ElectricMotorcycleForum.com
Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: jesus on March 17, 2023, 12:39:49 AM
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ok guys I bought a 2013 zero S.
when I turned it, dash came up flashing battery level.
I put multimeter to battery contacts I got 95v
at this point I'm assuming the battery is not getting charge.
I will be diagnosing chargers, charger fuse.
but I don't have a lot of information regarding the ccu
what is it what does it look like where is it located ???
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I pressed the reset button, nothing happened no lights.
am I supposed to get lights when pressing ?????
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i read a little about Dr bass standalone battery trailer.
1) When I enable contactor standalone.... am I then able to connect to MBB BMS and read cell voltages ?
2) Where is the circuitry designed to cutoff charge ??? is it the ccu? is it the BMS? are the mean well PSU connected to the contactor? sorry for ignorance, complicated motorcycle...
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Hey,
the 2013 S has dumb chargers. They are just mean-well LED power supplies. They are trying to reach 116 V and won't go any higher, therefore that is automatically gonna end the charging.
The 2013 S has the CCU, because the chargers are dumb and have no control whatsoever. The CCU takes the voltage from the chargers, activate the contactor and passes the current through to the battery.
Just to understand you correctly, when you turn the key nothing happens?
And when you connect the charging cable, nothing happens?
Any silent clicks from the bottom of the bike? (that'd be the chargers, they should click)
And loud click? (that'd be the contactor)
Any green blinking charging light?
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I will try charging the bike again tomorrow.
let's say one of the 28 cells is over charged, and the pack keeps charging what mechanism wether ccu or BMS cuts out the charge to prevent overcharging
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While the owner's manual doesn't have lot of information, there are some details in it that might help.
https://prismic-io.s3.amazonaws.com/zero-cms-disco/f1a79d1b-c177-4f25-83a8-0ea854d70715_OM-SDS-MY13.pdf
Available from the Zero website: https://www.zeromotorcycles.com/owner-resources
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The BMS will not allow any cell to be overcharged. It'll open the contactor.
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ok sounds like the wiring of the contactor is more complex than described in the wiring diagram.
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ok today I tried charging the bike.
-theres a clicking sound every second or so close to the chargers
-the chargers are energized
-when I turn the key, error O1 comes up
please see two videos attached
https://youtu.be/jUhJaUy124M
https://youtu.be/Fbh7dCqbDBQ
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Hey, I checked with my 2013 and it's exactly the same display. I did not know that o1 is supposed to be an error. I have it, too. The only difference is that my bike clicks and closes the main contactor.
I would almost say your bike is perfectly fine, possibly including the chargers, it's just discharged a bit too low so it does not allow to close the contactor, which also prevents it from charging. You must find a different way to charge it a bit until it's in its normal voltage range again (I am sure someone has figured out how to do that).
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The o l in the display is not an error code. Dash error codes came later.
At the front of the bike battery there is a round window where you can see the BMS LEDs blinking. Look up your manual online and see what your flashing LEDs say, if anything.
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- the front BMS lights never blink, even when I press reset, only ccu blinks
- I will check today that chargers are outputting correct voltage
- it is possible that battery is too discharged to allow charging. from my estimate the cells are at 3.4v maybe for the chemistry zero is using this is too discharged.
I could still try to bypass charging system and charge the battery a little bit, I can either connect to the contactor doghouse. or trigger the contactor.
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Hey jesus,
checking the chargers is a good idea (if you can get to them without cutting the wires, which is what I did).
You mentioned your battery has 95V "at the terminals". What does that mean, which terminals?
Zero is using NMC cells, they are happy at 3,4 V and that's a good state for long time storage (just a bit risky in case they'd drop any lower, which didn't happen in your case).
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"at the terminals" I removed the doghouse cover and measure before the contactor.
if NMC is fine at 3.4v for cell why is the BMS shutting down?
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If the battery voltage is at 95v the average cell voltage will be 3.39v but some cells will be higher and some will be lower. It only takes one low cell to shut things down. I would suggest getting two small cheap chargers made for a 48 volt SLA bike battery. One or two amp output would be fine. They will each put out 60v so wire the outputs in series and you can charge up to 120v. Use them to get the battery to something like 100v. Don't let the battery get near 116v because you can't know what voltage the individual cells are at and you are bypassing the contactor. Then try charging with the OBC. Good luck!
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today I charged the bike with my benchtop power supply set to 105vdc 3amps.
I only charged for 1hour as I ran out of time.
my multimeter read 101v after charging.
the meanwell still don't charge, the BMS light still haven't seen them.
tomorrow I will spend more time charging to maybe 108v
I'm not sure if the bms is dead or is triggering faults or something else???
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101 V should be enough. Maybe you can access the BMS to see if it has any faults. There is a UART interface to it, but I'm not sure if it can be used without the bike being turned on, maybe someone can help with that info