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Author Topic: onboard charger problem  (Read 528 times)

FirstZeroFinland

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onboard charger problem
« on: June 06, 2017, 09:56:41 PM »

I have been using my elcon for a while now because onboard charger is not working. When I connect charger it clicks but it fails to start charging,on dash the charge indicator blinks red light. Now I was checking with multimeter and charger gives correct voltage and fuse is ok.. 
 What might be the problem? Anyone had similar problems?
 I post some pics on facebook now also.
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Erasmo

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Re: onboard charger problem
« Reply #1 on: June 07, 2017, 12:10:49 PM »

Do you have any error codes on the dash?
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FirstZeroFinland

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Re: onboard charger problem
« Reply #2 on: June 09, 2017, 09:00:38 PM »

Now I was testing again..
 When I plug the charger with power on it starts charging but after like fife seconds it stops and gives error  0017.
 
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e-volution

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Re: onboard charger problem
« Reply #3 on: June 09, 2017, 09:30:21 PM »

Hey FirstZeroFinland,
error code 0017 means charger failure. I had that on my Zero too. My onboard charger had to be
replaced under warranty.
see you   Peter
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FirstZeroFinland

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Re: onboard charger problem
« Reply #4 on: June 09, 2017, 10:03:55 PM »

Ok. Thanks.
 Weird it gives full voltage for multimeter tough..
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Lenny

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Re: onboard charger problem
« Reply #5 on: June 10, 2017, 01:35:03 PM »

I had something similar on my FXS recently. Charger apparently had 116 V, but wasn't charging and the dash threw a variety of red flashing error codes. To be honest I forgot to take a look at the error codes in the display. As this happened after some heavy rain (bike was parked outside) and the dash was flickering in general, I thought it might be just some corrosion/connecting issue. So I disconnected the onboard charger connector, cleaned it with electric cleaner, and put it back on. I threw some weird errors one more time but then it stopped until today. Charging as usual for about two weeks now.

You could give it a try as well, as its pretty simple to do. I'll do it again soon and use some dielectric grease after cleaning to avoid the problem in the future.
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Zero FXS 6.5 MY16
Luggage rack and Eltek FastCharger

#ride365

clay.leihy

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Re: onboard charger problem
« Reply #6 on: June 11, 2017, 04:52:39 AM »

The charger on my 2015 FX just stopped working. My dealer said it seems to be common in that year and her's also needs replacing. They loaned me their Quick Charger until they can get me in (a week or so) to check it and replace the bad charger (supposing that's what it needs). And I was just about to bring it in for the firmware update.
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Clay
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clay.leihy

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Re: onboard charger problem
« Reply #7 on: June 11, 2017, 04:54:14 AM »

I had something similar on my FXS recently. Charger apparently had 116 V, but wasn't charging and the dash threw a variety of red flashing error codes. To be honest I forgot to take a look at the error codes in the display. As this happened after some heavy rain (bike was parked outside) and the dash was flickering in general, I thought it might be just some corrosion/connecting issue. So I disconnected the onboard charger connector, cleaned it with electric cleaner, and put it back on. I threw some weird errors one more time but then it stopped until today. Charging as usual for about two weeks now.

You could give it a try as well, as its pretty simple to do. I'll do it again soon and use some dielectric grease after cleaning to avoid the problem in the future.
Is it just a plug, and is there high voltage involved? Behind the rubber cover on the side?
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Clay
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Lenny

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Re: onboard charger problem
« Reply #8 on: June 11, 2017, 02:05:47 PM »

Is it just a plug, and is there high voltage involved? Behind the rubber cover on the side?

You have to remove the left side tank plastics (3/4 screws). Then you will see the onboard charger. On it's upper side is a connector with about 12-15 tiny wires, that's the one I'm referring to. Just pull it of and clean the pins in the charger and the connector itself with the electronic cleaner spray.

As long as the bike is keyed off for at least a minute and the charger is not turned on, there won't be any voltage. You can make sure by measuring on the aux charge port. In addition to that, as long as you don't touch both HV+ and HV- at the same time, you won't get shocked. You could easily touch either one of them without anything happening, because it's an isolated system. But this is obviously not the case anymore if there's an isolation fault. So to avoid any risk measure on the aux charge port to see that the voltage ist gone and just have a look at where your fingers are.
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Zero FXS 6.5 MY16
Luggage rack and Eltek FastCharger

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FirstZeroFinland

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Re: onboard charger problem
« Reply #9 on: June 12, 2017, 03:19:32 PM »

I did clean that connector earlier..
 If I buy new charger I dont really want to spend money on useless 650w onboard charger :/
  Any options to buy more powerfull one? Does the pack ballance trough quick charging? I have elcon but it doesn't charge to full.. Cell ballance seems good anyway after few months using only elcon..
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Cama

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Re: onboard charger problem
« Reply #10 on: June 12, 2017, 07:08:08 PM »

May the app isnt working correct referring cell-balance?

I didnt charge full since the new charging guidelines came up here online.

Although I dont see more than 5 mV ...
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ZERO SR 2016

Shadow

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Re: onboard charger problem
« Reply #11 on: June 13, 2017, 01:19:29 AM »

  Any options to buy more powerfull one? Does the pack ballance trough quick charging? I have elcon but it doesn't charge to full.. Cell ballance seems good anyway after few months using only elcon..
Diginow Super Charger v2 safely charges the battery to 100% and allows a cell balancing to happen. The SCv2 units I've seen to date need the bike keyed on to close the contactor and begin the charging process (after which time you can key off and charging stays "awake" with some auxiliary connector signalling from the SCv2 control computer). Also the SCv2 does not appear to allow passing direct current like the stock onboard charger, which is a rare trick you can use to charge a few percent of one Zero off of the DC system voltage from another Zero, i.e. "bike rescue cable". Thus I would be careful about using the SCv2 for months-long storage maintenance charging instead of the stock onboard charger; I don't think this has been designed for or tested extensively yet.

The wiring connectors needed to make a bolt-in replacement of the stock onboard charger are expensive to source, and its mounting is of a limited physical size, which is why you don't yet see any direct bolt-in aftermarket replacements. Some folks are already prototyping this kind of replacement but at the moment it involves a lot of warranty-voiding labor with rotary grinders and additional clearances.

For an easy no-modification install you could get a Diginow Super Charger v2 one-module (1x3.3kW) or two-module (2x3.3kW) charging system. Mounting a J1772 inlet is easy you don't need to put it in the tank area, you can use some zip-ties (or a fancier metal bracket - I'm prototyping and will do a run of these soon) and there's a few locations depending on your bike and accessories installed to put the inlet. When mounting the charging modules that is very easy to do on S(R) or DS(R), and the FX(S) a bracket can be made above the pillion seat area (or as a small backpack to carry).
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Starpower

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Re: onboard charger problem
« Reply #12 on: June 13, 2017, 03:19:53 AM »

Finland, hummm. Mine would not charge on cool winter days and would do as yours - look to start charging only to shut down after about 5 sec. and a red led flashing. This happens anytime the battery is below 45F. (7C), this is considerably warmer than Zero claims for the shutoff.  I push it out into the sun exposing the battery side to the sun for about 20-30 mins and it takes the charge.
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'13 Zero S 12.5 100% Solar charged, '14 BMW S1000R, '14 Honda Grom.

mrwilsn

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Re: onboard charger problem
« Reply #13 on: June 13, 2017, 05:17:25 AM »

Finland, hummm. Mine would not charge on cool winter days and would do as yours - look to start charging only to shut down after about 5 sec. and a red led flashing. This happens anytime the battery is below 45F. (7C), this is considerably warmer than Zero claims for the shutoff.  I push it out into the sun exposing the battery side to the sun for about 20-30 mins and it takes the charge.

Sounds like something's not right here....

Is that 45F the actual battery temp (from the app) or ambient temp?  I ride through the winter in temps as low as 14F and I am still able to charge as long as I plug in as soon as I get home from work while the batteries are still a little warmed up from the ride.  When it's really cold I will deliberately ride it hard to heat the batteries up so it will charge when I get home.  Although, power is limited when the bike has been cold soaked outside at work all day.  Regardless, as long as battery temp is above 32F it should accept a charge.
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2014 Zero S

FirstZeroFinland

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Re: onboard charger problem
« Reply #14 on: June 13, 2017, 10:29:49 AM »

Well, mayby I buy that new onboard charger if its not that expensive..

I allways keep my zero in warm garage.
 I bought my fx from germany in 2014. There was no dealer in Finland until this year, but I was lucky I have had only small issues with my bike so far..
 I have been driving on snow and ice with spike tires and now its summer so lots of fun with wheelies and stuff..
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