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Author Topic: Controller Issue? 2017 DSR  (Read 697 times)

Doc_Rock

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Controller Issue? 2017 DSR
« on: November 12, 2019, 08:16:28 AM »

Greetings All,
I currently have a 2017 Zero DSR with approx 37,000 miles and it's been trouble free until this past week. Basically I'm seeing an increase in energy consumption. Starting at 100% I would typically arrive at work in the low to mid 60's which actually corresponded nicely with the distance (approx 40 miles one way). Starting this past week I'm now arriving to work in the low 30's (nothing has changed in my riding style). The odd thing is if I stop for a couple of min I'll gain 10% back (no matter how low the SOC gets).  Does this sound like a controller or battery issue?
Thanks,
Dan
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Crilly

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Re: Controller Issue? 2017 DSR
« Reply #1 on: November 12, 2019, 09:39:05 AM »

Sounds like cold weather.
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BrianTRice@gmail.com

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Re: Controller Issue? 2017 DSR
« Reply #2 on: November 12, 2019, 10:34:29 AM »

I agree that cold weather effects are worth serious consideration.

Bike performance can degrade by 15-25% depending on how cold the weather is, particularly if riding in cold damp air or precipitation that lands on the battery case.

One mechanism for this performance reduction is that the chemistry winds up with increased resistance to current flow in cells at lower temperatures. The other is that colder air is denser (and wet air is much denser) which increases drag and the demand on the motor will be higher.

These effects usually start at about 45F (7C) and get more pronounced as it gets colder.

The effect of the SoC rising as you stand still is a little odd but can happen because the coldest cells probably absorb heat from their warmer neighbors (the cells not at the edge of the battery case).

First, what ambient temperature are you riding in? If you check battery temperature on the Zero app, does it seem to dip as you ride (this is less certain because there are multiple sensors but can happen)?

My typical suggestion for this is to try covering the battery securely with an insulating sheet, just enough to keep the cold air from directly contacting the battery case. If you put a sheet of hard plastic (â…›" thick neoprene or polycarbonate) behind the front cover, you might see a good amount of your range/performance return.

Now, there may be another explanation that is about how SoC is computed (it's not a direct measurement; the firmware has algorithms to decide what to show you) where maybe the cold weather is throwing it for a loop. But I can only guess that if it's true, then SoC will probably act more normal the more you ride in cold weather.
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Current: 2020 DSR, 2012 Suzuki V-Strom
Former: 2016 DSR, 2013 DS

Doc_Rock

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Re: Controller Issue? 2017 DSR
« Reply #3 on: November 13, 2019, 09:33:30 PM »

Thanks so much for the response. The morning temps have been right around the mid to upper 40s. The bike gets charged every night (usually return home with around 30% remaining) but when the bike gets to 100% I kill the power (energy is still applied after it reaches 100% for about an hour). The other night I left charging for several hours after reaching 100% thinking it might also be a cell balance issue and that seemed to help significantly. For the past two mornings I've been arriving at work with 60% remaining..  Same outside temps..
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BrianTRice@gmail.com

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Re: Controller Issue? 2017 DSR
« Reply #4 on: November 14, 2019, 03:41:51 AM »

Okay. Cell balance issues could explain the SoC variation, which often goes conservative if a cell is particularly low.

As long as keeping the balance low doesn't require a lot of fiddling, you're probably fine and this is just an occasional maintenance hassle (like tire pressure checks). Remember you can check cell balance in the app, and "100%" usually has a cell balancing period.

Usually, you can just cut power after the charging light goes solid or such, but the app will also tell if / when cell imbalance gets really low. It probably only takes an hour typically.
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Current: 2020 DSR, 2012 Suzuki V-Strom
Former: 2016 DSR, 2013 DS

Doc_Rock

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Re: Controller Issue? 2017 DSR
« Reply #5 on: November 14, 2019, 06:05:10 AM »

Thanks Brian!! Appreciate the response and will certainly keep an eye on the cell balance!
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