De-Energize Controller

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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:
    1. Set the instrument to sense VDC.
    2. Touch the sensor leads together.
    3. 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.
Steps
  1. Toggle the cutout switch to off.
  2. Key off the bike.
    Remove the key from the ignition lock to prevent re-energizing without positive intent.
  3. 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.
  4. 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.
  5. Verify that voltage has dissipated to safe levels (under 12V DC):
    1. Remove the seat.
    2. Before proceeding, ensure that anything on the tester's person cannot make conductive contact with the frame or non-vehicle equipment.
    3. Uncover the controller.
    4. 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.
    5. 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.