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[Burton]

Etched foil heaters could even fit on the inside of the battery case. Maybe even between the modules?

I am sure I could work some magic in the case but I rather not void my warranty ... If I still have one lol This is why I was thinking of external stick-on ones.

[Burton]

Made it home without shutting down but as soon as I hit the highway the temp sensor error started. When I got the bike home even after it started to charge it was throwing the error to the koso display :/

Good news though, it seems my settings returned somehow for the trip home ... It was nice to have my dynamic engine braking back. Tempted to make a temporary foam fairing for the bike to see if the issue goes away but idk ...

[Burton]

Ok I have made progress.

First I found someone kind enough to take my logs (attached) on the day I lost power and give them to me in a readable format. It appears my controller got down to 2 to -2C and around 0C the MBB started to loose contact with the controller. After a while the MBB decided to restart the controller.

This is when I first lost throttle response. I tried to move throttle a lot to see if it would work again but eventually pulled over since it wasn't responding. During this time the MBB restarted the sevcon several times and each time a throttle error was thrown. The battery temps were well in range and should not have been the cause of the loss of power.

It was suggested I cover my sevcon to see if the issue happens because it is getting cold. I decided to run two days at 75mph for 30 minutes to and from work to see if the sevcon would overheat. It appears to keep the same temp as the battery and or motor or all three. So it certainly is warmer. I found a simple Jif 6 pack box worked great and tapped it onto the bike.



But since it is due to rain for two days I had to make a new one out of metal or plastic. While making this I shot a ton of video I have not uploaded yet. It is not really a how to video but is something I like to call an "empowerment video" as it shows my thought processes and problems as I run into them and ultimately solve them.

This is what I came up with





It fits on the bike without the need of any screws or fasteners. I can take it off and put it on in under a minute. Check out my flickr zero stream toward the bottom to see more pictures. I will try to get the long video up asap and will post it here when I do.

https://www.flickr.com/photos/71805301@N05/sets/72157643430171885/

I will be sure to post up performance results vs my cardboard solution and how well it performs in the rain

The things I do to make sure I can ride year round :/

[Burton]

UPDATE:

it was 18F this morning, front battery cover still on bike. I was traveling at 70mph and the controller temps stayed above 55 the whole trip along with motor / battery temps. So it was a success ... I think; since when I plugged it in to charge it didn't start charging right away.

[Justin Andrews]

I did'nt think it was the controller that dictated the low temperature charging cutoff?

I've yet to work out what is actually causing the low temp charging cutoff, it is NOT battery pack temperature, as I've seen that hovering around 12C (53F) when its been refusing to charge. I'm not convinced its the BMS either as it was not reporting that the battery temp was low.

Hmm, looking at my logs, where the bike was refusing to charge do to the cold, the Sevcon was reading being at a temp of 1C
The bike status was reporting temps of 0C for the controller, and 5C for the motor.

Maybe the Sevcon does play a part in the cold charging condition. I wonder if the charging software polls all of the temps of the bike to play it safe and get an accurate picture of the external temperature. Difficult to know for certain without seeing the source code for the bike.

For reference, some dumps from last week when my bike was refusing to charge in cold weather (it started charging a few hours later when things warmed up a bit).

****************************************
*               BMS Data               *
****************************************

*************  BMS #0  ***************
  - BMS Board Rev             :  03
  - BMS Firmware Rev          :  40
  - CAN Rx in last second     :   63

  - Pack SOC                  :  0%
  - Fuel Gauge                :  -8%
  - Age of SOC Data           :  249 ms

  - Pack Capacity             :  92 AH
  - Pack Capacity Remaining   : 46573 AH
  - Total Energy Used         :1513 KWH
  - Number Of Bricks          :   4

  - Pack Discharge Current    :   1 A
  - Pack Sum Voltage          :   90.347 V
  - Sag-Adj Pack Sum Voltage  :   90.346 V
  - Bank Voltages             :     1    2    3    4    5    6    7    8    9   10   11   12   13   14   15   16   17   18   19   20   21   22   23   24   25   26   27   28
                              :  3216 3198 3219 3236 3203 3239 3226 3270 3211 3286 3251 3246 3197 3211 3205 3209 3262 3238 3225 3228 3234 3227 3275 3194 3180 3229 3219 3212
  - Lowest Cell Voltage       :  3180 mV ( Cell 25 )
  - Highest Cell Voltage      :  3286 mV ( Cell 10 )
  - Pack Balance              :  106 mV
  - Lowest Sag Adj Cell mV    :  3180 mV
  - Age of Bank Voltage Data  :  476 ms

  - Isolation Resistance      :  0 KOhms (0x0000)
  - Least Isolated Cell       :  0

                              :      0     1     2     3     4     5     6     7
  - Pack Temps                :     5C    5C    5C    5C    5C    5C    5C    5C
  - Fet Temps                 :  -100C -100C
  - Highest Present Fet Temp  :  -100 C
  - Highest Present Pack Temp :  5 C
  - Lowest Present Pack Temp  :  5 C
  - Max Pack Temp This Ride   :  6 C
  - Min Pack Temp This Ride   :  5 C
  - Max FET Temp This Ride    :  -127 C
  - Min FET Temp This Ride    :  127 C
  - Age of BMS Temp Data      :  124 ms

  - Max Discharge Temp        :  60 C
  - Min Power Reduction Temp  :  55 C
  - Min Discharge Temp        :  -30 C
  - Max Charge Temp           :  50 C
  - Min Charge Temp           :  0 C
  - Max Charge C-Rate         :  1.0
  - Min Discharge C-Rate      : 10.0

  - Cell mV Cutback Start     :  3300 mV
  - Cell mV Cutback End       :  3050 mV

  - Num Charge Cycles         :  726

  - BMS Total Bike Run Time   :  00:05:36
  - BMS Clock                 :  01/29/2015 15:44:10 ( 1422571450, 0x54CAB7BA )
  - Age of BMS Time Data      :  270 ms

  - Age of BMS Status Data    :  281 ms
  - Discrete Throttle En      :  Disabled

  CAN Status
  - Charger Attached          :   No
  - Batt Unbalanced           :   No
  - Batt Low                  :  Yes
  - Batt Full                 :   No
  - Batt Critically Low       :   No
  - Batt Temp High            :   No
  - Batt Temp Critically High :   No
  - Batt Temp Low             :   No
  - FETs Closed               :  Yes
  - Contactor Closed          :  Yes
  - Isolation Fault           :  No

  CAN Commands
  - Close FET                 :   No
  - Close Contactor           :   No
  - Connect Module            :  Yes
  - Key On                    :   No
  - Charger Connected         :  Yes
  - Time Since Cmds Last Sent : 1678 ms


****************************************
*             Sevcon Data              *
****************************************

  Received PDOs
  - Motor speed               :     0 RPM
  - Age of motor speed data   :    41 ms

  - Throttle Input Voltage    :     0 mV
  - Age of throttle data      :    67 ms

  - Motor Temp                :     4 C
  - Max Motor Temp This Ride  :     6 C
  - Age of motor temp data    :    99 ms

  - Controller Temp           :     1 C
  - Max Ctrl Temp This Ride   :     1 C
  - Age of ctrl temp data     :   132 ms

  - Battery Voltage           :    89.375 V
  - Capacitor Voltage         :    90.187 V
  - Contactor Coil Voltage    :   116.000 V
  - Age of voltage data       :   176 ms

  - Current Target            :     0 Amps
  - Motor Torque              :     0 ft-lbs ( 0 Nm )
  - Motor Power               :     0 Watts
  - Age of current data       :   228 ms

  - Speed Target              :     0 units?
  - Age of speed target data  :   250 ms

  - Digital Inputs 1-8        :  0x08


  Transmitted PDOs
  --Drive Control--
  - Max Batt Chg Current      :   -40 A
  - Max Batt Dishg Current    :   260 A
  - Time Since DrvCtrl Sent   :  2000 ms

  SDOs
  - Access Level              :        4
  - Motor Temp Control Mode   :     0x01
  - Odometer Km               :  57292.4
  - Odometer Miles            :  35583.9

  - Key on Hours              :  2096
  - Key on Minutes            :    50
  - Traction on Hours         :   369
  - Traction on Minutes       :    26

  - Max Eco Speed             :    95 MPH ( 153 KPH ) ( 6090 RPM )
  - Max Eco Torque            :   100 %
  - Max Eco Regen Coast Tq    :     0 %
  - Max Eco Regen Brake Tq    :    15 %

  - Sevcon Firmware Rev       : SN0058.04
  - Sevcon Hardware Rev       : 0x01040004
  - Sevcon Serial num         : 1211100573

  - In Operational Mode       : Yes

  Active Sevcon Faults
  - Number of Faults          :    0


*************************************************************
*                        Bike Status                        *
*************************************************************

***  Motor Controller
   - On                     : Yes
   - CAN connected          : Yes
   - CAN Operational        : Yes
   - In Operational Mode    : Yes
   - Motor Temp             :   5C - Normal
   - Controller Temp        :   0C - Normal
   - Enabled                :  No
     - Kickstand Switch
     - MBB charger connected
   - Number of Faults       :   0


***  Batteries
   - Num Modules in System  :   1
   - Num Registered Modules :   1
   - Total SOC              :   0 %
   - Total Capacity         :  92 AH
   - Remaining Capacity     :   0 AH
   - Total Energy Used      :1513 KWH
   - Throttle En Wire       :  Disabled

    ------------------------------------------------------------------------------------------------------------------------------------
     Num  Node Ver SOC  Cap(AH) Volts   SCVolts Bal(mV) Cur(A) HTemp LTemp ChgAtt Low Crit OvTmp UndTmp FETs Cont IsoErr IsoResK IsoCell
    +----+----+---+----+-------+-------+-------+-------+------+-----+-----+------+---+----+-----+------+----+----+------+-------+-------+
     00     8   40   0%  92      90.345  90.348  106       1      5C    5C  -      +   -    -     -      +    +    +          0   00     

***  Chargers

***  Info Messages
 - INFO    : Kickstand switch is in DOWN position
 - INFO    : MBB Charger Connected

*****************************************************************
*  Event Log
*****************************************************************

 Entry    Time of Log            Event                      Conditions
+--------+----------------------+--------------------------+----------------------------------
 06111     01/29/2015 15:33:33   Charging                   PackTemp: h  5C, l  5C, PackSOC:  0%, Vpack: 90.379V, BattAmps:   1, Mods: 10, MbbChgEn: Yes, BmsChgEn: No
 06113     01/29/2015 15:43:33   Charging                   PackTemp: h  5C, l  5C, PackSOC:  0%, Vpack: 90.350V, BattAmps:   1, Mods: 10, MbbChgEn: Yes, BmsChgEn: No

[kensiko]

In a cold region like mine (Quebec), I occasionally saw a situation where I plugged the bike and it would not start charging, this is always occurring at low temperature. I would not worry about it. Once the bike temperature stabilize over 0 C, it works.

[Erasmo]

Burton do you still have the dimensions of the controller cover?

[Burton]

Burton do you still have the dimensions of the controller cover?

If I were you I would simply make a template from scratch. I have a 2013 SR (which technically doesn't exist) with a top box mounting solution so anything I tell you will likely be wrong.

Look at the images in this thread. Get some cardboard, get some tape, and make a template for your own bike. If you really wanted to know the dimension for my highly customized bike I could get them for you as it isn't on the bike at the moment (though it will be soon as it is getting colder)

Note: the "cover" sides lip over the edge of the frame so I can simply move the sides out to remove this from the bike in a couple seconds and or reinstall it. So account for this in your final design.

[Erasmo]

Oh that's right yes. I'll look into it because the temperatures are steadily approaching below zero.

I'll probably tinker something together that is permanently mounted on the controller in the winter months.

[BrianTRice@gmail.com]

I think there's room for a generic plan for a controller cozy like the battery cozy that Aerostitch made for their FX commute trials.

[Burton]

I think there's room for a generally plan for a controller cozy like the battery cozy that Aerostitch made for their FX commute trials.
Sent from my iPhone using Tapatalk

Who is going to be making them?

If I had access to stock bikes I would have made a pattern a while ago This isn't something too hard to put in sketchup and prep a pdf for printing so others could make their own. That said if Zero does make one that would be best so long as it doesn't cost an arm and a leg