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[JESSinSD]

Hi Zero folks.   I have a 2016 FXS and it has nothing but issues since I bought it.

Now, it is barely out of warranty and when I went to plug it in, it wouldn't charge.   I was told that the charging module was bad.   (Green Watt Power EVC-116-720).   Found a new one on eBay and it started charging just fine.   But after about 20 minutes, it will shut off.   I reset the BMS on the batteries as per the AMAZING Unofficial Zero Manual at https://zeromanual.com/wiki/Unofficial_Service_Manual#Charger.   

Now, it won't charge at all.

Any advice is most appreciated.


Jessica in San Diego

[BrianTRice@gmail.com]

I'm glad the unofficial manual helped out. Have you checked the logs? Are there any other symptoms, maybe with the 12V system?

The DC-DC converter sometimes triggers charger failures.

[JESSinSD]

Thanks for the response.   Yes, the manual is incredible.  SO MUCH GOOD STUFF!   I owe that guy a steak dinner and a beer.
I downloaded the logs today and currently in the process of parsing the logs and analyzing the data.   However, being a bit of a newbie on electric bike repair, I am not certain what I am looking at.   I am sure the answer (or a clue) is in there somewhere.   I noticed that the charger heated up quite a bit.   I am wondering if there is a bad or dirty contact somewhere.   I also noticed that there was very little dialectic grease in one of the battery modules whereas the other one is packed.   

[BrianTRice@gmail.com]

I'm the main editor of the unofficial manual, so thanks.

Log interpretation is an arcane skillset, for sure. You can forward those logs to Zero for advice, although I admit often enough they'll just tell you to go to a dealer with no real guidance. And it could be that they don't know, either.

Uploading the logs to the forum for others to check might help if you're comfortable with that. The vehicle's VIN and some other information will be in there.

[JESSinSD]

Wow..  Great job!!      You are right.  Zero Customer Service has all but ignored me and/or just told me to bring the bike to the dealer.    But I am an "unofficial" Electrical Engineer so I am going to take a crack at it and do my best to decipher some of the data.  It is actually well time stamped and intuitive.  As I trip over some of the acronyms and nomenclatures, I may resort to this thread and your manual for advice.   Stay tuned. 

I want to get this bike running again.  Again, thanks for your wealth of knowledge and documentation.   Without it, I would be absolutely blind.  Now, because of your manual, I have hope and troubleshooting ammunition. 

Cheers,

jess

[BrianTRice@gmail.com]

No problem. You've probably found the FX wiring diagram which I did not develop, notably, since I've only had a DS+DSR, personally.

You'll find that others have posted logs in the forum. It's possible that a message of note near the time when the error occurs can be found by a search (here or via Google, etc).

Also, one vague recommendation is to look for patterns, and see whether a sequence of events that normally happens is missing some critical event when things go wrong. This recommendation works better when you can compare a working bike with a broken/glitchy one...

[Jarrett]

How do you download the logs and view them?

[Curt]

Connect to the bike with Bluetooth according to instructions in the owner's manual, then there is an option in the app to download and email the logs to a specified address.

[JESSinSD]

Here is the link to parse the binary code so you can read the logs: http://home.hasslers.net/zerologparser/log_parser.php

Here is a link with a wealth of knowledge:  http://home.hasslers.net/zerologparser/

[JESSinSD]

Hi Brian.  So I downloaded the logs from yesterday's charging attempt.   It would charge for a few minutes, then quit.   The charging module got quite warm.  Almost to hot to touch.     I think the clue is in here somewhere, I have the whole log but didn't want to inundate you. 

 08879     02/25/2019 11:24:54   Exiting Hibernate
 08880     02/25/2019 11:24:54   DEBUG: Entered Idle State
 08881     02/25/2019 11:24:54   System Turned On
 08882     02/25/2019 11:24:54   DEBUG: Entered Standby State
 08883     02/25/2019 11:24:55   DEBUG: CAN Link Is Up
 08884     02/25/2019 11:24:55   DEBUG: Entered Charging State
 08885     02/25/2019 11:24:56   Discharge level            010 AH, SOC: 60%, I:  0A, L:3697, l:3692, H:3703, B:006, PT:012C, BT:012C, PV:103602, M:Charge
 08886     02/25/2019 11:24:56   SOC:8974,21913,10711,26000,59,57,60,0
 08887     02/25/2019 11:24:56   Contactor drive turned on  Pack V: 103616mV, Switched V: 90308mV, Duty Cycle: 39%
 08888     02/25/2019 11:24:56   Contactor was Closed       Pack V: 103616mV, Switched V: 90308mV, Prechg Pct: 87%, Dischg Cur: -698mA
 08889     02/25/2019 11:24:56   DEBUG: CAN Receiving Syncs
 08890     02/25/2019 11:32:19   DEBUG: Entered Standby State
 08891     02/25/2019 11:32:19   DEBUG: CAN NOT Receiving Syncs
 08892     02/25/2019 11:32:20   System Turned Off
 08893     02/25/2019 11:32:21   DEBUG: CAN Link Is Down
 08894     02/25/2019 11:32:21   DEBUG: Entered Idle State
 08895     02/25/2019 11:32:21   Contactor was Opened       Pack V: 104409mV, Switched V: 103030mV, Prechg Pct: 98%, Dischg Cur: 0mA
 08896     02/25/2019 11:32:24   System Turned On
 08897     02/25/2019 11:32:24   DEBUG: Entered Standby State
 08898     02/25/2019 11:32:25   DEBUG: CAN Link Is Up
 08899     02/25/2019 11:32:25   DEBUG: Entered Running State
 08900     02/25/2019 11:32:26   Discharge level            010 AH, SOC: 60%, I:  0A, L:3722, l:3705, H:3727, B:005, PT:013C, BT:020C, PV:104303, M:Bike On
 08901     02/25/2019 11:32:26   SOC:8976,21913,10347,26000,61,59,60,-2
 08902     02/25/2019 11:32:26   Discharge cutback          70%
 08903     02/25/2019 11:32:26   181A
 08904     02/25/2019 11:32:26   DEBUG: CAN Receiving Syncs
 08905     02/25/2019 11:32:27   Contactor drive turned on  Pack V: 104297mV, Switched V: 94129mV, Duty Cycle: 39%
 08906     02/25/2019 11:32:27   Contactor was Closed       Pack V: 104297mV, Switched V: 94129mV, Prechg Pct: 90%, Dischg Cur: 0mA
 08907     02/25/2019 11:33:26   Discharge level            010 AH, SOC: 59%, I:  0A, L:3713, l:3706, H:3718, B:005, PT:013C, BT:020C, PV:104037, M:Bike On
 08908     02/25/2019 11:33:26   SOC:9105,21913,10347,26000,61,58,59,-1
 08909     02/25/2019 11:34:26   Discharge level            010 AH, SOC: 59%, I:  0A, L:3709, l:3705, H:3715, B:006, PT:013C, BT:021C, PV:103937, M:Bike On
 08910     02/25/2019 11:34:26   SOC:9125,21913,10347,26000,61,58,59,0
 08911     02/25/2019 11:35:26   Discharge level            010 AH, SOC: 59%, I:  0A, L:3708, l:3706, H:3713, B:005, PT:013C, BT:021C, PV:103889, M:Bike On
 08912     02/25/2019 11:35:26   SOC:9190,21913,10347,26000,61,58,59,0
 08913     02/25/2019 11:36:26   Discharge level            010 AH, SOC: 59%, I:  0A, L:3706, l:3705, H:3712, B:006, PT:013C, BT:021C, PV:103852, M:Bike On
 08914     02/25/2019 11:36:26   SOC:9200,21913,10347,26000,61,58,59,0
 08915     02/25/2019 11:36:34   DEBUG: CAN Link Is Down
 08916     02/25/2019 11:36:34   DEBUG: CAN Link Is Up
 08917     02/25/2019 11:36:44   DEBUG: CAN Link Is Down
 08918     02/25/2019 11:36:44   DEBUG: CAN Link Is Up
 08919     02/25/2019 11:36:47   DEBUG: CAN Link Is Down
 08920     02/25/2019 11:36:47   DEBUG: CAN Link Is Up
 08921     02/25/2019 11:37:26   Discharge level            010 AH, SOC: 58%, I:  0A, L:3705, l:3704, H:3711, B:006, PT:013C, BT:021C, PV:103823, M:Bike On
 08922     02/25/2019 11:37:26   SOC:9203,21913,10347,26000,61,58,58,0
 08923     02/25/2019 11:37:59   DEBUG: CAN Link Is Down
 08924     02/25/2019 11:37:59   DEBUG: CAN Link Is Up
 08925     02/25/2019 11:38:26   Discharge level            010 AH, SOC: 58%, I:  0A, L:3705, l:3704, H:3710, B:005, PT:013C, BT:021C, PV:103803, M:Bike On
 08926     02/25/2019 11:38:26   SOC:9203,21913,10347,26000,61,58,58,0
 08927     02/25/2019 11:38:59   DEBUG: CAN Link Is Down
 08928     02/25/2019 11:38:59   DEBUG: CAN Link Is Up
 08929     02/25/2019 11:39:12   DEBUG: CAN Link Is Down
 08930     02/25/2019 11:39:12   DEBUG: CAN Link Is Up
 08931     02/25/2019 11:39:26   Discharge level            010 AH, SOC: 58%, I:  0A, L:3704, l:3704, H:3710, B:006, PT:013C, BT:022C, PV:103781, M:Bike On
 08932     02/25/2019 11:39:26   SOC:9203,21913,10347,26000,61,58,58,0
 08933     02/25/2019 11:40:26   Discharge level            010 AH, SOC: 58%, I:  0A, L:3703, l:3703, H:3709, B:006, PT:013C, BT:022C, PV:103763, M:Bike On
 08934     02/25/2019 11:40:26   SOC:9203,21913,10347,26000,61,58,58,0
 08935     02/25/2019 11:40:31   DEBUG: CAN Link Is Down
 08936     02/25/2019 11:40:31   DEBUG: CAN Link Is Up
 08937     02/25/2019 11:40:40   DEBUG: CAN Link Is Down
 08938     02/25/2019 11:40:40   DEBUG: CAN Link Is Up
 08939     02/25/2019 11:40:41   DEBUG: CAN Link Is Down
 08940     02/25/2019 11:40:41   DEBUG: CAN Link Is Up
 08941     02/25/2019 11:41:26   Discharge level            010 AH, SOC: 58%, I:  0A, L:3703, l:3703, H:3708, B:005, PT:013C, BT:022C, PV:103745, M:Bike On
 08942     02/25/2019 11:41:26   SOC:9238,21913,10347,26000,61,58,58,0
 08943     02/25/2019 11:42:26   Discharge level            010 AH, SOC: 58%, I:  0A, L:3702, l:3702, H:3708, B:006, PT:013C, BT:022C, PV:103727, M:Bike On
 08944     02/25/2019 11:42:26   SOC:9383,21913,10347,26000,61,57,58,0
 08945     02/25/2019 11:42:35   DEBUG: CAN Link Is Down
 08946     02/25/2019 11:42:35   DEBUG: CAN Link Is Up
 08947     02/25/2019 11:42:47   DEBUG: CAN Link Is Down
 08948     02/25/2019 11:42:47   DEBUG: CAN Link Is Up
 08949     02/25/2019 11:43:26   Discharge level            010 AH, SOC: 58%, I:  0A, L:3701, l:3701, H:3707, B:006, PT:013C, BT:022C, PV:103714, M:Bike On
 08950     02/25/2019 11:43:26   SOC:9416,21913,10347,26000,61,57,58,0
 08951     02/25/2019 11:43:26   DEBUG: CAN Link Is Down
 08952     02/25/2019 11:43:26   DEBUG: CAN Link Is Up
 08953     02/25/2019 11:43:58   DEBUG: CAN Link Is Down
 08954     02/25/2019 11:43:58   DEBUG: CAN Link Is Up
 08955     02/25/2019 11:44:16   DEBUG: CAN Link Is Down
 08956     02/25/2019 11:44:16   DEBUG: CAN Link Is Up
 08957     02/25/2019 11:44:26   Discharge level            010 AH, SOC: 58%, I:  0A, L:3701, l:3701, H:3706, B:005, PT:013C, BT:022C, PV:103702, M:Bike On
 08958     02/25/2019 11:44:26   SOC:9421,21913,10347,26000,61,57,58,0
 08959     02/25/2019 11:44:44   DEBUG: CAN Link Is Down
 08960     02/25/2019 11:44:44   DEBUG: CAN Link Is Up
 08961     02/25/2019 11:44:49   DEBUG: CAN Link Is Down
 08962     02/25/2019 11:44:49   DEBUG: CAN Link Is Up
 08963     02/25/2019 11:44:50   DEBUG: CAN Link Is Down
 08964     02/25/2019 11:44:50   DEBUG: CAN Link Is Up
 08965     02/25/2019 11:45:22   DEBUG: CAN Link Is Down
 08966     02/25/2019 11:45:22   DEBUG: CAN Link Is Up
 08967     02/25/2019 11:45:26   Discharge level            010 AH, SOC: 57%, I:  0A, L:3701, l:3701, H:3706, B:005, PT:013C, BT:022C, PV:103686, M:Bike On
 08968     02/25/2019 11:45:26   SOC:9422,21913,10347,26000,61,57,57,0
 08969     02/25/2019 11:45:34   DEBUG: CAN Link Is Down
 08970     02/25/2019 11:45:34   DEBUG: CAN Link Is Up
 08971     02/25/2019 11:46:26   Discharge level            010 AH, SOC: 57%, I:  0A, L:3700, l:3700, H:3706, B:006, PT:013C, BT:022C, PV:103671, M:Bike On
 08972     02/25/2019 11:46:26   SOC:9422,21913,10347,26000,61,57,57,0
 08973     02/25/2019 11:47:26   Discharge level            010 AH, SOC: 57%, I:  0A, L:3700, l:3700, H:3706, B:006, PT:013C, BT:022C, PV:103663, M:Bike On
 08974     02/25/2019 11:47:26   SOC:9422,21913,10347,26000,61,57,57,0
 08975     02/25/2019 11:48:26   Discharge level            010 AH, SOC: 57%, I:  0A, L:3698, l:3698, H:3705, B:007, PT:013C, BT:022C, PV:103647, M:Bike On
 08976     02/25/2019 11:48:26   SOC:9422,21913,10347,26000,61,57,57,0
 08977     02/25/2019 11:49:26   Discharge level            010 AH, SOC: 57%, I:  0A, L:3698, l:3698, H:3705, B:007, PT:013C, BT:022C, PV:103636, M:Bike On
 08978     02/25/2019 11:49:26   SOC:9422,21913,10347,26000,61,57,57,0
 08979     02/25/2019 11:50:26   Discharge level            010 AH, SOC: 57%, I:  0A, L:3698, l:3698, H:3705, B:007, PT:013C, BT:022C, PV:103623, M:Bike On
 08980     02/25/2019 11:50:26   SOC:9422,21913,10347,26000,61,57,57,0
 08981     02/25/2019 11:51:26   Discharge level            010 AH, SOC: 57%, I:  0A, L:3697, l:3697, H:3704, B:007, PT:014C, BT:022C, PV:103610, M:Bike On
 08982     02/25/2019 11:51:26   SOC:9422,21913,10347,26000,61,57,57,0
 08983     02/25/2019 11:52:26   Discharge level            010 AH, SOC: 57%, I:  0A, L:3697, l:3697, H:3703, B:006, PT:014C, BT:022C, PV:103598, M:Bike On
 08984     02/25/2019 11:52:26   SOC:9422,21913,10347,26000,61,57,57,0
 08985     02/25/2019 11:53:03   Contactor was Opened       Pack V: 103592mV, Switched V: 102203mV, Prechg Pct: 98%, Dischg Cur: 0mA
 08986     02/25/2019 11:53:03   System Turned Off
 08987     02/25/2019 11:53:04   DEBUG: CAN NOT Receiving Syncs
 08988     02/25/2019 11:53:04   DEBUG: CAN Link Is Down
 08989     02/25/2019 11:53:04   DEBUG: Entered Idle State
 08990     02/25/2019 11:53:11   Discharge level            010 AH, SOC: 57%, I:  0A, L:3700, l:3700, H:3705, B:005, PT:013C, BT:022C, PV:103675, M:Idle
 08991     02/25/2019 11:53:11   SOC:9422,21913,10347,26000,61,57,57,0
 08992     02/25/2019 11:53:12   System Turned On
 08993     02/25/2019 11:53:12   DEBUG: Entered Running State
 08994     02/25/2019 11:53:12   DEBUG: CAN Link Is Up
 08995     02/25/2019 11:53:13   DEBUG: Entered Charging State
 08996     02/25/2019 11:53:14   Discharge level            010 AH, SOC: 57%, I:  0A, L:3700, l:3700, H:3706, B:006, PT:014C, BT:022C, PV:103678, M:Charge
 08997     02/25/2019 11:53:14   SOC:9422,21913,10347,26000,61,57,57,0
 08998     02/25/2019 11:53:14   Contactor drive turned on  Pack V: 103682mV, Switched V: 91608mV, Duty Cycle: 39%
 08999     02/25/2019 11:53:14   Contactor was Closed       Pack V: 103682mV, Switched V: 91608mV, Prechg Pct: 88%, Dischg Cur: 0mA
 09000     02/25/2019 11:53:14   DEBUG: CAN Receiving Syncs
 09001     02/25/2019 12:03:14   Discharge level            009 AH, SOC: 61%, I: -2A, L:3747, l:3719, H:3753, B:006, PT:014C, BT:025C, PV:105030, M:Charge
 09002     02/25/2019 12:03:14   SOC:8647,21913,9862,26000,63,60,61,-4
 09003     02/25/2019 12:04:22   DEBUG: Entered Running State
 09004     02/25/2019 12:04:22   DEBUG: CAN NOT Receiving Syncs
 09005     02/25/2019 12:04:23   Discharge level            009 AH, SOC: 61%, I:  0A, L:3734, l:3717, H:3737, B:003, PT:014C, BT:025C, PV:104583, M:Bike On
 09006     02/25/2019 12:04:23   SOC:8668,21913,9807,26000,63,60,61,-3
 09007     02/25/2019 12:04:23   Discharge cutback          64%
 09008     02/25/2019 12:04:23   166A
 09009     02/25/2019 12:04:24   DEBUG: CAN Receiving Syncs
 09010     02/25/2019 12:05:23   Discharge level            009 AH, SOC: 61%, I:  0A, L:3725, l:3719, H:3728, B:003, PT:014C, BT:024C, PV:104330, M:Bike On
 09011     02/25/2019 12:05:23   SOC:8751,21913,9807,26000,63,60,61,-1
 09012     02/25/2019 12:06:21   Contactor was Opened       Pack V: 104239mV, Switched V: 102912mV, Prechg Pct: 98%, Dischg Cur: 0mA
 09013     02/25/2019 12:06:22   System Turned Off
 09014     02/25/2019 12:06:22   DEBUG: CAN NOT Receiving Syncs
 09015     02/25/2019 12:06:23   DEBUG: CAN Link Is Down
 09016     02/25/2019 12:06:23   DEBUG: Entered Idle State
 09017     02/25/2019 12:06:29   Current Sensor Zeroed      old: 2519mV, new: 2519mV, corrfact: 237
 09018     02/25/2019 12:06:30   Discharge level            009 AH, SOC: 61%, I:  0A, L:3724, l:3720, H:3727, B:003, PT:014C, BT:024C, PV:104317, M:Idle
 09019     02/25/2019 12:06:30   SOC:8763,21913,9807,26000,63,60,61,0
 09020     02/25/2019 12:06:35   System Turned On
 09021     02/25/2019 12:06:35   DEBUG: Entered Running State
 09022     02/25/2019 12:06:35   DEBUG: CAN Link Is Up
 09023     02/25/2019 12:06:36   Discharge level            009 AH, SOC: 61%, I:  0A, L:3722, l:3719, H:3726, B:004, PT:014C, BT:024C, PV:104255, M:Bike On
 09024     02/25/2019 12:06:36   SOC:8763,21913,9807,26000,63,60,61,0
 09025     02/25/2019 12:06:37   DEBUG: CAN Receiving Syncs
 09026     02/25/2019 12:06:37   Contactor drive turned on  Pack V: 104249mV, Switched V: 91923mV, Duty Cycle: 39%
 09027     02/25/2019 12:06:37   Contactor was Closed       Pack V: 104249mV, Switched V: 91923mV, Prechg Pct: 88%, Dischg Cur: 0mA
 09028     02/25/2019 12:07:11   Contactor was Opened       Pack V: 104203mV, Switched V: 102793mV, Prechg Pct: 98%, Dischg Cur: 0mA
 09029     02/25/2019 12:07:11   System Turned Off
 09030     02/25/2019 12:07:12   DEBUG: CAN NOT Receiving Syncs
 09031     02/25/2019 12:07:12   DEBUG: CAN Link Is Down
 09032     02/25/2019 12:07:12   DEBUG: Entered Idle State

[cpallenjr]

IAW the KISS principle and the issue with the CAN bus link going up and down - check for loose cable, socket, or maybe a bent pin.

[JESSinSD]

Great advice.  Thank You.    I think it could just be a bad charger.  I bought the second one on eBay.    Hoping and waiting for DigiNow to come out with a better solution.   

[davidpastorino]

Hi Jessica,

I am the owner of a 2016 FXS too. I think I am having a similar problem to yours. I am stuck at a simpler step though, which is finding the BMS reset buttons. Would you be able to tell me where they are located on the bike? I've spent 45 minutes looking for them and can only find the "big" com plug.

Thank you in advance
Did changing the charger a second time solve your issue?

Best