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[2013ZeroSMarc]

Looking for a suggestion how to proceed.  Here's the background info.  2013 S with 14K miles and 850 charge cycles on the bike.  I bought it used, so I don't know if the charger is original or not.  I have put the vast majority of the miles on, commuting each day in nearly rain free Los Angeles, CA.  Two days ago I noticed the power cord was badly burned on the female end, that attaches to the bike.  I cleaned up the contacts on the bike, which appeared to be OK, and the next day I used a brand new cord.  When I pulled the cord out after charging, one of the pins came out of the bike (!) and was stuck in the female end of the cord!  There was evidence of some heat again on the plug.  Clearly I still have a problem.  Leading up to this, I recently seemed to notice more of an audible sound when I plugged the cord in (I was always using the outlet side first, then the bike plug).  With the new cord, I reversed the order after having read some suggestions to do so (although, when I had asked a Zero rep, they said it didn't make a difference).  But, because it would be easier and less expensive to replace the 110v outlet, then the internal cord on the bike, that was the direction I went in.  Anyway, even today, the bike did still charge completely and in the normal amount of time.  Is the charger on it's way out?  Should I first attempt to obtain and replace the internal cord on the bike?  Should I replace with a new charger from Zero?  Or do you have a suggestion for another, currently available brand?  I could manage with a non, on-board charger if that is the most cost effective repair, if replacement is necessary.  I will add, my pack temperatures have not been abnormally high, the most recent download show that it has never exceeded 45 degrees (C), while either riding or charging.   Thanks all!  I appreciate your input! Marc

[TheRan]

It's a known issue when charging the bikes on 110V. The C13/14 connection is only really rated for 10A (some will say 11A on them), but because of the lower voltage in America rating agencies there (such as UL) will rate them up to 15A. The 1500W charger in your bike can pull up to about 13.5A.

If the pin came out of the port on your bike then it's not a good idea to continue using it. Unfortunately it's hardwired to the charger so you'd need to solder a new one on.

[2013ZeroSMarc]

Thanks, so your thinking is, the charger is probably still OK.  So owners just replace these periodically as they fail?  UGH. 

[ESokoloff]

If you search my posts, you’ll find a lot of information on the subject. 

[ESokoloff]

Found it…..

https://www.electricmotorcycleforum.com/boards/index.php?topic=10514.0

[DonTom]

Looking for a suggestion how to proceed.  Here's the background info.  2013 S with 14K miles and 850 charge cycles on the bike.  I bought it used, so I don't know if the charger is original or not.  I have put the vast majority of the miles on, commuting each day in nearly rain free Los Angeles, CA.  Two days ago I noticed the power cord was badly burned on the female end, that attaches to the bike.  I cleaned up the contacts on the bike, which appeared to be OK, and the next day I used a brand new cord.  When I pulled the cord out after charging, one of the pins came out of the bike (!) and was stuck in the female end of the cord!  There was evidence of some heat again on the plug.  Clearly I still have a problem.  Leading up to this, I recently seemed to notice more of an audible sound when I plugged the cord in (I was always using the outlet side first, then the bike plug).  With the new cord, I reversed the order after having read some suggestions to do so (although, when I had asked a Zero rep, they said it didn't make a difference).  But, because it would be easier and less expensive to replace the 110v outlet, then the internal cord on the bike, that was the direction I went in.  Anyway, even today, the bike did still charge completely and in the normal amount of time.  Is the charger on it's way out?  Should I first attempt to obtain and replace the internal cord on the bike?  Should I replace with a new charger from Zero?  Or do you have a suggestion for another, currently available brand?  I could manage with a non, on-board charger if that is the most cost effective repair, if replacement is necessary.  I will add, my pack temperatures have not been abnormally high, the most recent download show that it has never exceeded 45 degrees (C), while either riding or charging.   Thanks all!  I appreciate your input! Marc

The first thing I would do is to deal with real numbers. Get yourself a Watt-O-Meter and see how many amps, KW and VA is being used.


Then post those numbers here.



-Don-  Auburn, CA

[Specter]

Even though the plug and cord may SAY it's rated at 15 amps, thats under pretty much perfect conditions.  Over time, things get corroded a bit, the contacts where you plug it in, on the female side, get a bit loose, etc etc and things start to heat up.

Even pulling 13 amps, for HOURS on end is going to heat that cord up, make things even looser and in the long run burn your cord up at the contact points. 

NOTE:  if you heated it up enough to physically burn the cord on your end, I will pretty much guarantee you burned stuff up on the bike end too.  THAT much heat will travel up the prongs, and wire, down the cord, into the bike, and it's cords there and burn them too.

I would recommend you stop using it until you at least open it up and see what damage may be incurred, and if you MUST use it, can you limit your current to say 5 amps or so?  Oxidized /Crystallized copper due to intense heat is just a fire waiting to happen.

Aaron

[2013ZeroSMarc]

Thanks for the input.  I proceeded to replace the stock c13/c14 connector on the bike with a standard 15 amp, 125 volt grounding plug, which I cut from a new extension cord (so it was as water tight as possible).  I then added another grounding plug to the shortened cord to make my charge cord.  It charged perfectly, no heat detected at all. 

[2013ZeroSMarc]

I am now adding this switch to the combination, which I hope will eliminate the "Sparking" we experience when plugging in to charge:    https://www.amazon.com/BindMaster-Grounded-Single-Adapter-Indicator/dp/B01M69KDSP/ref=sxin_16_pa_sp_search_thematic_sspa?content-id=amzn1.sym.1c86ab1a-a73c-4131-85f1-15bd92ae152d%3Aamzn1.sym.1c86ab1a-a73c-4131-85f1-15bd92ae152d&crid=Z6C2V5JZMH8O&cv_ct_cx=portable%2Blight%2Bswitch%2Boutlet&keywords=portable%2Blight%2Bswitch%2Boutlet&pd_rd_i=B01M69KDSP&pd_rd_r=146729c0-2489-4b67-9e64-e1b9fc856a74&pd_rd_w=lJ7pN&pd_rd_wg=QYPXk&pf_rd_p=1c86ab1a-a73c-4131-85f1-15bd92ae152d&pf_rd_r=DY98AAM72XR9PB8MHVEG&qid=1694532356&sbo=RZvfv%2F%2FHxDF%2BO5021pAnSA%3D%3D&sprefix=portable%2Boutlet%2Bswitch%2B%2Caps%2C138&sr=1-3-364cf978-ce2a-480a-9bb0-bdb96faa0f61-spons&sp_csd=d2lkZ2V0TmFtZT1zcF9zZWFyY2hfdGhlbWF0aWM&th=1

[ESokoloff]

For what it’s worth, I don’t think the plug-in is any big deal as the Contactor has to close before charge current begins to flow. 
Un-plugging on the other hand is as long as the bikes still charging. 

[TheRan]

There's still power going to the charger prior to the contactor closing. When I plug my bike in with the mains outlet already on (we have switched outlets here in the UK, handy for situations like this) I can hear it arcing. It's not like that on its own is going to cause a significant amount of heat, but over time it could lead to pitting of the contacts and a potential slight increase in resistance and thus more heat during charging. I'm not worried because I'm on 240V, but when 110V is already pushing the limits of the connector it's not a bad idea to take every precaution.

[ESokoloff]

Ok, for the sake of science I just checked the peak amp inrush upon initial energizing of my 2016 DSR with a warranty replaced onboard charger. 
I found inrush to be 1.2a (on 120vac).
So roughly 1/10 that of the current draw after Contactor closure.
1.2a isn’t too much but agree best to let a component handle it that is either designed for switching or is easiest to change out if needed. 
I utilize a spring wound timer that I turn on after the cords plugged in. 

[2013ZeroSMarc]

I truly appreciate everyone's input and feedback!  Ride safely!