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Tech => Tech Help => Topic started by: fractalsource on November 22, 2013, 01:33:42 PM

Title: ZERO FX - Cold Charging 36 degrees F.
Post by: fractalsource on November 22, 2013, 01:33:42 PM

Issue: Cold Charging.
36 degrees.

My bike:
Zero FX 2.8, upgraded by adding an additional battery to a  5.7.
Quick history.
Bought the 2.8 Zero FX.
Rode it like I stole it.
Left it on a charger for a week. Came back to it and it was not charging.
Entire system shut down.
Had a quick charger on back order - with an additional battery.
Returned bike to dealership to have it analyzed.
Battery defective.
Got new battery.
Got additional battery and quick charger.
Quick charger has adapter that has dealership stumped as to where it connects.
Waiting on reply.
Took Zero FX home.
Rode it in 36 degree F. weather.
Unit operated fine.
Put it in garage and plugged it in.
Green charge light blinked - and then I heard a "click" near the electric motor.
Green light went dark.
Stopped flashing.
Could wait a few minutes and plug it in again.

Then,  as each time I repeated the same actions,  after unplugging the bike, and waiting a few minutes, the bike would appear to be charging normally  for a few seconds and then -  relay would "click"
- and then the green light would stop flashing and go dark again.

Green light flashes - as if it is charging - and then the "click."
Green charging light, goes off.
Brought bike indoors. A warmer environment.
In the kitchen. It's clean.
No oil from bike. Not too hard to convince the girlfriend -  the bike is Ok in the kitchen.
After about a half hor the bike began to charge normally.

Title: Re: Cold Charging 36 degrees F.
Post by: Justin Andrews on November 22, 2013, 01:47:15 PM

Sounds like you are fairly close to the low temperature charging cut off point (around 32F - 36F).
At a guess I'd say that maybe wind chill had dragged the battery pack temp sensor below 32F at the end of the ride.

http://www.zeromotorcycles.com/owner-resources/Guidelines-for-Hot-and-Cold%20Weather-Operation-SV-ZMC-012-050.pdf (http://www.zeromotorcycles.com/owner-resources/Guidelines-for-Hot-and-Cold%20Weather-Operation-SV-ZMC-012-050.pdf)

Title: Re: ZERO FX - Cold Charging 36 degrees F.
Post by: fractalsource on November 22, 2013, 02:03:35 PM

Thank you for the reply.
Yeah.
i haven't had time. (Made time) to read the manual yet.
I bought the demo so the manual was shown to me online.
Good to know.
I think you are correct.
I really love this bike. It is RAD!
So. Knowing what the problems are - makes it more fun!

Have the Best Day Ever!
and thanks for the quick response! 
-- More later! --

Title: Re: ZERO FX - Cold Charging 36 degrees F.
Post by: Justin Andrews on November 22, 2013, 02:28:39 PM

Another option for you to consider.

Given you have removable battery packs, you could buy the charging adaptor:
http://www.zeromotorcycles.com/shop/index.php?main_page=product_info&cPath=15_5&products_id=186&zenid=q4akoiftpulrpkn23219meutp0 (http://www.zeromotorcycles.com/shop/index.php?main_page=product_info&cPath=15_5&products_id=186&zenid=q4akoiftpulrpkn23219meutp0)
as well as an additional quick charger. That way you can remove both packs and charge them indoors without bringing the whole bike in.

Not a cheap solution I grant you, but the additional charger is useful anyway.

Title: Re: ZERO FX - Cold Charging 36 degrees F.
Post by: Richard230 on November 22, 2013, 09:43:26 PM

Is there any chance that one of those cheap IR heat lamp spot lights would help warm the battery pack?

Title: Re: ZERO FX - Cold Charging 36 degrees F.
Post by: Biff on November 22, 2013, 10:41:39 PM

Another possiblity is to take the batteries in the house to get them warm, then take them to the bike to charge.

In canada you can buy battery warmers (to complement the block heater) like this:

http://www.canadiantire.ca/en/pdp/automotive/batteries-boosters-chargers/chargers/temro-80w-battery-warmer-0113116p.html#.Uo-HdcMupk8 (http://www.canadiantire.ca/en/pdp/automotive/batteries-boosters-chargers/chargers/temro-80w-battery-warmer-0113116p.html#.Uo-HdcMupk8)

you could make a little battery warmer for you bike by sewing a couple of those together like saddle bags, so you have a heater on each side of the battery while charging or just sitting in your garage.  I bet if you did a nice job of it so that it could stay on during the ride, you could wire in a plug on the switched side of your contactor so that when riding you could plug your battery warmer into the 100V DC from the battery itself and it would be a nice seat warmer.  you would have to be sure to not have it plugged into the bike when keying it on, plug it in after it is turned on and the contactor is closed, otherwise it will cause a pre-charge failure, and you would probably want to always un-plug it before turning the bike off.

-ryan