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[BrianTRice@gmail.com]

A word to wise. If you are poking around the high voltage wiring for any reason, be aware that there is stored charge of 100 volts or more around waiting to bite you, make arcs or worse. This is especially true of the motor and controller connections, but also the DC/DC, MBB and charger connectors.

I have found a way to discharge the bike that is quick, easy and works. A regular incandescent light bulb is of course rated for 120V and is low resistance and capable of quickly and safely discharging the wiring. A low wattage bulb will have a lower surge current while discharging. I find the best place to connect such a bulb is across the external charger contacts.  No guarantees that doing that removes all of the hazards, but this method has worked well for me.

The Zero owners manual says don't touch the orange wires, good advice for sure.

Right. Various parts of the Zero have capacitor banks or capacitive qualities, so there's some energy that can give you more than a sting, potentially.

And if the state of the contactor is ever in question, the charge won't decay. Although the light bulb could be okay, using a digital voltmeter first never hurts.

[Keith]

The light bulb will stay lit if the contactor is closed, you can light up your workshop with it.  And use a voltmeter after discharging just to be sure it worked.

[Doctorbass]

A word to wise. If you are poking around the high voltage wiring for any reason, be aware that there is stored charge of 100 volts or more around waiting to bite you, make arcs or worse. This is especially true of the motor and controller connections, but also the DC/DC, MBB and charger connectors.

I have found a way to discharge the bike that is quick, easy and works. A regular incandescent light bulb is of course rated for 120V and is low resistance and capable of quickly and safely discharging the wiring. A low wattage bulb will have a lower surge current while discharging. I find the best place to connect such a bulb is across the external charger contacts.  No guarantees that doing that removes all of the hazards, but this method has worked well for me.

The Zero owners manual says don't touch the orange wires, good advice for sure.

Keith, Thanks for the advice, However i am aware of that as well i have the special Zero discharge tool witch is also a lightbulb and a charger plug... I am familar with electronic and caps stored energy as well as 100+V ebike setup.

100V can kill as well as 40V.. it all depend on various conditions... personally i have dry skin so toutching 100V is not painfull but anyway i'm making sure everything is discharged as well because it can also zap $$$ components...

 Doc

[BrianTRice@gmail.com]

Keith, Thanks for the advice, However i am aware of that as well i have the special Zero discharge tool witch is also a lightbulb and a charger plug... I am familar with electronic and caps stored energy as well as 100+V ebike setup.

100V can kill as well as 40V.. it all depend on various conditions... personally i have dry skin so toutching 100V is not painfull but anyway i'm making sure everything is discharged as well because it can also zap $$$ components...

 Doc

I think Keith has the same concern I have, which is to inform people who read this discussion, not you specifically.

Sometimes it's not clear enough what practices underly an experienced professionals recommendations, and the literal advice given might cause damage if performed without the right care or safety practices.

This is exactly why I think speculatively about danger and how to be extra safe. I'm never advising you, just imagining a 19 year old kid around complicated equipment and helping them navigate it safely. (I was this kid learning to run navy nuclear reactors and 4160V electrical distribution equipment once.)

[Keith]

Yes, Brian is correct, my intention was to advise caution to others, and was not directed at the expert who started this thread. I am pleased to learn that the special Zero discharge tool uses the same method as my original idea of a good way to do it.

[Guy_H]

Old thread but reading it - DoctorBass - did replacing the controller end up being the correct fix ?