The following is my report on an electrical issue that shut the Quark down
for 10 weeks, starting Sept 5, 2019. Here is what I think happened:
The Quark's (second) power train was harvested from a 2016 Zero Motorcycles
DSR wreck. The BMS (Battery Management System) on the battery puts out a
low-power 12V signal that goes through the key switch to the MBB (Main Bike
Board). This line is always powered on (whenever the battery is plugged
in). This is necessary to allow the key switch to wake up the system.
As far as I can tell from evidence and through elimination, the circuit
through the key switch got shorted to ground at some point. I found a nick
in one of the leads and a sharp edge on a sheet metal panel nut close
enough to where twisting the nut or even careless toes could have caused a
temporary ground short. This could have damaged the power supply on the BMS
board. An important clue was that none of the LEDs on the BMS board
(visible through a hole in the housing) were lit or blinking, even though I
measured almost full voltage on the battery. Another suspect was the
wrinkled housing near where the battery rests on the rear frame tabs, but I
don't think anything ever got through to the board (which is
shock-mounted). I have since reinforced the housing with 1 x 1 x 1/8 Al
angle.
Repair: I replaced the BMS board with a new one from the Zero factory, That
was all it took to get the LEDs on the BMS going, and the Quark operated
normally after that, so I know the BMS had been damaged. (Note: It took me
a couple tries to properly seat and latch the connector on the top of the
board.) I also re-routed and added insulation to the cable between the
harness and the key switch, and added insulation to cover the switch
terminals.
Through all this, the battery never dropped below 107 V, and cell balance
is still 3 mV, so I don't think the Quark took permanent damage.
The kickstand circuit is lower voltage and protected on the MBB, but it too
is vulnerable. I moved the switch from the panel to a comm panel near my
right elbow to keep the line short. As far as I know, the kickstand switch
is only required for initial Bluetooth pairing.
Lessons learned:
1. whenever working on the key switch or its cabling, unplug the battery!
2. harden the key switch circuit against ground shorts
3. protect the other cables (throttle, motor, mode, kickstand) and keep
them as short as possible.
4. when the LEDs on the battery are dead even though the battery is
charged, look no further than the BMS.
The good news is, we have learned a lot about the power train on our eGulls
and will be able to trouble shoot more focused in the future. A big Thank
You to all who helped with suggestions, explanations and encouragement
along the way. There are still 15 open squawks on my list for the winter,
but I am already looking forward to the next flying season!
Martin & the Quark
Protect your key switch circuit!
-
rahulchoudhary73
Re: Protect your key switch circuit!
Niice. "15 open squawks” like open issues to resolve? Please elaborate.
Do we need a tamper proof safety cover for a key entry way now? something that can at least just say, somebody tried to sneak here.
Just resolved two; wondering just how many are there. unrelated to these magnificent flying machines. Thought i’d share.
1. Control electronics of head&mist lamp damaged due to faulty relay. Evidence; slight smell of burnt insulation for few seconds, in the middle of the night; and a headlamp switch getting slowly erratic over days. (called blown relay in dailyspeak).
2. Two control knobs of a (propane) stove burner damaged on the inside copper ends, that look a like small firearm shell casing. folks are making knobs with thin casings these days, much easier to damage. first in many decades. Evidence; very slight smell of sulphur, very intermittent like early cool mornings. damage is the size a one carat diamond. My old man would’nt even detect it or want to fix it ASAP.
2cents,
Rahul
Do we need a tamper proof safety cover for a key entry way now? something that can at least just say, somebody tried to sneak here.
Just resolved two; wondering just how many are there. unrelated to these magnificent flying machines. Thought i’d share.
1. Control electronics of head&mist lamp damaged due to faulty relay. Evidence; slight smell of burnt insulation for few seconds, in the middle of the night; and a headlamp switch getting slowly erratic over days. (called blown relay in dailyspeak).
2. Two control knobs of a (propane) stove burner damaged on the inside copper ends, that look a like small firearm shell casing. folks are making knobs with thin casings these days, much easier to damage. first in many decades. Evidence; very slight smell of sulphur, very intermittent like early cool mornings. damage is the size a one carat diamond. My old man would’nt even detect it or want to fix it ASAP.
2cents,
Rahul
-
mkoxxy
Re: Protect your key switch circuit!
The term "squawk" used to mean transponder code, but until recently, it was
also used to indicate an issue to be addressed by maintenance. Here is a
quote I found on the web:
*I was in the USAF 77 - 81 and the term Squawk was used by maintenance
troops to describe pilot complaints about the aircraft. Typically the A/C
Crew Chief would write the pilot's "Squawks" in the left side of the form
in the A/C log book Problem Statement section and then rate its
significance with respect to safety of flight. Then they would troubleshoot
the problem or coordinate with the other systems folks to work off the
issues. This was clearly a very well established term then, so I'm sure it
was around throughout the Viet-Nam era. *
The key switch short I was suspecting was probably my own fault, maybe
carelessness, but certainly not sabotage. But I do have a keyed lock on the
door and it would be obvious if tampered.
also used to indicate an issue to be addressed by maintenance. Here is a
quote I found on the web:
*I was in the USAF 77 - 81 and the term Squawk was used by maintenance
troops to describe pilot complaints about the aircraft. Typically the A/C
Crew Chief would write the pilot's "Squawks" in the left side of the form
in the A/C log book Problem Statement section and then rate its
significance with respect to safety of flight. Then they would troubleshoot
the problem or coordinate with the other systems folks to work off the
issues. This was clearly a very well established term then, so I'm sure it
was around throughout the Viet-Nam era. *
The key switch short I was suspecting was probably my own fault, maybe
carelessness, but certainly not sabotage. But I do have a keyed lock on the
door and it would be obvious if tampered.
-
rahulchoudhary73
Re: Protect your key switch circuit!
Yes, til now i thought pilots only squawked on the radio when talking to ATC or each other. do we have a Gull pilots log book with blank well designed forms like problem statements, general flight review? I can help make some.
Have a diary sized hard covered blue book with to log paraglide sessions and sign off with an instructor during training and then maintain. Just asking as I saw a detailed TeX form template, which looked like a lot of thought went into it. Does look like all (American) Gov printed form interfaces to the public are built on TeX.
Have been reading about locks for a few years now. seems gov locks are rated for 30minutes deterrence only, the usual combinations and key ones. Feynman used to have to have a lot of fun in his day, practising on large file cabinet locks it seems.
Have a diary sized hard covered blue book with to log paraglide sessions and sign off with an instructor during training and then maintain. Just asking as I saw a detailed TeX form template, which looked like a lot of thought went into it. Does look like all (American) Gov printed form interfaces to the public are built on TeX.
Have been reading about locks for a few years now. seems gov locks are rated for 30minutes deterrence only, the usual combinations and key ones. Feynman used to have to have a lot of fun in his day, practising on large file cabinet locks it seems.
-
mkoxxy
Re: Protect your key switch circuit!
Happy New Year, Earthstar forum!
In case you need a diversion from the proceedings in Congress, here is a
list and a few photos of what I have been doing with the Quark.
The new tail stand (scissor type) is now mounted on the cargo box. In the
photo, you can also see how I have arranged my instruments and switches. I
use the dash only to display motor rpm; mounting it on the side (as far
forward as the (original) cord allows) seemed like an easy choice. While
charging, the dash is easy to read from outside. The iPod in the panel
shows a lot more useful info (power, SOC, a couple temps). The Cycle
Analyst acts as a backup, but I have not been able to calibrate it to the
shunt, so at this point, it acts as a fancy voltmeter. I'll start a
separate thread on that.
As you can see, with my right hand on the stick, my left hand operates
knobs and buttons, throttle, and flaps. I can even reach across and get my
water bottle. If I had a handheld radio, I would mount the charger base
ahead of the cup holder, where you can still reach it with your left hand.
Plugging the head set into a little panel near my right elbow keeps the
cables out of the way.
A word on the aileron PP-tube behind the seat: You are all using some sort
of safety cage there to prevent jamming, right? I had to move mine forward
a bit to accommodate the larger battery. It is simply epoxied the the
floor. The right rudder cable runs right across the top, so keep the cage
short, or even better, close it on top just high enough to allow full
travel. In my case, the cage deflects the cable up by maybe 1/4", no
problem.
Motor mount fairings and cowling are now smooth and tight and blend in
nicely. I glued some acoustic mat to the larger surfaces inside the
cowling, hoping to suppress some rattling and resonances. We'll see.
I decided to recover the rudder. 4 summers in the sun had turned the
original red into more like orange, and Lanitz-Prena (Oratex) sent me
replacement material at no charge. I had recovered the horiz. stab last
winter. In no case did I see weakening of the faded fabric, and all glue
joints still held firmly. From here on, I will apply an occasional coat of
the special protective wax Lanitz-Prena offers (and which I did not know
about for 3 seasons). Still a believer in Oratex.
Which of these topics (including working on the BMS) would make a good Wiki
to share?
Can't wait to start the 2020 flying season!
Martin & the Quark
In case you need a diversion from the proceedings in Congress, here is a
list and a few photos of what I have been doing with the Quark.
The new tail stand (scissor type) is now mounted on the cargo box. In the
photo, you can also see how I have arranged my instruments and switches. I
use the dash only to display motor rpm; mounting it on the side (as far
forward as the (original) cord allows) seemed like an easy choice. While
charging, the dash is easy to read from outside. The iPod in the panel
shows a lot more useful info (power, SOC, a couple temps). The Cycle
Analyst acts as a backup, but I have not been able to calibrate it to the
shunt, so at this point, it acts as a fancy voltmeter. I'll start a
separate thread on that.
As you can see, with my right hand on the stick, my left hand operates
knobs and buttons, throttle, and flaps. I can even reach across and get my
water bottle. If I had a handheld radio, I would mount the charger base
ahead of the cup holder, where you can still reach it with your left hand.
Plugging the head set into a little panel near my right elbow keeps the
cables out of the way.
A word on the aileron PP-tube behind the seat: You are all using some sort
of safety cage there to prevent jamming, right? I had to move mine forward
a bit to accommodate the larger battery. It is simply epoxied the the
floor. The right rudder cable runs right across the top, so keep the cage
short, or even better, close it on top just high enough to allow full
travel. In my case, the cage deflects the cable up by maybe 1/4", no
problem.
Motor mount fairings and cowling are now smooth and tight and blend in
nicely. I glued some acoustic mat to the larger surfaces inside the
cowling, hoping to suppress some rattling and resonances. We'll see.
I decided to recover the rudder. 4 summers in the sun had turned the
original red into more like orange, and Lanitz-Prena (Oratex) sent me
replacement material at no charge. I had recovered the horiz. stab last
winter. In no case did I see weakening of the faded fabric, and all glue
joints still held firmly. From here on, I will apply an occasional coat of
the special protective wax Lanitz-Prena offers (and which I did not know
about for 3 seasons). Still a believer in Oratex.
Which of these topics (including working on the BMS) would make a good Wiki
to share?
Can't wait to start the 2020 flying season!
Martin & the Quark
- Attachments
-
- squawks, winter 2019-20.xlsx
- (13.28 KiB) Downloaded 74 times
-
-
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rahulchoudhary73
Re: Protect your key switch circuit!
Happy New Year, Martin and everyone here. some comments off the top of my hat,
o May want to color the nose cone mirrory (tin or silver coat) or a bright reflective paint.
o Leather the steering grip. an inch wide strip of leftover leather, wrapped around like a tennis racquet would be nice. seems leather goods units, usually trim leather thicknesses and the plenty is unused. bought an Orange sheepskin, started use it on everything, cameras, electronics, elbow rests in vehicles, and stuff. still just put a safety pin on a leather napkin to cover a 6yr oold iphone. got to make a pair gloves from it too this month.
o Curious, which wax you using? i make beeswax salve at home, use it on everything. ~$14 a kilo here, bleached; how much does it cost there? what’s it with grease, they come with plenty of health warnings, even on a bicycle. that steel cable sliding on the metal cage, a dab of salve on it will definitely reduce some friction.
o What you wear on the flights of the Quark in cold wx? some felt cashmere, double layer may reduce some weight there by a pound or two. custom fine wool weave trousers too. 10-17micron wool felt seem to be priced way out there in the stratosphere in this century.
o What’s the real story on battery life in this decade past? i still keep wondering, why i get replacement batteries with the same battery life, even after 12 years in a couple of cases of small handy (opto)electronics. it was difficult to articulate and raise it with an iphone service specialist, to raise it with the firm as a future request, he just got defensive and i let it pass.
Aloha 2cents,
Rahul
o May want to color the nose cone mirrory (tin or silver coat) or a bright reflective paint.
o Leather the steering grip. an inch wide strip of leftover leather, wrapped around like a tennis racquet would be nice. seems leather goods units, usually trim leather thicknesses and the plenty is unused. bought an Orange sheepskin, started use it on everything, cameras, electronics, elbow rests in vehicles, and stuff. still just put a safety pin on a leather napkin to cover a 6yr oold iphone. got to make a pair gloves from it too this month.
o Curious, which wax you using? i make beeswax salve at home, use it on everything. ~$14 a kilo here, bleached; how much does it cost there? what’s it with grease, they come with plenty of health warnings, even on a bicycle. that steel cable sliding on the metal cage, a dab of salve on it will definitely reduce some friction.
o What you wear on the flights of the Quark in cold wx? some felt cashmere, double layer may reduce some weight there by a pound or two. custom fine wool weave trousers too. 10-17micron wool felt seem to be priced way out there in the stratosphere in this century.
o What’s the real story on battery life in this decade past? i still keep wondering, why i get replacement batteries with the same battery life, even after 12 years in a couple of cases of small handy (opto)electronics. it was difficult to articulate and raise it with an iphone service specialist, to raise it with the firm as a future request, he just got defensive and i let it pass.
Aloha 2cents,
Rahul
-
rahulchoudhary73
Re: Protect your key switch circuit!
Happy New Year, Martin and everyone here. some comments off the top of my hat,
o May want to color the nose cone mirrory (tin or silver coat) or a bright reflective paint.
o Leather the steering grip. an inch wide strip of leftover leather, wrapped around like a tennis racquet would be nice. seems leather goods units, usually trim leather thicknesses and the plenty is unused. bought an Orange sheepskin, started use it on everything, cameras, electronics, elbow rests in vehicles, and stuff. still just put a safety pin on a leather napkin to cover a 6yr oold iphone. got to make a pair gloves from it too this month.
o Curious, which wax you using? i make beeswax salve at home, use it on everything. ~$14 a kilo here, bleached; how much does it cost there? what’s it with grease, they come with plenty of health warnings, even on a bicycle. that steel cable sliding on the metal cage, a dab of salve on it will definitely reduce some friction.
o What you wear on the flights of the Quark in cold wx? some felt cashmere, double layer may reduce some weight there by a pound or two. custom fine wool weave trousers too. 10-17micron wool felt seem to be priced way out there in the stratosphere in this century.
o What’s the real story on battery life in this decade past? i still keep wondering, why i get replacement batteries with the same battery life, even after 12 years in a couple of cases of small handy (opto)electronics. it was difficult to articulate and raise it with an iphone service specialist, to raise it with the firm as a future request, he just got defensive and i let it pass.
Aloha 2cents,
Rahul
o May want to color the nose cone mirrory (tin or silver coat) or a bright reflective paint.
o Leather the steering grip. an inch wide strip of leftover leather, wrapped around like a tennis racquet would be nice. seems leather goods units, usually trim leather thicknesses and the plenty is unused. bought an Orange sheepskin, started use it on everything, cameras, electronics, elbow rests in vehicles, and stuff. still just put a safety pin on a leather napkin to cover a 6yr oold iphone. got to make a pair gloves from it too this month.
o Curious, which wax you using? i make beeswax salve at home, use it on everything. ~$14 a kilo here, bleached; how much does it cost there? what’s it with grease, they come with plenty of health warnings, even on a bicycle. that steel cable sliding on the metal cage, a dab of salve on it will definitely reduce some friction.
o What you wear on the flights of the Quark in cold wx? some felt cashmere, double layer may reduce some weight there by a pound or two. custom fine wool weave trousers too. 10-17micron wool felt seem to be priced way out there in the stratosphere in this century.
o What’s the real story on battery life in this decade past? i still keep wondering, why i get replacement batteries with the same battery life, even after 12 years in a couple of cases of small handy (opto)electronics. it was difficult to articulate and raise it with an iphone service specialist, to raise it with the firm as a future request, he just got defensive and i let it pass.
Aloha 2cents,
Rahul