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[Peter-se]

Hi guys (and, statistically also a lady maybe),

I’ve enjoyed my DSR’18 for a few months. It has worked flawlessly. Until it didn’t.

I was charging it overnight, usual place, factory cable, nothing different. Came back to find it shut down. Turned the key and it has stopped on 79%. Shows some error messages then boot itself down.

The red flashes are 2 then 3, indicating a CAN error.
Which, according to the manual, says for me to bring it to the shop. Which, unfortunately for me, is 5 hours away.

It shows these error messages before powering itself off.

C09
C25
C47
C44
C45
C48
C49
C25
C27
C31

It shuts down before I can download/send the logs.

Any suggestions besides “take it to the shop”?

I’ve unironucally tried “turning it on and off”.
Some of the error codes are for the BMS which I’ve tried resetting. Soft and hard.
I’ve tried talking to it really nicely.

Other than that I’ve refrained from poking around.

It’s a new bike. Bought it new just as the 19 year models were launched. I’ve only charged it 22 times. It’s under warranty.

Suggestions very welcome.

[dalamario]

Did you check MBB connection cables?

Maybe what Burpman wrote on this thread  can help you.

[Peter-se]

I have not, I don’t even know what that is. But I’ll look into it and give it a go. Hopefully I won’t fry.

That thread reminded me -
I did try removing and reinserting some of the fuses.
No luck.

Edit: also, thank you for the reply

[BamBam]

What fuses did you R&R?  Did you try the Low Power B+ fuse?  It's located under the seat on the left side I believe.  That fixed my DSR when it I had power issues on start up.

[Peter-se]

What fuses did you R&R?  Did you try the Low Power B+ fuse?  It's located under the seat on the left side I believe.  That fixed my DSR when it I had power issues on start up.

That’s the one I went for.
I read it on a thread here, that I think you started.

Will try the MBB unplug in an hour.

[alko]

I had a similar but not exactly same problem, and burpmans solution fixed it for me just a couple weeks ago. In fact, I posted that topic. I keep a tool on my bike now to remove the seat, so I can fix it on the road if it ever happens again.

[Peter-se]

MBB unplug/replug didn’t work either.

[alko]

MBB unplug/replug didn’t work either.

That's too bad. I hope someone here can help you. I was in a similar situation with my dsr. With a dealer being couple hours away. If I was forced to take it to dealer where it would be weeks before I got it back, I would have said goodbye to Zero, and would have traded it in for a reliable ICE bike on the spot.

[Peter-se]

Sad because it’s such a sparkling new purchase.
They've put years worth of iterations in the product but it still feels like a product in development phase. How long can one claim-, and excuse oneself and products, to be a "startup"?

Found that unplugging one of the MBB cables allows the bike to stay on long enough to download the logs.
Might help. Will do that.

Pics from latest drive in the meantime. Suited up for half the ride.

[Peter-se]

Long file. Snipped what may be interesting (few charging percentages until the problem happened, to keying on/off later, after the problem has manifested itself):


Firmware rev.      1536
Board rev.         125
Model              W

....


04761     04/26/2019 16:41:37   Charging                   PackTemp: h 31C, l 26C, AmbTemp: 15C, PackSOC: 78%, Vpack:108.979V, BattAmps: -11, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
 04762     04/26/2019 16:51:37   Charging                   PackTemp: h 31C, l 26C, AmbTemp: 15C, PackSOC: 79%, Vpack:109.466V, BattAmps: -11, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
 04763     04/26/2019 16:54:13   Sevcon CAN Link Down
 04764     04/26/2019 16:54:15   Sevcon CAN was lost.  Restarting.
 04765     04/26/2019 16:54:15   Module 00 Opening Contactor  vmod: 109.457V, batt curr: -13A
 04766     04/26/2019 16:54:15   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 04767     04/26/2019 16:54:15   Sevcon Turned Off
 04768     04/26/2019 16:54:15   DEBUG: Sevcon Contactor Drive OFF
 04769     04/26/2019 16:54:15   DEBUG: Sevcon Has Turned Off Contactor Drive
 04770     04/26/2019 16:54:15   Module 00 Opening Contactor  vmod: 109.457V, batt curr: -13A
 04771     04/26/2019 16:54:15   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 04772     04/26/2019 16:54:15   INFO:  Disabling Calex 720W Charger 0
 04773     04/26/2019 16:54:15   INFO:  Disabling Calex 1200W Charger 1
 04774     04/26/2019 16:54:16   DEBUG: Module 00 Contactor is now Open
 04775     04/26/2019 16:54:17   Sevcon Turned On
 04776     04/26/2019 16:54:27   Precharge Timed Out. CapV: 0V
 04777     04/26/2019 16:54:27   Module 00 Opening Contactor  vmod: 109.363V, batt curr:   0A
 04778     04/26/2019 16:54:27   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 04779     04/26/2019 16:54:27   Sevcon Turned Off
 04780     04/26/2019 16:54:29   Sevcon Turned On
 04781     04/26/2019 16:54:39   Precharge Timed Out. CapV: 0V
 04782     04/26/2019 16:54:39   Module 00 Opening Contactor  vmod: 109.332V, batt curr:   0A
 04783     04/26/2019 16:54:39   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 04784     04/26/2019 16:54:39   Sevcon Turned Off
 04785     04/26/2019 16:54:40   Malfunction Indicator (Engine light) turned on because of Sevcon can error
 04786     04/26/2019 16:54:42   Sevcon Turned On
 04787     04/26/2019 16:54:51   Too many Sevcon CAN retries. Shutting Down.
 04788     04/26/2019 16:54:51   Entering Critical Error Low Power Shutdown
 04789     04/26/2019 16:54:51   INFO:  Disabling External Chg 0 Charger 2
 04790     04/26/2019 16:54:51   INFO:  Disabling External Chg 1 Charger 3
 04791     04/26/2019 16:54:51   Sevcon Turned Off
 04792     04/26/2019 16:54:51   Module 00 Opening Contactor  vmod: 109.316V, batt curr:   0A
 04793     04/26/2019 16:54:51   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 04794     04/26/2019 16:54:51   Key On
 04795     04/26/2019 16:54:51   Resetting because of key cycle.
 04796     04/26/2019 16:54:51   CPU Soft Reset:            Key cycle from low power shutdown.
 04797                       0   DEBUG: Reset: External
 04798                       0   BMS Reset                  Unknown
 04799                       0   Key On
 04800                       0   DEBUG: Module scheme changed from None mode to Stopped mode
 04801                       0   Module 00 Opening Contactor  vmod:   0.000V, batt curr:   0A
 04802                       0   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 04803                       0   Turning ON DCDC
 04804                       0   Calex 720W Charger 0 Connected   
 04805                       0   Calex 1200W Charger 1 Connected   
 04806                       1   DEBUG: Module scheme changed from Stopped mode to Charging mode
 04807                       1   Module 00 CAN Link Up
 04808                       1   Module 00 Registered       serial: 18tb0197,  vmod: 108.788V
 04809     04/28/2019 02:03:48   Sevcon Turned On
 04810     04/28/2019 02:03:48   INFO: Max allowed voltage difference is 500mV
 04811     04/28/2019 02:03:57   Charging                   PackTemp: h 16C, l 15C, AmbTemp: 11C, PackSOC: 80%, Vpack:108.606V, BattAmps:   0, Mods: 00, MbbChgEn: Yes, BmsChgEn: No
 04812     04/28/2019 02:03:58   Precharge Timed Out. CapV: 0V
 04813     04/28/2019 02:03:58   Module 00 Opening Contactor  vmod: 108.781V, batt curr:   0A
 04814     04/28/2019 02:03:58   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 04815     04/28/2019 02:03:58   Sevcon Turned Off
 04816     04/28/2019 02:04:00   Sevcon Turned On
 04817     04/28/2019 02:04:10   Precharge Timed Out. CapV: 0V
 04818     04/28/2019 02:04:10   Module 00 Opening Contactor  vmod: 108.629V, batt curr:   0A
 04819     04/28/2019 02:04:10   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 04820     04/28/2019 02:04:10   Sevcon Turned Off
 04821     04/28/2019 02:04:11   Malfunction Indicator (Engine light) turned on because of Sevcon can error
 04822     04/28/2019 02:04:12   Sevcon Turned On
 04823     04/28/2019 02:04:22   Precharge Timed Out. CapV: 0V
 04824     04/28/2019 02:04:22   Module 00 Opening Contactor  vmod: 108.599V, batt curr:   0A
 04825     04/28/2019 02:04:22   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 04826     04/28/2019 02:04:22   Sevcon Turned Off
 04827     04/28/2019 02:04:24   Sevcon Turned On
 04828     04/28/2019 02:04:27   Too many Sevcon CAN retries. Shutting Down.
 04829     04/28/2019 02:04:27   Entering Critical Error Low Power Shutdown
 04830     04/28/2019 02:04:27   Sevcon Turned Off
 04831     04/28/2019 02:04:27   Turning OFF DCDC. Flags: 0x00
 04832     04/28/2019 02:04:27   Module 00 Opening Contactor  vmod: 108.592V, batt curr:   0A
 04833     04/28/2019 02:04:27   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 04834     04/28/2019 02:04:27   Key Off
 04835     04/28/2019 02:04:27   Key On
 04836     04/28/2019 02:04:27   Resetting because of key cycle.
 04837     04/28/2019 02:04:27   CPU Soft Reset:            Key cycle from low power shutdown.
 04838                       0   DEBUG: Reset: External
 04839                       0   BMS Reset                  Unknown
 04840                       0   Key On
 04841                       0   DEBUG: Module scheme changed from None mode to Stopped mode
 04842                       0   Module 00 Opening Contactor  vmod:   0.000V, batt curr:   0A
 04843                       0   Module 01 Opening Contactor  vmod:   0.000V, batt curr:   0A
 04844                       0   Turning ON DCDC
 04845                       0   Module 00 CAN Link Up
 04846                       1   Module 00 Registered       serial: 18tb0197,  vmod: 108.780V

[remmie]

do you have a powertank ?
there were some problems with different firmware versions of the big battery and the powertank which caused problems.

Updating both firmwares fixed the issue if i recall correctly.

Maybe unplugging the powertank gets things going again ?

[Peter-se]

do you have a powertank ?

Maybe unplugging the powertank gets things going again ?

No powertank. Got the vanilla version.

[Peter-se]

Update for anyone in the same situation.

The bike was transported to the zero dealer and getting the MBB replaced.

Hopefully it’ll run without fault. But have to admit I’ve lost some confidence in the bike. For now.