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[ki6eph]

Hi all,

Over the past months my Zero has been getting to a lower and lower max battery percentage. I'm now at 91%. After reading lots of posts on here saying the original Calex charger is the most likely culprit, I'm assuming the remedy is to replace it. Before I pull the trigger on that purchase, is there anything more I should do to troubleshoot? Anything specific I should look for in the logs? I've only got about 6k miles on the bike and I've tried to be very nice to the battery pack, so I feel like that's less likely the issue.

Eventually I'd like to be able to take advantage of L2 charging but I'm currently in an apartment and the only place I can really charge is at work on 110V. That said, if there are any recommendations for more affordable alternative chargers, either 110V or L2, that are or or less drop-in replacement, I'm all ears! Open to more challenging installs as well if there's a good guide.

Thanks! 

[Richard230]

That is what happened with the OBC on my daughter's 2014 S five years ago. Eventually it would stall at 88%. After replacing the OBC with an updated version, it has worked flawlessly every since.

[MVetter]

Does a 2014 even have a Calex or is it the stack of Mean Wells?

[Richard230]

Does a 2014 even have a Calex or is it the stack of Mean Wells?

It was a Calex. Photo attached.

[MVetter]

Ok, yours was a Calex. Doesn't mean OP's is. Some 2014s still had the stacks of Mean Wells.

[DonTom]

Hi all,

Over the past months my Zero has been getting to a lower and lower max battery percentage. I'm now at 91%. After reading lots of posts on here saying the original Calex charger is the most likely culprit, I'm assuming the remedy is to replace it. Before I pull the trigger on that purchase, is there anything more I should do to troubleshoot? Anything specific I should look for in the logs? I've only got about 6k miles on the bike and I've tried to be very nice to the battery pack, so I feel like that's less likely the issue.

Eventually I'd like to be able to take advantage of L2 charging but I'm currently in an apartment and the only place I can really charge is at work on 110V. That said, if there are any recommendations for more affordable alternative chargers, either 110V or L2, that are or or less drop-in replacement, I'm all ears! Open to more challenging installs as well if there's a good guide.

Thanks! 

Justin,


Yes. At least if the 2014 S has the DC cable above the motor. Troubleshoot by using a DeltaQ charger, don't even use the OBC and see if it then charges to 100%. Key on if no OBC being used. Do you know anybody who has one for a 2014 down there in Los Angeles?


There are other ways to charge it up, but requires the correct equipment. Your old Zero OBC has no Level Two charging. It will have the same power output when used on 240 VAC and most likely the exact same issue. Same with the Delta Q's.


But IMO, it's fairly safe to assume the problem is the OBC. It's not putting out enough voltage under the load of the battery, so it cannot get to 100% SOC.


73, -Don-  AA6GA/7  Reno, NV

[DonTom]

That is what happened with the OBC on my daughter's 2014 S five years ago. Eventually it would stall at 88%. After replacing the OBC with an updated version, it has worked flawlessly every since.

Are you saying the bike would die at 88% SOC? Or the charging will stop at 88% SOC?


-Don-  Reno, NV

[ki6eph]

Thanks, all, for the responses. 🙏🏻

Justin,


Yes. At least if the 2014 S has the DC cable above the motor. Troubleshoot by using a DeltaQ charger, don't even use the OBC and see if it then charges to 100%. Key on if no OBC being used. Do you know anybody who has one for a 2014 down there in Los Angeles?


There are other ways to charge it up, but requires the correct equipment. Your old Zero OBC has no Level Two charging. It will have the same power output when used on 240 VAC and most likely the exact same issue. Same with the Delta Q's.


But IMO, it's fairly safe to assume the problem is the OBC. It's not putting out enough voltage under the load of the battery, so it cannot get to 100% SOC.


73, -Don-  AA6GA/7  Reno, NV

I'll have to take a closer look when I get home to see if there's a DC cable above the motor. I haven't had the pleasure of connecting with many other Zero riders in the area so I don't know anyone with a Delta-Q charger. I do know of a dealership that does Zero parts and repairs so I could reach out to them and see if they have any suggestions. Given the high confidence in that being the issue though, it sounds like it might be easiest to just buy the replacement once I've confirmed it's a Calex.

Thanks and 73's!

[TheRan]

If it's close enough that you can ride there chances are they will have a delta and they'll probably let you use it to do a test. You can even use it in conjunction with the on board charger so you won't be waiting around as long, just unplug that when it gets to 90% and see if the delta carries it on to 100%. If you want to save some money and get a used charger off Ebay or the like (I managed to get one for almost a third of the new price) they're not too difficult to fit yourself.

[Richard230]

On my daughter's 2014 S, the charging would stop at 88% SOC, but the bike would run OK. It just wouldn't go the distance.

When the OBC failed on my 2018 S with Power Tank, it was due to a small internal fire that melted some of the components of the OBC. In addition to installing a new OBC, I also bought a Delta Q from Zero as a backup, which I really like as it charges nice and slow and really takes its time balancing the battery pack. However, it is no fun connecting the Delta Q to the bike's connector located where the sun don't shine, on top of the motor. If I really needed a faster charge (which I never do), I coould plug in both the OBC and the Delta Q and it improves the charging rate by over 50%.

[DonTom]

On my daughter's 2014 S, the charging would stop at 88% SOC, but the bike would run OK. It just wouldn't go the distance.

When the OBC failed on my 2018 S with Power Tank, it was due to a small internal fire that melted some of the components of the OBC. In addition to installing a new OBC, I also bought a Delta Q from Zero as a backup, which I really like as it charges nice and slow and really takes its time balancing the battery pack. However, it is no fun connecting the Delta Q to the bike's connector located where the sun don't shine, on top of the motor. If I really needed a faster charge (which I never do), I coould plug in both the OBC and the Delta Q and it improves the charging rate by over 50%.

I can connect my Delta Q's in seconds. I have a "Y" cable permanently installed to bring the Andersons to the rear of the bike. I can add two Delta Q's in seconds on either of my 2017 Zeros. I also have another couple of connectors for my Elcon Chargers. I can charge my 2017 Zero SR with Powertank at 10KW here at home if I want to. Around 8 KW when on the road as I do not bring the Delta Q's. They are too large for the low power they put out on 240 VAC.


The fire in your OBC was caused by shorted components putting excessive voltages on other components. Because of the design necessary of switching power supplies such as the OBC, it is common for one part to short out and cause another ten parts or so  to short out and this can cause a small internal fire.



If you only have one, you can make your own jumper cable with an Andersen connector on each end and put the connector wherever you want. Never even touch the one on top of the motor again after once installed.


You can buy the "Y" cable from a Zero dealer or make your own cable the way you want. But if you buy it from Zero, it will set you back around $260.00.


-Don-  Reno, NV