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Tech Help / Re: 2018 Zero FXS Not Charging
« on: December 08, 2024, 10:29:21 PM »
Hi there all,
i had similar issues with charging my 2014 Zero FX since i bought it one year ago, nearly always when it was cold and wet weather.
As initially Described:
1. Plug in
2. Charge light starts flashing green
3. Slightly audible clicks from minor relais and very audible click of the BMS contactors
4. No change in time to charge, stays at 0:00
5. Green flashing charge light turns off completely after a few more seconds
6. In my case in most of the times, it starts to charge after 10 minutes, but does not charge reliably to 100%
I changed the chargers and due to another issue also the charging control unit - but the problem was still there.
Finally, i got it solved and at least in my case the problem was a contact inside the fuse holder for the abc10a-fuse. Turned out, the contact on the top-lid has moved back over the years. i bent it back a little bit forward and cleaned all contact suraces includiing the outer contacts conneting to the cables.
This issue was not measurable - i put an ohm-meter on the contacts of the fuse holder and it showed almost no resistance, as it should.
There might be some measurements by the CCU (Charging Control Unit) as switches through initially. I had once tried to measure if it even switches through, with the fuse holder disconneted and instead the cable from the CCU connected a volt meter (the other pole to battery mass); there was a short burst to charging voltage and immediately afterwards 0V again, so i assume, the CCU makes some initial amp-checking and if that fails, it seems to switch off entirely to try again after 10 minutes. This might be triggered or enhanced by that bad contact inside the fuse holder.
Since then i had no issue anymore with the bike starting to charge - it charges as it should right away as soon as it gets power in all conditions.
I hope, this might help anyone who's having similar charging issues with his FX - it made me mad for months!!
i had similar issues with charging my 2014 Zero FX since i bought it one year ago, nearly always when it was cold and wet weather.
As initially Described:
1. Plug in
2. Charge light starts flashing green
3. Slightly audible clicks from minor relais and very audible click of the BMS contactors
4. No change in time to charge, stays at 0:00
5. Green flashing charge light turns off completely after a few more seconds
6. In my case in most of the times, it starts to charge after 10 minutes, but does not charge reliably to 100%
I changed the chargers and due to another issue also the charging control unit - but the problem was still there.
Finally, i got it solved and at least in my case the problem was a contact inside the fuse holder for the abc10a-fuse. Turned out, the contact on the top-lid has moved back over the years. i bent it back a little bit forward and cleaned all contact suraces includiing the outer contacts conneting to the cables.
This issue was not measurable - i put an ohm-meter on the contacts of the fuse holder and it showed almost no resistance, as it should.
There might be some measurements by the CCU (Charging Control Unit) as switches through initially. I had once tried to measure if it even switches through, with the fuse holder disconneted and instead the cable from the CCU connected a volt meter (the other pole to battery mass); there was a short burst to charging voltage and immediately afterwards 0V again, so i assume, the CCU makes some initial amp-checking and if that fails, it seems to switch off entirely to try again after 10 minutes. This might be triggered or enhanced by that bad contact inside the fuse holder.
Since then i had no issue anymore with the bike starting to charge - it charges as it should right away as soon as it gets power in all conditions.
I hope, this might help anyone who's having similar charging issues with his FX - it made me mad for months!!
as a private man from US to Germany?!