Figured out the electrical.. or how it’ll go on this bike.
I decided all my high power electrical will be under the battery box, that being my basic components which are controller, charger, J1772 plug, and motor in the wheel. With the controller under I can shorten my motor phase wires by half and gain a little efficiency.
I will have two 12V systems. We will consider “engine running” to be “controller on”. Hazard lights must work when engine is off or on, and headlight must be on when engine is “running”.
My controller requires an isolated DC step down and all I have is a regular 110vac switching 12v7a. It can be run right off the 72v battery. Ran it before, works fine. For headlight and brake/taillights. Cutting it close, but with the uLight module of the Nucular 24f controller outputting 12v2a the 7a isolated should be able to run my headlight with no dimming using the brake as it requires 12v7a.
My blinkers and hazards will run off a 12v10a non-isolated DC step down I got off alibaba for $6. So will the horn, AVC2 J1772 com board, and possibly a sound system.
I bought diodes so I could wire up hazards (all blinkers) and turn signals (one side or the other) through a single flasher. This handlebar switch cost $19 on Amazon and came with a horn and flasher relay. High beam switch will be used for hazards. Left and right circuits will have the diodes to prevent turning the other side on when I have one selected.
I’ll be using my old J1772 plug adapter. J1772 handles are essentially high power 240vac plugs so you must have a 240v capable charger for the bike or cellphone to charge off it. They go up to 7.3kw, most are 6.6kw. I’ll be charging at 4000w max (50 amps DC).
This one I actually bought the bare plug and soldered everything myself with 10awg cables within it. I put a hole in the side for power and communication (L, N, GND, Pilot, Proximity) and opened up the old cable end to fit a regular 110v wall plug. So I can charge my cell or something else, or a friend can charge with me off the same J-plug.
I have a double ended cable that I plug in that socket for 110v charging. Just plug the bike first or it’s hot...
For handling J1772 communication I use this little circuit board called an AVC2.r. All that’s really needed to begin charging is a resistor and diode from pilot to ground, however this one also handles the proximity pin which is the latch on the J-handle. The extra connections on it that are not used are direct taps to the relay within the board, for people who have more complicated contactor setups. The unit requires 12vdc, thus it has two plugs which are power and Pilot/Prox/GND going to the J-plug.
So all my high power stuff will be under batt box, and charger will be in a small bag as it is not waterproof. Plugged but in the case, so I can roll up and take it out of the bag for cooling, and fit a few small items like tools, a lunch, a bottle of whiskey, a glock... there will be a single 72v lead, controller display cable, and AVC2 com cable going up to the tank area where my DCDC step downs and lights wiring will be. And maybe a little stereo. I was thinking a single 6x9 speaker if I could fit it, would be plenty. A cool feature of the controller is that I can plug my controls into the display, or the light module, or the controller itself in case an accident destroys the other components. Will do a lot to keep wiring short and organized.