Scotchmo
Member
People have implemented numerous different configurations of charging systems using the white wire on an HT engine. This thread will be devoted to one particular version; a 6v, negative ground, lead acid system. A few people, including myself have had success with different versions of it. It can keep a 6v lead acid battery charged during regular intermittent usage or occasional heavy usage. The main limitation is the minimal charge current so it is not suitable if you do all your driving at night. With the proper battery, it can handle occasional night driving even with a high output headlight.
We can start with the simplest system that requires only a diode, battery, and fuse. The battery acts as a voltage regulator and keeps voltage within a narrow range so that you do not burn out sensitive components, or suffer from dim lights at low speeds. The fuse protects your wiring and the diode rectifies the current in order to charge the battery.
A small 6v motorcycle battery is a good choice to use in the simplified system. These are typically wet cell batteries in the 2ah to 8ah range. They are somewhat tolerant of overcharging so should do the job even without a charge regulator. Later, you can add two more components to implement a zener diode charge regulator. That will prevent even smaller, sealed lead acid batteries from overcharging which could happen if you drive often but never use your lights.
Except for the optional zener diode, all of the components are available at Radio Shack. The ratings for the components are in the ballpark but we may be able to use even lower wattage items. The use of a terminal strip means that you do not even have to solder any components. I would like to see some people implement the simple system and report back on the results. We can then discuss limitations and possible improvements, as well as coming up with optimal components. Suggestions for suitable 6v lights, horns, bulbs, LEDs, etc. are also welcome in this thread.
The first image shows a mock up of the simplified system.
The second image shows a mockup of the zener diode system.
The third image shows a diagram of the zener diode system.
The forth image shows the battery box that I used on my system.
The bill of materials below is for the zener system that I am currently using. For the simplified system, you only need the rectifier diode, fuse, and any 6v lead acid battery.
Terminal strip - Radio Shack 274-679
WHITE 18g wire - to motor
RED 16g wire - to light, horn, switches, etc.
BLACK 16g wire - to motor or to ground
D1 - rectifier diode, I used Radio Shack 276-1141
Z1 - zener diode, 6.8v, 5w - 1N5342B
R1 - power resistor, 10ohm, 5watt, I used Radio Shack 271-132
F1 - fuse, I used a 5 amp fuse
B1 - 6v lead acid battery, I used a 1.3ah SLA
Battery box - 2.0x2.5x5.0 plastic Radio Shack project box
Mounting brackets - plastic conduit clamps from Home Depot
We can start with the simplest system that requires only a diode, battery, and fuse. The battery acts as a voltage regulator and keeps voltage within a narrow range so that you do not burn out sensitive components, or suffer from dim lights at low speeds. The fuse protects your wiring and the diode rectifies the current in order to charge the battery.
A small 6v motorcycle battery is a good choice to use in the simplified system. These are typically wet cell batteries in the 2ah to 8ah range. They are somewhat tolerant of overcharging so should do the job even without a charge regulator. Later, you can add two more components to implement a zener diode charge regulator. That will prevent even smaller, sealed lead acid batteries from overcharging which could happen if you drive often but never use your lights.
Except for the optional zener diode, all of the components are available at Radio Shack. The ratings for the components are in the ballpark but we may be able to use even lower wattage items. The use of a terminal strip means that you do not even have to solder any components. I would like to see some people implement the simple system and report back on the results. We can then discuss limitations and possible improvements, as well as coming up with optimal components. Suggestions for suitable 6v lights, horns, bulbs, LEDs, etc. are also welcome in this thread.
The first image shows a mock up of the simplified system.
The second image shows a mockup of the zener diode system.
The third image shows a diagram of the zener diode system.
The forth image shows the battery box that I used on my system.
The bill of materials below is for the zener system that I am currently using. For the simplified system, you only need the rectifier diode, fuse, and any 6v lead acid battery.
Terminal strip - Radio Shack 274-679
WHITE 18g wire - to motor
RED 16g wire - to light, horn, switches, etc.
BLACK 16g wire - to motor or to ground
D1 - rectifier diode, I used Radio Shack 276-1141
Z1 - zener diode, 6.8v, 5w - 1N5342B
R1 - power resistor, 10ohm, 5watt, I used Radio Shack 271-132
F1 - fuse, I used a 5 amp fuse
B1 - 6v lead acid battery, I used a 1.3ah SLA
Battery box - 2.0x2.5x5.0 plastic Radio Shack project box
Mounting brackets - plastic conduit clamps from Home Depot
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