provide adequate ventilation & easy cable socket access.
3. Ensure the consistency between the alternating supply voltage and the allowable voltage input of the charger, please approach a retailer or local Power Utility for inquiry.
4. For safety and electromagnetic compatibility, the battery charger has a 3-prong plug that apply to the socket with grounded outlet.
5. If you are using an extension cord for alternating current power supply, make sure that it is affordable to the maximum input current.
6. The voltage-drop between the charger and connection wire of the battery should be as less than 1% of the battery voltage as it can. Otherwise, it affects charging effect possibly. Meanwhile, the diameter of the wire should satisfy the output current value.
7.The thermal compensation probe for the battery voltage must be placed in the area of the highest battery temperature, such as between two batteries near the center of the pack.
8.If the charger does not work correctly or if it has been damaged, unplug it immediately from the supply socket, from the battery and contact a retailer.
9. Do not try to service the charger yourself. Opening the cover may expose you to shock or other hazards.
10. To avoid damaging the power cord, do not put anything on it or place it where it will be walked on. If the cord becomes damaged or frayed, replace it immediately.

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