Hawkeye Mfg TC 6.6kW User manual
TC 6.6kW Battery Charger Manual | Rev 01
TC 6.6kW Battery Charger
---Manual---
Copyright © 2022 Hawkeye Innovations, LLC. All Rights Reserved 1
TC 6.6kW Battery Charger Manual | Rev 01
Table of Contents
Safety First!...............................................................................................................3
Charger Specifications...............................................................................................5
Safety Notes...............................................................................................................6
Installation…….........................................................................................................7
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TC 6.6kW Battery Charger Manual | Rev 01
Safety First!
This list is not all inclusive. Use common sense and be responsible when working with high
voltage and high voltage components. High voltage components are dangerous and can
cause injury or death if not correctly or safely handled.
Always wear safety equipment such as high voltage rated shoes, gloves, and safety glasses.
Be sure to remove all metal jewelry or any metal objects prior to working with any high
voltage. Use insulated tools or insulate any tools that may be coming in contact with high
voltage points.
Always check over the high voltage wiring and connections several times. Always use
precautions when working with high voltage and/or series connected batteries. Be sure that
the vehicle is off of the ground, and the wheels will not make contact with anything. It is
good practice to have more than one support mechanism that supports the vehicle for extra
safety.
Always refer to the component manufacturers’ manuals for the most up to date
information on their specific products. Please be sure to always use correct high voltage
fusing and high voltage disconnect devices that are fully operational.
If you ever feel uncomfortable or uncertain in any way, STOP and seek advice from a
knowledgeable person immediately.
DISCLAIMER:
Hawkeye Innovations LLC TC 6.6kW Battery Charger manuals can change and be
updated at any time without notice. Except for Hawkeye Innovations, LLC’s
express warranties, if any, set forth in the manual regarding TC 6.6kW Battery
Charger located at
https://www.hawkeyeinnovationsllc.com/store/p9/Elcon%2FTC_6.6kW_Battery_C
harger_%284th_Generation%29.html , Hawkeye Innovations, LLC, makes no
representations or warranties whatsoever with respect to the TC 6.6kW Battery
Charger, including but not limited to any warranty of merchantability, warranty of
fitness for a particular purpose, or warranty against infringement of intellectual
property rights, whether express or implied by law, course of dealing, course of
performance, usage of trade, or otherwise. Hawkeye Innovations, LLC, has no
control of third-party installation or use of the TC 6.6kW Battery Charger.
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TC 6.6kW Battery Charger Manual | Rev 01
Accordingly, Hawkeye Innovations, LLC, assumes no liability for vehicle
functionality or safety during or after third-party installation of the TC 6.6kW
Battery Charger. Additionally, Hawkeye Innovations, LLC, assumes no liability for
any damage caused to the vehicle or the TC 6.6kW Battery Charger as a result of
installation of the TC 6.6kW Battery Charger. Hawkeye Innovations, LLC, assumes
no responsibility for this product in any use.
______________________________________________________________________
Copyright © 2022 Hawkeye Innovations, LLC. All Rights Reserved 4
TC 6.6kW Battery Charger Manual | Rev 01
6.6kW Battery Charger Specifications
Features:
- >93% efficient
- Automotive grade
- IP67 rated
- Excellent protection features (output over-voltage, output over-current,
output short-circuit, charger over temperature)
- Built in temperature sensor shuts down the charger in an overheated
condition.
- Fully sealed design.
- Auto shut down if the CAN message is not received within 5 seconds.
Technical specifications:
Operational Temperature
-40°F - 140°F
Storage Temperature
-40°F - 194°F
Relative Humidity
5%-95%
Heat Dissipation Method
Air Cooled
Input Voltage/Current
95-260VAC 32A
Input Frequency
50-60Hz
Size
10.91 x 10.59 x 4.41 inches
Weight
20 lbs
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TC 6.6kW Battery Charger Manual | Rev 01
Safety Notes
1. While the charger is IP67 rated, care should be taken so that the charger does
not get excessive spray (i.e. mounted under the car near the wheels).
2. Ensure that the AC power input connections are good.
3. The charger should have adequate ventilation to ensure proper cooling. It is
recommended to have at least 6 inches of space around the heatsink of the
charger, the more the better.
4. Do not operate the charger with poor quality, high resistance, or defective
batteries.
5. Do not operate the unit if charger wire harnesses are damaged.
6. Charger must be securely mounted to the vehicle.
7. Do not reverse polarity of the charger output.
8. Take caution to connect the AC input properly.
9. If you are ever unsure, STOP, and consult a technician.
10. Please refer to the official TC Charger manual on our product page for
complete instructions. This manual is only to supplement the
manufacturer’s documentation.
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TC 6.6kW Battery Charger Manual | Rev 01
Installation
(AC INPUT, 3 PIN, LEFT) (SIGNAL, 20 PIN, MIDDLE) (DC OUTPUT, 2 PIN, RIGHT)
1. Without any power present on the high voltage system, the 12V system or the CAN bus
network, wire up the included charger signal harness shown in Figure 1.
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TC 6.6kW Battery Charger Manual | Rev 01
Figure 1
20 Pin Signal Harness:
Pin #10, (top right, red wire) +12V 1A Supply
Pin #11, (bottom left, pink wire) CAN High
Pin #12, (bottom, second from left, green) Can Low
Pin #17, (bottom, 4th from right, black) -12V Supply Ground
2. With the high voltage (HV) disconnect switch in the off position, ensuring no high voltage
present, wire-up the included HV Battery Output harness shown in Figure 2 to the battery
pack/HV distribution box. Ensure that the polarity is correct, as incorrect polarity will damage
the charger. It is recommended to add a fuse in between the charger DC output and the battery
pack. The fuse should be sized accordingly.
Figure 2
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TC 6.6kW Battery Charger Manual | Rev 01
3. Once the HV Battery output harness shown in Figure 2 is connected to the pack, plug in the
harness into the orange 2 pin HV out connector of the charger.
4. Figure 3 below shows the AC Input harness. We have made this harness with individual wires
to make it much easier to install per feedback from our customers. The red wires are both Hot,
for 240VAC, the green wire is ground (ground of AC mains). This should be wired directly
to your J1772 port. Always be sure to use high quality connectors, that have good conductivity,
and rated for more than the expected draw. The body of the charger should have contact with the
chassis ground of the vehicle, to ensure proper grounding for J1772 and safety.
Figure 3
5. Once you have verified that the wiring is correct, connect the AC input harness shown in
Figure 3 to the AC input 3 pin port on the charger. Incorrect wiring can damage the charger.
6. Finally, after verifying all of the wiring is connected correctly, turn on your HV disconnect
switch. Log into your Orion BMS, and once connected, select the Elcon Charger under ‘third
party devices’ shown in Figure 4. If you need more assistance with the Orion BMS, please
contact your Orion BMS dealer. We only recommend the Orion BMS, but if you are using a
different BMS and need the CAN byte structure, please contact us for more information. The
default CAN speed for this charger is 250kbps. The CAN bus baud rate of the Orion BMS needs
to be set to 250kbps as it defaults to 500kbps. This can be done by changing the CAN speed in
Copyright © 2022 Hawkeye Innovations, LLC. All Rights Reserved 9
TC 6.6kW Battery Charger Manual | Rev 01
the drop down menu shown in Figure 4. Upload the changes to the BMS and power cycle the
unit. If needed, please contact your Orion dealer for more information.
Figure 4
The 6.6kW Battery Charger should now be fully operational and set up with your system. If you
have any questions, please feel free to contact us.
Hawkeye Innovations, LLC
Email: [email protected]
Phone: 1-800-961-9492
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