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[Burton]

This is only relevant if you have a bike which features a sevcon gen4 controller ...

SOURCE: http://jan.peman.com/hacks/EmergencyErrorCodes.txt

Emergency (EMCY) codes from the Sevcon Gen4 drives

Can messages looks like this:

ID    b0 b1 b2 b3 b4 b5 b6 b7
"81";"00 31 04 C3 4D 00 00 00"
"81";"00 31 14 C3 4D 00 00 00"
"81";"00 82 10 0F 53 02 00 00"
"82";"00 10 01 54 4F 00 40 00"
"82";"00 10 11 54 4F 00 40 00"
"82";"00 31 04 C2 51 00 00 00"
"82";"00 31 04 C2 51 00 04 00"
"82";"00 31 04 C3 4D 00 00 00"
"82";"00 31 05 C3 4D 00 00 00"
"82";"00 31 15 C3 4D 00 00 00"
"82";"30 81 10 0B 53 01 00 00"

Bytes b1+b0 (switch bytes) describes CanOpen error code according to DS-301

Error code (hex)   Error description
00xx   Error Reset / No Error
10xx   Generic Error
2xxx   Current
3xxx   Voltage
4xxx   Temperature
50xx   Device Hardware
6xxx   Device Software
70xx   Additional Modules
8xxx   Monitoring
90xx   External Error
F0xx   Additional Functions
FFxx   Device Specific

Byte b2 is error register, bit-wise coding, also according to DS-301:

Bit   Error cause
0   Generic Error
1   Current
2   Voltage
3   Temperature
4   Communication Error
5   Device Profile Specific
6   Reserved (always 0)
7   Manufacturer Specific

Bytes b5-b7:
If any of bytes b5-b7 are not 0x00 means error is set. *
If bytes b5-b7 are all 00 it means the error is reset. *
*) might be only b6?

Bytes b4+b3 (switched bytes) describes Sevcon specific errors according to
table below:

0x2401 Login
0x3441 Host SW Upgrade
0x3442 DSP SW Upgrade
0x34C1 Watchdog Reset
0x45C1 BDI Warning
0x45C2 BDI Cutout
0x45c3 Low battery
0x45C3 Low battery
0x45C4 High battery
0x45c5 High capacitor
0x45C5 High capacitor
0x45c6 Vbat below rated min
0x45C6 Vbat below rated min
0x45C7 Vbat above rated max
0x45c8 Vcap above rated max
0x45C8 Vcap above rated max
0x45c9 Motor low voltage
0x45ca Motor high voltage
0x4601 Device too cold
0x4602 Device too hot
0x4603 Motor in thermal c/b
0x4603 Motor in thermal c/b
0x4681 Preop
0x4781 Anon EMCY
0x47C1 Service Required
0x4881 Seat
0x4882 Two Dir Fault
0x4883 SRO Fault
0x4884 Sequence Fault
0x4884 Sequence Fault
0x4885 FS1 Recycle Fault
0x4941 Low oil
0x4981 Throttle Fault
0x4981 Throttle Fault
0x4B81 Anon EMCY
0x4C41 Too Many Slaves
0x4dc3 Supply Critical
0x4F01 Bad State
0x4F02 EMCY Fail
0x4f41 Internal Fault
0x4F41 Internal Fault
0x4F42 Out of Memory
0x4F43 General DSP Error
0x4F44 Timer Error
0x4F45 Queue Error
0x4F46 Sched Error
0x4F47 DSP Heartbeat
0x4F48 IO SS Error
0x4F49 GIO SS Error
0x4F4A LCM SS Error
0x4F4B LCP SS Error
0x4F4C OBD SS Error
0x4F4D VEHAPP SS Error
0x4F4E DMC SS Error
0x4F4F TracApp SS Error
0x4F50 New PF Detected
0x4F51 DSP not detected
0x4F52 DSP Comms Error
0x4F53 App Mgr SS Error
0x4f55 DSP param
0x4F81 Anon EMCY
0x5041 Bad NVM Data
0x5042 VPDO out of range
0x5043 Param fixed range error
0x5043 Param fixed range error
0x5044 Param dyn range error
0x5044 Param dyn range error
0x5081 Invalid Steer Switches
0x5101 Line Contactor o/c
0x5141 Line Contactor welded
0x5181 Dig In Wire Off
0x5182 Alg In Wire Off
0x5183 Alg Out Over I
0x5184 Alg Out On with No FS
0x5185 Alg Out Off with FS
0x51C1 Power Supply Interrupt
0x51C2 Precharge fail
0x52c1 Encoder fault
0x52c3 Current Control Fault
0x5301 CANbus Fault
0x5302 No Bootup
0x5303 LPRX CAN
0x5304 LPTX CAN
0x5305 HPRX CAN
0x5306 HPTX CAN
0x5307 CAN Overrun
0x5308 CAN Off
0x5309 Nodeguard Error
0x530A PDO Short
0x530B HBeat Error
0x530C CANopen Device State
0x530D CAN Error State
0x530E SDO Handle Error
0x530F SDO Timeout
0x5310 SDO Abort
0x5311 SDO State Error
0x5312 SDO Toggle Error
0x5313 SDO Rx Error
0x5314 SDO Length Error
0x5315 SDO Tx Error
0x5316 CANopen Ev Unknown
0x5317 SDO Bad Source
0x5318 SDO Bad Error No
0x5319 Mtr Slv in Wrong State
0x5319 Mtr Slv in Wrong State
0x5341 Wrong DSP protocol
0x5342 Osc WDog Tripped
0x5343 Flt o/flow
0x5381 Anon EMCY
0x54c1 DSP Overvoltage
0x54C1 DSP Overvoltage
0x54C2 DSP PF Fault
0x54C3 Mosfet s/c M1 Top
0x54C4 Mosfet s/c M1 Bottom
0x54C5 Mosfet s/c M2 Top
0x54C6 Mosfet s/c M2 Bottom
0x54C7 Mosfet s/c M3 Top
0x54C8 Mosfet s/c M3 Bottom
0x54C9 Mosfet tests incomplete
0x5741 Invalid Rating
0x5781 Anon EMCY

Example:
ID    b0 b1 b2 b3 b4 b5 b6 b7
"82";"00 31 04 C2 51 00 04 00"

Node id 2 sends emergency error.
Error code: 0x3100 (b1+b0) meaning "Voltage" error category
Error cause: 0x04 (b2) bit 2 set meaning "Voltage" error cause
Sevcon error: 0x51C2 meaning "Precharge fail"

Today while riding home my bike decided to become unresponsive ... nothing new for a vet zero rider who has had similar things happen in a snow storm of all things.

I calmly pull over and wait for the bike to reset. Reassess the situation and decide it is ok to move forward and go home.

I get home and pull my logs twice using dumpall command and reaper dongle. First time somehow the COM6 port connection was lost near end.

Reviewed logs and found Sevcon CAN EMCY Frame error code 0x5182 Uknown in logs. I found the site previously linked and it shows my Analog wire IN was reading "Off" ... this means the voltage was out of range specified as safe in the controller.

From here the controller shows events which disabled then enabled it all within a minute shortly finishing after I had pulled over.

I now know to look at two things (as it doesn't show you which are "off" but does give "data 01 02 00" leading me to assume Analogs mapped to 1 and 2 are suspect ... first the connections leading to my regen lever, and second the connections coming from the step down converter (takes 24vdc to 5vdc for the regen lever)

Somewhere in this circuit the voltage was out of spec long enough for sevcon not to like me ...

[MajorMajor]

Which models have the Gen4 Sevcon?

[Lenny]

Interesting, thanks for letting us know!

[hubert]

A Zero with a "regen lever"? What's that?

[Cama]

Hubert: I guess that's what I would call awesome.

[Burton]

Which models have the Gen4 Sevcon?

I want to say MY13 - MY16 but I could be wrong ... I think the newer MY17's use a different controller
 

A Zero with a "regen lever"? What's that?

It is awesome enough that if I ever bought another zero I would spend considerable amount of money installing one

In my signature you will find a single link with all my "mods" or research on the bike. In there is a link with my use of evtricky's regen lever mod, in sevcon this is called a "footbrake"

http://electricmotorcycleforum.com/boards/index.php?topic=4357.msg27950#msg27950

[BrianTRice@gmail.com]

This is wikified now:
http://zeromanual.com/index.php/Unofficial_Service_Manual#Controller_CAN_Diagnostics

[BrianTRice@gmail.com]

Which models have the Gen4 Sevcon?

I want to say MY13 - MY16 but I could be wrong ... I think the newer MY17's use a different controller

MY17's use a Gen4 controller with possibly some hardware modifications for increased (peak?) current capacity but the interface is identical, so MY13+ is applicable.

A Zero with a "regen lever"? What's that?

It is awesome enough that if I ever bought another zero I would spend considerable amount of money installing one

In my signature you will find a single link with all my "mods" or research on the bike. In there is a link with my use of evtricky's regen lever mod, in sevcon this is called a "footbrake"

http://electricmotorcycleforum.com/boards/index.php?topic=4357.msg27950#msg27950

This is a modification that deserves further instructions/commodification.

[Burton]

This is wikified now:
http://zeromanual.com/index.php/Unofficial_Service_Manual#Controller_CAN_Diagnostics

Looks good

This is a modification that deserves further instructions/commodification.

Did you just need someone to go through and summarize the posts there? I haven't seen too much interest in people modding their bike at a controller level since it now requires more expensive software to access the newer MY's :/

[BrianTRice@gmail.com]

This is a modification that deserves further instructions/commodification.

Did you just need someone to go through and summarize the posts there? I haven't seen too much interest in people modding their bike at a controller level since it now requires more expensive software to access the newer MY's :/

The unlicensed version still seems able to apply a DCF file, just is not capable of performing a "commissioning".

I think lack of interest is just fungible on the general perceived complexity and skills required of the job. Sevcon modification has two parts that are daunting:

• IXXAT and DVT arrangement. For me, I got lucky avoiding the $900 range cost. But I have to maintain a dinky old Windows laptop because this won't run under emulation on my preferred Mac laptop, rather annoying.
• Making new pinned connections through the Sevcon interface. This requires legitimate skills and practice to get right.

I think trying to tackle these elements would bring customization overhead down. Dealers could do it if they felt the mothership approved (which they officially don't but tacitly do if the dealership has exceptional skills).


The other half is getting the right lever and not spending a lot of money setting it up and tuning it. This is also commoditizable but not straightforward yet; in fact it's the only thing I'm not prepared to do offhand. I'd like to know that there's a lever I could just buy and it would have some extremely simple instructions for setting up.


One thing I don't want is something that will corrode and require repair every winter, which is something that most early adopters like yourself probably take for granted that doesn't scale.

[Burton]

The unlicensed version still seems able to apply a DCF file, just is not capable of performing a "commissioning".

you cannot apply a DCF without overwriting the commission settings as they are stored with the exported DCF file ... Are you suggesting you can backup / upload your own DCF, and make individual changes but you can't do something more complex like commission a motor? Since I don't have a need for using DVT on a higher MY bike yet I am not familiar with limitations outside what I have read. However if you can backup and upload a DCF then the mod should be accessible less you cannot overwrite RDPO's :/

The other half is getting the right lever and not spending a lot of money setting it up and tuning it. This is also commoditizable but not straightforward yet; in fact it's the only thing I'm not prepared to do offhand. I'd like to know that there's a lever I could just buy and it would have some extremely simple instructions for setting up.

One thing I don't want is something that will corrode and require repair every winter, which is something that most early adopters like yourself probably take for granted that doesn't scale.

I feel ya. The biggest issue with the hydraulic clutch is the transducer and the transformer. I told my airforce buddy at work about the mod and he shook his head and said "I hope you have extra transducers available," ... I told him I already replaced one and ended up using a higher PSI one to get around maxing it out. lol

You could go 100% mechanical clutch with a potentiometer box and now your point of failure is the pot and the transformer ... ultimately anything will wear over time.

I agree I could see "dealers" doing this mod but how many are competent enough with these systems to do so and are they allowed to do so as a zero dealer?

When I have time I will try to make the process more apparent / accessible than it already is and reference my wire diagram and pin numbers etc. Right now if anyone were to do this mod they need to have access to DVT / IXXAT and that is a pretty steep price for the mod in general less you are doing several other mods ... So this leaves dealers ... who can't seem to be able to fix anything correctly without zero's help.

[BrianTRice@gmail.com]

The unlicensed version still seems able to apply a DCF file, just is not capable of performing a "commissioning".

you cannot apply a DCF without overwriting the commission settings as they are stored with the exported DCF file ... Are you suggesting you can backup / upload your own DCF, and make individual changes but you can't do something more complex like commission a motor? Since I don't have a need for using DVT on a higher MY bike yet I am not familiar with limitations outside what I have read. However if you can backup and upload a DCF then the mod should be accessible less you cannot overwrite RDPO's :/

Yes, you're describing the process that seems workable for IPM bikes. Which means that the patch process is a set of manual instructions for whoever is using DVT. It's sufficient for assigning input signals and reading them for testing I think.

It also means that any firmware updates would require re-applying the modifications. And possibly recommissioning as well.

The other half is getting the right lever and not spending a lot of money setting it up and tuning it. This is also commoditizable but not straightforward yet; in fact it's the only thing I'm not prepared to do offhand. I'd like to know that there's a lever I could just buy and it would have some extremely simple instructions for setting up.

One thing I don't want is something that will corrode and require repair every winter, which is something that most early adopters like yourself probably take for granted that doesn't scale.

I feel ya. The biggest issue with the hydraulic clutch is the transducer and the transformer. I told my airforce buddy at work about the mod and he shook his head and said "I hope you have extra transducers available," ... I told him I already replaced one and ended up using a higher PSI one to get around maxing it out. lol

You could go 100% mechanical clutch with a potentiometer box and now your point of failure is the pot and the transformer ... ultimately anything will wear over time.

Maybe it's best to get an extra Magura throttle for the job.

I agree I could see "dealers" doing this mod but how many are competent enough with these systems to do so and are they allowed to do so as a zero dealer?

Literally a handful, I'm sure. There's clearly some sort of dealer telemetry possible if one assumes a huge amount of goodwill from the manufacturer, but that's not going to scale either.

Scripting DVT would be conceivable if it's a .Net program maybe... okay, I'm going to reel this back in now.

When I have time I will try to make the process more apparent / accessible than it already is and reference my wire diagram and pin numbers etc. Right now if anyone were to do this mod they need to have access to DVT / IXXAT and that is a pretty steep price for the mod in general less you are doing several other mods ... So this leaves dealers ... who can't seem to be able to fix anything correctly without zero's help.

Yes, trying to commoditize what the $900 toolchain does is hard to fathom, depending on their licensing mechanism. But maybe exactly one code path could be captured in I/O and made to replay portably without making mistakes on different models or configurations.

[Burton]

Yes, you're describing the process that seems workable for IPM bikes. Which means that the patch process is a set of manual instructions for whoever is using DVT. It's sufficient for assigning input signals and reading them for testing I think.

Quick! Who is going to be the test dummy? lol It is reasons like this I wish I had another couple bikes laying around from other MY's juts to test things like this and maybe to make fairing kits / accessories.

It also means that any firmware updates would require re-applying the modifications. And possibly recommissioning as well.

I don't think firmware updates affect recommissioning at all ... this would be very very bad given the "skill" it requires to commission a motor. If I upload an old DCF from when I had my MY13 ventilated motor the commission data wouldn't match my current motor. But if I updated the firmware of the bike nothing happens to this data Not saying there couldn't be such an issue though but I haven't experienced it yet. Again ... oh how it would be nice to be buddy buddy with a local zero dealer

Maybe it's best to get an extra Magura throttle for the job.

This might reduce the circuit to one point of failure ... the pot switch ... assuming the pot can take 24vdc and using the voltage out from the 24vdc pin doesn't affect anything else. This might be worth testing for sure. The stock throttle uses 12vdc ... i will have to look to see what the input pin can accept without frying to see if this could be a valid installation. Mind you the "regen" would be a reverse twisting throttle on the left hand post mod and some might not like this for various reasons.

But yeah worth a test for sure. A box you hook up to a cable for a clutch could be valid as well if people wanted a clutch action but adds other mechanical failure points and engineering (which has largely already been done).

Scripting DVT would be conceivable if it's a .Net program maybe... okay, I'm going to reel this back in now.

LOL  I can think of a way this might work but it would have nothing to do with .net ... also you need a reaper dongle for the install as well if i recall as you have to set some variables at the MBB but the dongles are cheap Now these sometimes DO get overwritten with bike updates :/

Yes, trying to commoditize what the $900 toolchain does is hard to fathom, depending on their licensing mechanism. But maybe exactly one code path could be captured in I/O and made to replay portably without making mistakes on different models or configurations.

There could be several avenues to monetize this for a single user installs but all require the DVT / IXXAT and dealer service bundle being in a users hands. This could mean "renting" a "ready to go" laptop with all the equipment and presets etc ... and of course that brings into itself a whole list of other issues considering the cost / insurance on equipment required etc. 

Now if we assume a dealer who already has the tools there might be a way to give them a kit to install this type of thing as well but i would need to test some stuff before confirming. The question I would have is how much would people be willing to pay for such a kit ... and I am thinking total cost out of pocket (so dealer fees and everything assuming you have a dealer do it) ... this ultimately determines viability of such an aftermarket solution, that and demand.