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Thread: Convert AC/DC bike to ALL DC.

  1. #1421
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    Default Re: Convert AC/DC bike to ALL DC.

    Quote Originally Posted by aumer98 View Post
    Checked bro there's no connectivity between ground and windings two wires, checked with DMM, winding wires have AC voltage upto 38v
    When connected to RR unit the output is zero 0
    From ape RR unit, have two RR unit. Both don't show any output, until connected to a battery.
    Ok so tested the output volts from RR unit using a capacitor, it's 10.4v at ideal and 12.3v at max


    I think i need more winding for more power
    I have used 19g wire for my three pole coil and i can't rewinding more turns to it, no space.


    Anyone please suggest which gage wire to b used for rewinding 3poles. as 19g wire is not producing much output for 3 poles
    Toshar Deven likes this.

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    Default Re: Convert AC/DC bike to ALL DC.

    Quote Originally Posted by aumer98 View Post
    Ok so tested the output volts from RR unit using a capacitor, it's 10.4v at ideal and 12.3v at max


    I think i need more winding for more power
    I have used 19g wire for my three pole coil and i can't rewinding more turns to it, no space.


    Anyone please suggest which gage wire to b used for rewinding 3poles. as 19g wire is not producing much output for 3 poles
    You should have gone thoroughly through this DC conversion thread. Somewhere on the very first few pages it is clearly mentioned that APE RR behaves strangely when connected directly to DMM and not the battery. This will not give you end results but may also lead to RR failure.

    AC output voltage directly from the rewinded stator can be measured with DMM and it is also dangerous as voltage may go all over 150v AC. These AC output wires should be directly connected to APR RR input wires.
    APE RR output wires should be connected properly to the battery and then only voltage should be measured. You may get anything above 12v easily if everything is properly done.
    APE RR output in amperes can only be measured with DMM in series as in between RR poisitve TO Battery positive. This will also work only if battery is partially charged as a fully charged battery simply does not accept any current but this doesnt mean RR unit is faulty.

    Now, Ideally the overall output (in terms of AC voltage) from the rewinded stator before the RR should peak around 180 volts. Dont ask me why but in my case I got this much of amount. Worth to note that I rewinded my stator with 17 gauge wire in the very best possible manner with 10 rounds and 10 layers on each pole resulting 100 rounds per pole. The stator itself became very heavy with loads of copper onto it but I have kept utmose care to not to ground it anywhere on pole.
    For some usefull information, take out you phone and start readin each and every post from page 101 on this thread. You will get to know how to rewind the stator by hand with best results.

    Also post couple of pictures of your stator.

  3. #1423
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    Default Re: Convert AC/DC bike to ALL DC.

    Quote Originally Posted by aumer98 View Post
    Ok so tested the output volts from RR unit using a capacitor, it's 10.4v at ideal and 12.3v at max

    I think i need more winding for more power
    I have used 19g wire for my three pole coil and i can't rewinding more turns to it, no space.

    Anyone please suggest which gage wire to b used for rewinding 3poles. as 19g wire is not producing much output for 3 poles
    we rewounded bajaj ct100 3 poles stator with 18, 19, 20 gauge wires and used Bajaj pulsar 180's RR Unit.
    The max AC voltage we managed to achieve was around 50v with 20G, 38~42v with 19G.
    Since it is a 3 pole stator the AC voltage cannot reach 100+ volts; an 8 pole stator will output those figures.
    With 19G the initial current(idle to 3000RPM) was less but managed max 70w at higher RPMS.
    With 20G a 55w bulb was fully lit even at low rpms(city riding) but at higher rpms the amount current was dropped.
    ANYWAY you can't use a 100w bulb with the 3 pole stator. if you can find 19.5G it would be good.

    Hero Honda's passion plus 3 pole stator is much better than Bajaj's; It gave good results with rewinding with 19G wire.

    I suggest you ditch the APE RR and go for any full DC bike's RR like Gixxer, Pulsar NS 200, FZ etc. NS200's RR is big and cheaper too I think.
    With APE RR and dead battery I was stranded with my Unicorn(as it has no ignition coil and uses battery for ignition) since your's has ignition coil there would be no such problem but APE RR is over kill and complicated for 3 pole stators and should have a working battery for it to function.

    Finally -- Rewind properly, tightly to achieve AC voltage of minimum 12v at idle.. experiment with 19, 19.5, 20 wires. Ditch APE RR.

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    Default Re: Convert AC/DC bike to ALL DC.

    Quote Originally Posted by Toshar Deven View Post
    You should have gone thoroughly through this DC conversion thread. Somewhere on the very first few pages it is clearly mentioned that APE RR behaves strangely when connected directly to DMM and not the battery. This will not give you end results but may also lead to RR failure.

    AC output voltage directly from the rewinded stator can be measured with DMM and it is also dangerous as voltage may go all over 150v AC. These AC output wires should be directly connected to APR RR input wires.
    APE RR output wires should be connected properly to the battery and then only voltage should be measured. You may get anything above 12v easily if everything is properly done.
    APE RR output in amperes can only be measured with DMM in series as in between RR poisitve TO Battery positive. This will also work only if battery is partially charged as a fully charged battery simply does not accept any current but this doesnt mean RR unit is faulty.

    Now, Ideally the overall output (in terms of AC voltage) from the rewinded stator before the RR should peak around 180 volts. Dont ask me why but in my case I got this much of amount. Worth to note that I rewinded my stator with 17 gauge wire in the very best possible manner with 10 rounds and 10 layers on each pole resulting 100 rounds per pole. The stator itself became very heavy with loads of copper onto it but I have kept utmose care to not to ground it anywhere on pole.
    For some usefull information, take out you phone and start readin each and every post from page 101 on this thread. You will get to know how to rewind the stator by hand with best results.

    Also post couple of pictures of your stator.
    Thank for reply bro and the information

    My battery was faulty to it was not charging full
    Changed the battery
    Winding was of 19g wire
    With ape rr - here its cheaper thn pulser 220
    Have both (ape rr and pulsar 220rr)
    Voltage Tested with both,
    Ape rr with capacitor and battery gives 12.98-13.50v
    Pulsar220 rr gives 12.6-13 v max
    Currently using ape rr
    With philips 60/55 extreme vision
    Battery is discharging after 2hr or riding
    When turned on headlight the output is 10.80v
    At battery terminals with bike on
    But discharging is still their when turned on headlight
    Tail-light is led as well.
    Anyone can help with that?
    Last edited by aumer98; 03-09-2020 at 02:16 PM.

  5. #1425
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    Default Re: Convert AC/DC bike to ALL DC.

    Quote Originally Posted by aumer98 View Post
    Thank for reply bro and the information

    My battery was faulty to it was not charging full
    Changed the battery
    Winding was of 19g wire
    With ape rr - here its cheaper thn pulser 220
    Have both (ape rr and pulsar 220rr)
    Voltage Tested with both,
    Ape rr with capacitor and battery gives 12.98-13.50v
    Pulsar220 rr gives 12.6-13 v max
    Currently using ape rr
    With philips 60/55 extreme vision
    Battery is discharging after 2hr or riding
    When turned on headlight the output is 10.80v
    At battery terminals with bike on
    But discharging is still their when turned on headlight
    Tail-light is led as well.
    Anyone can help with that?
    Can you elaborate how many turns per pole.

    Also the voltage you mentioned was it above 3k RPM?

    If the 3 pole stator isn't putting out enough current you voltage will drop.
    Better move to LED headlamps. Main reason is a 55/60w halos will consume a reasonable 4.6A at 13.5V DC.
    LED on other hand will consume somewhere around 3A DC
    As of we can't modify the stator and rotor arrangements in a motorcycle without major modification.
    Last edited by Manoj Sivaraman; 03-23-2020 at 08:07 PM.

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    Default Re: Convert AC/DC bike to ALL DC.

    Quote Originally Posted by Manoj Sivaraman View Post
    Can you elaborate how many turns per pole.

    Also the voltage you mentioned was it above 3k RPM?

    If the 3 pole stator isn't putting out enough current you voltage will drop.
    Better move to LED headlamps. Main reason is a 55/60w halos will consume a reasonable 4.6A at 13.5V DC.
    LED on other hand will consume somewhere around 3A DC
    As of we can't modify the stator and rotor arrangements in a motorcycle without major modification.
    100-112 turns per pole
    Total 3 poles
    and at max RPM total AC current is 52v with 19g wire
    And output dc volts is 13v at max RPM
    My amp meter is not working to get the Amp reading.

  7. #1427
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    Default Re: Convert AC/DC bike to ALL DC.

    Quote Originally Posted by aumer98 View Post
    100-112 turns per pole
    Total 3 poles
    and at max RPM total AC current is 52v with 19g wire
    And output dc volts is 13v at max RPM
    My amp meter is not working to get the Amp reading.
    Can I know the Battery voltage at no load above 3k RPM

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    Default Re: Convert AC/DC bike to ALL DC.

    Quote Originally Posted by Manoj Sivaraman View Post
    Can I know the Battery voltage at no load above 3k RPM
    at max rpm with no load the dc voltage of battery is 12.80-13v

  9. #1429
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    Default Re: Convert AC/DC bike to ALL DC.

    Quote Originally Posted by aumer98 View Post
    at max rpm with no load the dc voltage of battery is 12.80-13v
    I guess something is wrong. At no load voltage must be 14.1 least.
    Take a closer inspection on the windings and wiring.

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