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[PeterFSX]

Hi all,
My FXS 2019 with just 7000 km stopped charging. I use this bike for commute, even when it rains. A new onboard charger wasnt the solution, it still doesnt charge. I dont have any error codes on the display.
When I plug in the onboard charger, I hear that click, the green charge light keeps flashing and the charge time displays 0:00. After a while the green light turns off and nothing happens.

In the bin files I can only find this relating to charging errors: DEBUG: Charge Fault Occured. Sevcon trying to close contactor, but one was not closed quickly enough.
Does this mean replacing the SEVCON converter? Can someone look at the bin file to see if thats correct?

Are there other things to check first?

An other option could be this, since I only charge at home, I am leaning towards buying an offboard charger, could that be the solution even if the onboard charger doesnt work?

[rgutt]

"One was not closed quickly enough." Sounds like a problem with the contactor in one of your battery modules ... or the system that monitors it.

[mdjak1]

Have you checked fuses?   I had an intermittent charging issue with my 2017 FXS that eventually became a full time issue.   I tracked it down to the 10 amp fuse that supplied power to the OBC.  First I 
cleaned the contacts of the fuse holder.   Eventually I replaced and relocated the entire fuse holder to a better location.


https://www.electricmotorcycleforum.com/boards/index.php?topic=11400.msg107353#msg107353

[PeterFSX]

Thanks for the replies!

"One was not closed quickly enough." Sounds like a problem with the contactor in one of your battery modules ... or the system that monitors it.

It sounds like it is. Its hard to interpret these logs right without experience, this is my first electric motorcycle.

Have you checked fuses?   I had an intermittent charging issue with my 2017 FXS that eventually became a full time issue.   I tracked it down to the 10 amp fuse that supplied power to the OBC.  First I 
cleaned the contacts of the fuse holder.   Eventually I replaced and relocated the entire fuse holder to a better location.


https://www.electricmotorcycleforum.com/boards/index.php?topic=11400.msg107353#msg107353

Thanks, didnt know about that, I will check the fuses tomorrow.

[Curt]

Sounds exactly like my 2016 FX earlier this year. I also tried a new charger, to no avail. It was the 10A fuse holder hidden in the wiring harness on the right side. Like mdjak1, I fixed it by cleaning the contacts, using emory paper, bending the prong inward a little, and spraying some WD-40. I then ordered the new waterproof fuse holder, and plan to put it in upon the next recurrence.
https://www.newark.com/eaton-bussmann-series/bk-hfa-r/fuse-holder-in-line-waterproof/dp/65K4436

[gt13013]

Hello

I have the same problem on my 2016 FXS.
Since a few days, my bike does not charge fully with the onboard charger. It stopped sometimes at 78%, sometimes at 58%.
But I am able to finish the charge to 100% using my external charger.

The logs give the errors (see attached file)
ERROR: Internal Fault on BMS1
ERROR: Internal Fault on BMS0
DEBUG: Charge Fault Occured. Sevcon trying to close contactor, but one was not closed quickly enough

I will try cleaning the fuse holder, as Curt said.

Gerard

[Richard230]

Hello

I have the same problem on my 2016 FXS.
Since a few days, my bike does not charge fully with the onboard charger. It stopped sometimes at 78%, sometimes at 58%.
But I am able to finish the charge to 100% using my external charger.

The logs give the errors (see attached file)
ERROR: Internal Fault on BMS1
ERROR: Internal Fault on BMS0
DEBUG: Charge Fault Occured. Sevcon trying to close contactor, but one was not closed quickly enough

I will try cleaning the fuse holder, as Curt said.

Gerard

My daughter's 2014 S had the same problem which was cured by installing a new (and improved?) OBC.

[PeterFSX]

Thanks guys! The bike is charging now. It was indeed the onboard charge fuse.

[Curt]

I have the same problem on my 2016 FXS.
Since a few days, my bike does not charge fully with the onboard charger. It stopped sometimes at 78%, sometimes at 58%.
But I am able to finish the charge to 100% using my external charger.

Crap, that sounds exactly like the classic Green Watt Power EVC-116-720 charger failure. I was able to find a replacement on eBay for $418 shipped, which it turned out I didn't need because it was the fuse holder. I keep it in case I get your same failure. I wonder if it is easy for you to get one in Europe.

There is another one here.

https://www.ebay.com/itm/266184083677?hash=item3df9cec8dd:g:qqgAAOSwxPFkGxmF&amdata=enc%3AAQAIAAAAwCEpVe1Urd66ge3bCUYH6GJjYmBQU86uMIXwS%2BzIF%2BG28gGg44EtbWinvkmiiGEUBs9QeazQ8FvbCIQYGw4joUMJa9Vm3gtwiX0P%2FGa1evaysKqUTWYOo%2Fr2ToIbGFHRU6B%2BiLFb28dwRf%2FCBGQPBjW6GINT3HI%2FHY8Rc1K3VjoUnDLpzS3yxWABlpIcxaissEBE%2BgsMIOd3Yw1O2vz0kJFMjlpc7p01WpmOFpfexUz2JjCC0Ly%2BW77QFWxxGFi%2FgQ%3D%3D%7Ctkp%3ABk9SR6L9z9D_YQ

[mdjak1]

Thanks guys! The bike is charging now. It was indeed the onboard charge fuse.

Excellent news.  Glad we were able to help with the issue.

[PeterFSX]

I have the same problem on my 2016 FXS.
Since a few days, my bike does not charge fully with the onboard charger. It stopped sometimes at 78%, sometimes at 58%.
But I am able to finish the charge to 100% using my external charger.

Crap, that sounds exactly like the classic Green Watt Power EVC-116-720 charger failure. I was able to find a replacement on eBay for $418 shipped, which it turned out I didn't need because it was the fuse holder. I keep it in case I get your same failure. I wonder if it is easy for you to get one in Europe.

There is another one here.

https://www.ebay.com/itm/266184083677?hash=item3df9cec8dd:g:qqgAAOSwxPFkGxmF&amdata=enc%3AAQAIAAAAwCEpVe1Urd66ge3bCUYH6GJjYmBQU86uMIXwS%2BzIF%2BG28gGg44EtbWinvkmiiGEUBs9QeazQ8FvbCIQYGw4joUMJa9Vm3gtwiX0P%2FGa1evaysKqUTWYOo%2Fr2ToIbGFHRU6B%2BiLFb28dwRf%2FCBGQPBjW6GINT3HI%2FHY8Rc1K3VjoUnDLpzS3yxWABlpIcxaissEBE%2BgsMIOd3Yw1O2vz0kJFMjlpc7p01WpmOFpfexUz2JjCC0Ly%2BW77QFWxxGFi%2FgQ%3D%3D%7Ctkp%3ABk9SR6L9z9D_YQ

Its very easy to get one, just expensive. Cost about 900 euros.

My motorcycle unfornately left me stranded today. I got a new issue. Which probably is not going to be so easy to fix. I drove to work and it decreased power untill it stopped. Went to the side of the road and now the motor goes backwards after turning it off and back on.

[Say10 15FX 16FXS]

Sounds like the motor timing is out of spec. The dealer should be able to "commission" it or whatever it's called. May fix it.

[gt13013]

Hello everybody
Thanks for your messages. Indeed, it seems that my problem comes from a defective onboard charger. But I will try to inspect the fuse first. Who knows... Yesterday the SOC was at 31% and the onboard charger did not start. The happy end would be a random bad electrical contact in the fuse 
I will let you informed.

[gt13013]

Bingo ! It was the fuse ! This crap was completely out of order. Unable to open the fuse container: everything was clogged. I cut the wires, soldered a new 10 amps fuse, and the bike charged immediately as usual. It is now at 100% and balancing 

This means that when the charger fuse begins to malfunction, the symptoms are not only the inability to charge, but it can also lead to charges starting, and then stopping prematurely.

Thanks guys !

[mdjak1]

The fuse holder is supposed to be waterproof or water resistant.   But it really isn't long term.   Also, the location is pretty low in the bike and if you ride in the rain or through a lot of water, or if you live near salt water, it is more likely to corrode and fail.   That is why I relocated mine to a higher, and more accessible location on my FXS.