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Messages - azwillnj

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Zero Motorcycles Forum | 2013+ / Re: 2019 'new' DS not charging on internal charger.
« on: September 18, 2023, 02:20:22 AM »
Quote from: TheRan on September 17, 2023, 12:11:13 AM
You say you've removed a few chargers before, have they been busted ones as well and have they had the same failure mode (turns the bike on with the key in the off position, closes the contactor, but doesn't charge)?

No, I have taken apart and put together the same 2 bikes a dozen times.

2
Zero Motorcycles Forum | 2013+ / Re: 2019 'new' DS not charging on internal charger.
« on: September 17, 2023, 12:07:49 AM »
Quote from: DonTom on September 16, 2023, 09:11:44 AM
IMO, the OBC is reasonable for 1.4KW in such a small space where it gets no cooling. Just some people's luck with the OBC will be better than others.

It is quite a compact package, I'm sure the potting causes a bit of stress on the components contributing to these issues. Just seems like there are quite a bit of failures reported on here, still probably a very low number overall though.

Quote from: TheRan on September 16, 2023, 09:14:46 AM
How did you test it, hook it up to the control connector on the bike? I daon't know a great deal about how these chargers function but that seems weird to me that the communication side of the dead charger would still be working. Even if whatever killed it didn't take out that part of the circuitry I would have expected it to have enough brains to not attempt to close the contactor.

I reseated all the connectors on the broken one and tried again, that did nothing. Then i just plugged in the spare outside the bike and it immediately started charging. I didn't have my multimeter in the garage and didn't feel like walking into the basement to get it so I just plugged the spare in and it worked. I might hit the broken one with the multimeter and see if it's doing anything. I had to get a ball end 2.5mm off amazon to get to the screws on the IEC connector, that should be coming today.

I think my plan is to contact my dealer with all these results and see if I can get some kind of coverage on the broken obc, not holding my breath considering its a 2019 but I'm going to try.

Alex.

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Zero Motorcycles Forum | 2013+ / Re: 2019 'new' DS not charging on internal charger.
« on: September 16, 2023, 08:40:50 AM »
Grabbed the charger off the bike at work and hooked it up externally and it worked just fine. I cant believe a charger used this little could die, this does not instill much faith in this bike. Thankfully I got it basically for free.

4
Zero Motorcycles Forum | 2013+ / Re: 2019 'new' DS not charging on internal charger.
« on: September 15, 2023, 06:57:07 PM »
Through my searching on the forums it seems like the fuse is a common problem which was the motivation for checking it. If it also handles the external Andersen connector then it seems like that's not the problem. The zip tie is still on the onboard's Andersen holding the connectors together so it didn't wiggle loose.

Quote from: TheRan on September 15, 2023, 03:43:34 PM
Could be a broken connection on the charger's side, unfortunately to test that it means unplugging that buried connector to get a multimeter in there.

I have removed about 3 of these at this point so I am pretty familiar with where the connector is. I will pop that off this weekend and probe it, I'm assuming I am looking for about 110v after charging starts and nothing if the charger is toast?

I am going to contact my dealer to see if there's anything they can do but I'm assuming the answer is no because it's so old. I do have another bike at work that I might be able to take the onboard charger from, it is currently in pieces with half a hybrid system installed on it. Might test that one just to make sure that's the issue, I think I can get it connected outside the bike to temporarily test.

5
Zero Motorcycles Forum | 2013+ / 2019 'new' DS not charging on internal charger.
« on: September 15, 2023, 10:34:13 AM »
I recently bought a 2019 DS with 23 miles on it that had been kept in an air conditioned garage its entire life. The battery currently has 16 cycles on it and is currently at about 150 miles on the odometer. It just suddenly stopped charging with the onboard charger, this is what I'm seeing:

Plug in IEC connector
Display lights up and counts down
Charging light starts blinking
Contactor closes
Timer shows 0:00
After some time, 15 ish mins you can hear the bike try to restart the charging, the contactor opens and closes again but it still doesn't charge
Eventually it throws a check engine light and the red triangle with the ! starts blinking

I have a DeltaQ charger also. If I plug that in and cycle the key the bike immediately starts charging and has no problem hitting 100%

I connected to the MBB and did some debugging, I attached the terminal output with some notes on what I was doing.

I am going to try checking the charging fuse over the weekend. I can't believe something like this has happened already, this thing is basically new, any other suggestions?

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