De-Energize Controller
From Unofficial Zero Manual
This describes the universal pre-requisite to all high-voltage procedures on a Zero.
- Overview
- De-energization is a process that is used to disconnect and isolate a system from a source of energy in order to prevent the release of that energy.
- Purpose
- By de-energizing the system, you are eliminating the chance that the system could inadvertently, accidentally or unintentionally cause harm to a person through movement, or the release of heat, light, or sound.
- Tools
- A voltmeter ranged to measure DC voltage beyond the powertrain's normal operating range (0-118VDC).
- Ensure/pre-test that this voltmeter is able to register 0VDC as such:
- Set the instrument to sense VDC.
- Touch the sensor leads together.
- Verify that it reads 0.0VDC immediately with no fluctuations.
- Test that a low-voltage DC measurement can be registered properly before testing a high-voltage DC system.
- Ensure/pre-test that this voltmeter is able to register 0VDC as such:
- Steps
- Toggle the cutout switch to off.
- Key off the bike.
- Remove the key from the ignition lock to prevent re-energizing without positive intent.
- Disconnect external power sources:
- Disconnect any cable leading to the Onboard Charger at the bike's inlet.
- Disconnect whatever is connected to the Accessory Charging Port at the port end.
- Disconnect any other power source from the vehicle.
- Verify indications that the bike is not connected to power:
- The Contactor Click Sound should have happened shortly after the last power source was disconnected.
- Dash charge enable light is off.
- Dash ride enable light is off.
- The dash is entirely off, really.
- Verify that voltage has dissipated to safe levels (under 12V DC):
- Remove the seat.
- Before proceeding, ensure that anything on the tester's person cannot make conductive contact with the frame or non-vehicle equipment.
- Uncover the controller.
- Check DC power bus voltage with a properly-rated voltmeter across controller terminals B+ and B-.
- Expect voltage to decay exponentially over time.
- If voltage is not decaying at a sufficient rate, or it plateaus, stop immediately and troubleshoot.
- If, after 10 minutes, voltage is not low enough to consider de-energized, use an appropriately-rated discharge tool.
- An incandescent light bulb circuit can be sufficient if operated with electrical safety gloves and eye protection.