OSV Manual Charging Procedure

IMPORTANT: If there signs of a Thermal Event such as Smoke, Sparks, Fire, Hot Cords: --> Disconnect Charger At The Wall Outlets and refer to When Done Charging below

Understand the system and how it works before connecting and powering up

Manual charging must be monitored continuously with someone in the room who knows how to shut off the charger

• To ensure safety of the CAN bus Steering Motor (EPAS) and Brake Actuator (Kar-Tech)
  • Disconnect both harness connectors at the EPAS (2 pin and 8 pin)
  • Disconnect the harness connector at the Kar-Tech unit (4 pin)
• Position Charger tower so all cables and cords can easily reach their needed connections
• Connect the Charger tower's positive (red wire) and negative (black wire) alligator clips to the spade terminals on the positive and negative OSV Li-Ion battery terminals
  • Positive Terminal on the OSV battery is front and right most cell under the front passenger seat
    • Indicated with a B + near terminal
  • Negative Terminal on the OSV battery is rear and right most cell under the rear passenger seat
    • Indicated with a B - near terminal
• Turn off the power of upper and lower black power sources
  • Both white switches flipped down
  • All 8 Voltage and Amperage knobs turned to zero in the counter clockwise direction
• Plug in power strip lead and the other extension cord lead from the Charger tower to a suitable outlet
  • The middle 5 small power source cooling fans should run
  • The OSV battery voltage should read on the red voltage meter display
• Turn on the power of upper and lower black power sources
  • Flip both white switches up
• Increase slowly the lower and upper voltages to be higher in total than the OSV State of Charge (SOC) and current is not higher than 12 A (limited by either power source adjustment)
  • Example: OSV battery is at 78V SOC read from the red voltmeter (before increasing Charger output)
    • The 5 small middle power sources make about 10 V each, 50 V total
    • Add Voltage to be higher than the OSV battery SOC
      • Increase output from the Lower and Upper Power Supplies slowly
        • Turn both Coarse Voltage adjustment knobs Clockwise incrementally to creep up on desired Charger output Voltage
          • The Lower Power supply Voltage output should be around 22 Volts
            • Read from the analog dials above knobs
          • The Upper Power supply Voltage output should be around 12 Volts
            • Read from the analog dials above knobs
          • In this example we set the Charger to output 50V + 22V + 12V = 84V > 78V OSV SOC
    • Note: Current may need to be increased past 0 by turning the Course adjustment knobs
    • DON'T Exceed 12 Amps on either analog dial above knobs on Upper or Lower Power Supply

When Done Charging or when leaving the room

• 1st Unplug the Charger electrical cords from the wall outlets
• 2nd Turn off the power output of upper and lower black power sources
  • Flip both white switches down
  • Turn all 8 Voltage and Amperage knobs to zero in the counter clockwise direction
• 3rd Disconnect Red wire and Black wire alligator clip Charger leads at OSV battery terminals
• Full Clean-up
  • Hang Red wire and Black wire Charger leads on Charger tower
  • Put Power strip and extension cords on bottom shelf of Charger tower
  • Park Charger Tower out of the way of walking aisles