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[Captainbeaky]

Hello - first post, and it's not a happy one, unfortunately.

2019 Zero FXS, about 10,000km, owned since new.
Bike has been cherished by the owner, never ridden in the wet, stored in the shade, and is gently ridden.
The bike is literally still in showroom condition - it's immaculate.

The DC/DC converter has just died (Keeps blowing the HV fuse) in the battery pack.
There is absolutely no evidence of water ingress at all.
This bike has no additional 12v loads, its completely standard.
There is no reason we can find for this to fail.
The converter is not showing any external signs of stress.
We do have a warm climate (Madeira) but not that hot - 30c max.

First question - do these have a history of failing?
Any idea why?

Second question - what is the actual Sevcon Part number fitted to peoples bikes please?
The parts list (Confirmed by the zero dealer in the UK) shows:-
Zero Part number 60-07190
Zero Part Description lists Sevcon Part number as 622/11211
But, the Sevcon part number of the part fitted to the bike is 611/11213 (the description on the part is "80v to 13.4v 500w dc/dc converter", so it would seem to be right.)

I cant find any proper spec sheets for the Sevcon 500w DC/DC converter range - any out there?

The UK Zero dealer (Streetbike) is trying to find a lead time for this part and is quoting £400 plus shipping etc etc,.
They are also challenging Zero about the part number actually fitted to the bike.

(I've given up trying to contact the Portugal Zero dealer - no response at all to any queries.).

Anyone have a contact in Europe where I might find one of these DC/DC converters please?
I've contacted the Sevcon dealers, awaiting response.

I'm not immediately finding any alternatives either - lots of people upgrading to this bigger 500w converter, but that's all.

TIA,

Mike.

[Richard230]

My 2018 S DC-DC converter failed earlier this year and was replaced with another Zero one. I posted a thread about my installation experience a few months ago. My daughter's 2014 S still has its original converter. Not too long ago there was a thread describing how someone sourced a higher power DC-DC converter and how they installed it in their bike. If you don't want to replace Zero's 500w converter with a new one you can try what that owner did.

I just realized that this was the video that I was thinking about (which was shown in another thread posted today):

[sharagan]

The most probable reason for the failure is the nominal voltage rating of the original part, which is 80 VDC. This is below the nominal voltage of the system. Even though it is within its operating range, it is still near its limits and for example an ABS system can have large current demands. A revenue minded design, lower cost to produce, higher revenue through selling more spare parts.

[Captainbeaky]

Yup, I've seen the youtube videos - they upgrade from the early version to the later one (which is what I already have).
I've got the part out, and on the bench, I'm just trying to find a replacement!

Zero quote  £500-odd and have it in stock in the Netherlands.
The Seven distributor in Europe wants €800 plus tax and a 4 week delay.

Anyone got an alternative source for a replacement that doesn't cost a sizeable fraction of the purchase price of the bike?

TIA,

Mike.

[Bodo]

Yup, I've seen the youtube videos - they upgrade from the early version to the later one (which is what I already have).
...

Mike, you didn't. In that embedded video above, they're replacing the 500$£€ 80V-Sevcon unit with a 300$£€ 96V-DMC unit off the shelf, and they're explaining why
from 8:02 to 9:54.

This solution should address all your trouble getting the Zero-supplied unit.