System UPGRADES
& Identification
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To get any system from Gen 1 to a Gen 2 revision, here's what's involved:
New parts for the Charger:
(2) New PWM control board assemblies
(1) Charger transformer replaced
(1) DC-DC transformer replaced
(1) Control interface board assembly
(1) PFC board assembly
(1) 48VDC cooling fan
Redrill heatsink for new PCB assemblies.
New parts for the Vehicle Integrator:
(1) Control interface board
New parts for the Controller:
(1) Gate Driver board
A different battery configuration (120V, 132V, 144V) should be addressed at this time, and may add cost.
With all these modifications is the need to recalibrate the Controller with the Potbox, recalibrate the Charger, and
rework the Vehicle Integrator. The battery monitors only need to be changed if a new battery is chosen over the
previous calibrated one. The warranty is renewed for 1 year parts and labor. The cost to do this revision is $500
(USD)
To get any system from Gen 1.5 (Improved DC-DC) to a Gen 2 revision, here's what's involved:
New parts for the Charger:
(1) New PWM control board assembly
(1) Charger transformer replaced
(1) Control interface board assembly
(1) PFC board assembly
(1) 48V cooling fan
Redrill heatsink for new PCB assemblies.
--------------------------------------------> The Charger / DC-DC portion above can be done for $250USD <-------------------
New parts for the Vehicle Integrator:
(1) Control interface board
New parts for the Controller:
(1) Gate Driver board
A different battery configuration (120V, 132V, 144V) should be addressed at this time, and may add cost.
With all these modifications is the need to recalibrate the Controller with the Potbox, recalibrate the Charger, and
replace the Vehicle Integrator. The battery monitors only need to be changed if a new battery is chosen over the
previous calibrated one. The warranty is renewed for 1 year parts and labor.
The cost to do this revision is $375 (USD)
To recalibrate the battery monitors for different AGM batteries and re-seal: $100
To recalibrate the battery monitors for GEL batteries and re-seal: $200
Changing charging system voltages on older systems requires the Charger to be modified. It may be more cost
effective to do a revision change (see below).
If you have a system that has failed and decide to have a revision upgrade rather than a repair, the warranty period
is not extended from the first warranty period.
System History Identifiers:
The first few systems Belktronix introduced were pre Gen 1: The Charge Detection Module didn't exist, the 3 Ohm
BatMon resistors are 6" long and handle up to 95W. Basic throttling control when all BMS report to charger together.
Gen 1: Introduced with the Charge Detection Module, no polarity on Charger Aux port. Internal AC relay
Gen 1.5: Improved over Gen 1 with: Charger Aux port is Polarized and powers the Charge Detection module, Indirect
BMS throttle control, eliminated the internal AC relay, improved DC-DC performance.
Gen 2: No Charge Detection Module, PFC International voltage input range, direct BMS throttle control, configurable
with AGM or LiFePO4 systems, External DC fan, Dual AC input charging configurations possible.
To get any system from Gen 1.5 (Improved DC-DC) to Gen 1.8 revision, here's what's involved:
This revision eliminates the Charge Detection Module, and operates from a single AC input:
(1) Reconfigure charger section to allow BMS system to throttle charger directly
(2) Add decoupling inductor to charger section
(3) Recalibrate charger
The cost to do this revision is $75.00
This is the cheapest upgrade and offers Gen 2 like performance without the wide range AC input. It retains the AC
fan for the charger.
Updated
6/28/10