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Tech => Parts, Mods And Hacks => Topic started by: Wimpie on December 08, 2022, 10:09:04 PM

Title: Connecting new diy battery to the controller zero ds
Post by: Wimpie on December 08, 2022, 10:09:04 PM: Anyone experience the build of a new battery for a zero.
Connecting the battery to the controller is poorly documented.. could use some advice.
Title: Re: Connecting new diy battery to the controller zero ds
Post by: TEV on December 09, 2022, 05:27:51 PM: Quote from: Wimpie on December 08, 2022, 10:09:04 PM
Anyone experience the build of a new battery for a zero.
Connecting the battery to the controller is poorly documented.. could use some advice.

In my opinion, the only way to do it will be to build a battery pack with cells that have the same voltage limits like the original Battery pack, and use the original BMS (like me, and others did with the old style of battery pack of the 2010 Zero model). This is because everything is controlled by a main board, and it will not recognize your after market BMS.

Another way is to buy the cable and software (~ $1.000,00) for the controller, and bypass the main board, but then you will have to make your own dashboard, that will show you the data from your BMS, and speedometer.

Good luck.

Tom
Title: Re: Connecting new diy battery to the controller zero ds
Post by: Wimpie on December 12, 2022, 10:44:58 PM: hi Tom, thanks..

The BMS is gone.. dead.. it was the reason why the battery got drained completely..

What do you mean with 'controlled by the main board'.
Is that a board sitting on the BMS?

also.. what cable and software are you referring to for the controller?

thanks again

wim
Title: Re: Connecting new diy battery to the controller zero ds
Post by: TEV on December 12, 2022, 11:12:29 PM: Quote from: Wimpie on December 12, 2022, 10:44:58 PM

What do you mean with 'controlled by the main board'.

This: https://zeromanual.com/wiki/Gen2/Main_Bike_Board
Title: Re: Connecting new diy battery to the controller zero ds
Post by: TEV on December 12, 2022, 11:20:11 PM: Quote from: Wimpie on December 12, 2022, 10:44:58 PM
what cable and software are you referring to for the controller?

This: https://www.thunderstruck-ev.com/sevcon-gen4-pc-based-programming-kit.html

You may find the software free here: https://www.electricmotorcycleforum.com/boards/index.php?topic=11302.0

Good luck.

Tom
Title: Re: Connecting new diy battery to the controller zero ds
Post by: Wimpie on December 20, 2022, 02:32:05 PM: thanks a lot tom.. will have a look into that..

the only thing that I see wright now is that it's software you may need if you use the controller with another motor..
Since I'm planning to use it with the same motor.. I don't think I need the programmer..

I think I need to know what signals go from BMS to controller and vice versa.. also, where the f*ck is the dc to dc converter :)

thanks again

wim
Title: Re: Connecting new diy battery to the controller zero ds
Post by: TEV on December 20, 2022, 05:38:16 PM: Quote from: Wimpie on December 20, 2022, 02:32:05 PM
thanks a lot tom.. will have a look into that..

the only thing that I see wright now is that it's software you may need if you use the controller with another motor..
Since I'm planning to use it with the same motor.. I don't think I need the programmer..

Again, everything goes through the Zero, proprietary, Main board (even your throttle is connected to the Main Board, and then the Main Board is controlling the controller ;D) , that won't recognize your BMS: https://zeromanual.com/wiki/Gen2/Main_Bike_Board
Title: Re: Connecting new diy battery to the controller zero ds
Post by: TEV on December 20, 2022, 05:41:11 PM: Quote from: Wimpie on December 20, 2022, 02:32:05 PM
where the f*ck is the dc to dc converter :)

See here: https://www.youtube.com/watch?v=b8sBThmXJ54

and here: https://youtu.be/yig2RtRuIoY