Zero X battery technical problems

faulty connectors

Early Zero batteries suffered failures so we thought we would take one to bits to find out what the problem was and we found that some spade connectors ( the one pictured on the right) were not making proper connection to the rows of cells as they were not crimped down tight enough and hence the cells could not be recognised by the Battery Management System and subsequently charged. The connectors did not become detatched because they were held on by copious amounts of hot glue which needed to be removed before the real problem was discovered.

If a bank of cells goes uncharged for a time it may be beyond reclaiming so we have been able to fit complete new banks of cells to redress the problem and restore the battery pack to a workable level without needing to purchase a whole newbattery for £1500

: inside a zero battery pack

Access can be gained to the connectors by opening the end of the battery pack.

WARNING! DO NOT OPEN THIS UP UNLESS YOU ARE ELECTRICALLY QUALIFIED AS THIS BATTERY SUPPLIES 300 AMPS and the + and – terminals are only an inch apart in places, any metal tool bridging this gap will be vapourised and any sustained short could cause thermal runaway.