ZIP_CHARGE_HARDWARE_FAULT
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Applicable alarms (1)
ZIP_CHARGE_HARDWARE_FAULT
Likely outcomes — click to expand
Based on 2 missions where this alarm fired in the last 90 days as of 2026-10-13
Grounding vs discrepancy (of 2 ZERP issues filed on these missions)
Aggregated from fleet operations and refreshed daily. Individual outcomes may vary by site and configuration.
Background
Section titled “Background”There was an overcurrent on the Zip charge load switch. This likely indicates a short or damage somewhere on the charging path and may indicate a serious hardware issue.
Troubleshooting Steps
Section titled “Troubleshooting Steps”graph TD
power-cycle-the-zip["<small><b>Step 1</b></small><br/>Action: Power cycle the Zip/procedures/pow..."]
restart-the-dock-charger-service["<small><b>Step 2</b></small><br/>Action: Restart the Dock charger service/p..."]
does-the-zip-charge-without-the-alarm-reappearing{"<small><b>Step 3</b></small><br/>Question: Does the Zip charge without ZIP_CHAR..."}
return-zip-and-docking-fin-to-service["<small><b>Step 4</b></small><br/>Action: The fault was likely caused by a dock..."]
disconnect-the-aircraft-battery["<small><b>Step 5</b></small><br/>Action: Disconnect the Aircraft battery from ..."]
measure-resistance-between-charge-terminals["<small><b>Step 6</b></small><br/>Action: Use a multimeter to measure resistanc..."]
is-the-resistance-under-or-over-65k{"<small><b>Step 7</b></small><br/>Question: Is the resistance measurement greater..."}
escalate-to-powertrain{{"<small><b>Step 8</b></small><br/>Escalation: Escalate to Powertrain On Call. Inclu..."}}
check-charge-path-continuity["<small><b>Step 9</b></small><br/>Action: Check continuity on the positive and ..."]
are-there-loose-connections-or-damage{"<small><b>Step 10</b></small><br/>Question: Are there loose connections or obviou..."}
create-work-order-for-damaged-part["<small><b>Step 11</b></small><br/>Action: Create a work order to repair or repl..."]
escalate-to-powertrain-after-continuity-check{{"<small><b>Step 12</b></small><br/>Escalation: Escalate to Powertrain On Call. Inclu..."}}
power-cycle-the-zip --> restart-the-dock-charger-service
restart-the-dock-charger-service --> does-the-zip-charge-without-the-alarm-reappearing
does-the-zip-charge-without-the-alarm-reappearing -->|Yes| return-zip-and-docking-fin-to-service
does-the-zip-charge-without-the-alarm-reappearing -->|No| disconnect-the-aircraft-battery
disconnect-the-aircraft-battery --> measure-resistance-between-charge-terminals
measure-resistance-between-charge-terminals --> is-the-resistance-under-or-over-65k
is-the-resistance-under-or-over-65k -->|Yes| check-charge-path-continuity
is-the-resistance-under-or-over-65k -->|No| escalate-to-powertrain
check-charge-path-continuity --> are-there-loose-connections-or-damage
are-there-loose-connections-or-damage -->|Yes| create-work-order-for-damaged-part
are-there-loose-connections-or-damage -->|No| escalate-to-powertrain-after-continuity-check
style power-cycle-the-zip fill:#dcfce7,stroke:#22c55e,color:#14532d
style restart-the-dock-charger-service fill:#dcfce7,stroke:#22c55e,color:#14532d
style does-the-zip-charge-without-the-alarm-reappearing fill:#dbeafe,stroke:#3b82f6,color:#1e3a5f
style return-zip-and-docking-fin-to-service fill:#dcfce7,stroke:#22c55e,color:#14532d
style disconnect-the-aircraft-battery fill:#dcfce7,stroke:#22c55e,color:#14532d
style measure-resistance-between-charge-terminals fill:#dcfce7,stroke:#22c55e,color:#14532d
style is-the-resistance-under-or-over-65k fill:#dbeafe,stroke:#3b82f6,color:#1e3a5f
style escalate-to-powertrain fill:#fef3c7,stroke:#f59e0b,color:#78350f
style check-charge-path-continuity fill:#dcfce7,stroke:#22c55e,color:#14532d
style are-there-loose-connections-or-damage fill:#dbeafe,stroke:#3b82f6,color:#1e3a5f
style create-work-order-for-damaged-part fill:#dcfce7,stroke:#22c55e,color:#14532d
style escalate-to-powertrain-after-continuity-check fill:#fef3c7,stroke:#f59e0b,color:#78350f Hover or focus a block to preview it. Select the block to keep the preview open.
1 action
2 action
3 question
Does the Zip charge without
ZIP_CHARGE_HARDWARE_FAULT reappearing? 4 action
The fault was likely caused by a dock Delta-Q charger hiccup.
The Zip and docking fin are likely not damaged and can be returned to service.
The Zip and docking fin are likely not damaged and can be returned to service.
5 action
Disconnect the Aircraft battery from the Zip, including the M5 connectors.
6 action
Use a multimeter to measure resistance between the docking-fin charge contacts. Put the red lead on the positive charge terminal middle pin on the starboard side of the Aircraft. Put the black lead on the negative charge terminal pin on the port side of the Aircraft.
Record the resistance value. While moving the docking fin, confirm that the value remains stable.
Record the resistance value. While moving the docking fin, confirm that the value remains stable.
7 question
Is the resistance measurement greater than or equal to 65 kOhm?
8 escalation
Escalate to Powertrain On Call. Include the recorded resistance measurement.
9 action
Check continuity on the positive and negative charge paths with a multimeter:
1. Measure between the positive charge terminal middle pin on the starboard side of the Aircraft and the charge terminal on the distro where the red docking-fin wire connects.
2. Measure between the negative charge terminal pin on the port side of the Aircraft and the GND terminal on the distro where the black docking-fin wire connects.
Each reading should be in the single-digit Ohm range when measured with a typical handheld multimeter. Each reading should remain steady while the docking fin and the power harness between the docking fin and distro are moved.
1. Measure between the positive charge terminal middle pin on the starboard side of the Aircraft and the charge terminal on the distro where the red docking-fin wire connects.
2. Measure between the negative charge terminal pin on the port side of the Aircraft and the GND terminal on the distro where the black docking-fin wire connects.
Each reading should be in the single-digit Ohm range when measured with a typical handheld multimeter. Each reading should remain steady while the docking fin and the power harness between the docking fin and distro are moved.
10 question
Are there loose connections or obvious signs of damage?
11 action
Create a work order to repair or replace the damaged part. Common corrective actions include a PDB swap, battery harness swap, or repair of the damaged docking-fin wire, connector, harness, or distro connection. Include photos of the damage and the recorded resistance and continuity measurements.
12 escalation
Escalate to Powertrain On Call. Include the recorded resistance and continuity measurements.
Resolution note
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