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Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: StoneAgeMan on January 18, 2024, 09:51:08 AM
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2016 DSR, ~5330 miles, Firmware rev. 56
It had sat (in an unheated external garage) for 10 days (Jan 3rd through 16th)
Went to ride today (Jan 16th) and it won't run
Shows 00 volts (was around 34F outside)
Console red triangle flashes code 8 (2,3) Controller Area Network (CAN) Error
That shows up in the Dash Code and the MBB log also.
Dash Codes:
25 Contactor Open Warning
30 BMS Can Error
6 BMS Throttle Enable Wire Error
40 BMS Throttle En Wire Disable
48 SEVCON Startup Disable
49 Contactor Open Disable
similar codes as "Brand new 2022 FXE broken"
https://www.electricmotorcycleforum.com/boards/index.php?topic=11391.0
No BMS LED activity (all off), no response to soft reset (right) nor hard reset (left)
// Background info
Used 3-4 times a week for about 120 trips commuting from 10/10/2023 through 01/03/2024
17 miles each way, mostly freeway, typically end up around 40% battery left
Typical charge is after each commute, at 240V, and started about 2hrs+ after arrival home
Kept in unheated external garage, cold (17F outside low) for last few days
Last trip on 01/03/2024 and was charged successfully
08146 0 DEBUG: Reset: Power-On, External
08147 0 Power On Key Switch
08148 0 Key On
08149 0 CAN0 FORM error. count=1
08150 0 DEBUG: Resetting CAN0 due to error passive mode
08151 0 DEBUG: Module scheme changed from None mode to Stopped mode
08152 0 Module 00 Opening Contactor vmod: 0.000V, batt curr: 0A
08153 0 Module 01 Opening Contactor vmod: 0.000V, batt curr: 0A
08154 5 Entering Hibernate
08155 10 Disarmed PackTemp: h 156C, l 156C, PackSOC: 0%, Vpack:114.097V, MotAmps: 0, BattAmps: 0, Mods: 00, MotTemp:-100C, CtrlTemp:-100C, AmbTemp: 1C, MotRPM: 0, Odo: 8580km
08156 70 Disarmed PackTemp: h 156C, l 156C, PackSOC: 0%, Vpack:114.097V, MotAmps: 0, BattAmps: 0, Mods: 00, MotTemp:-100C, CtrlTemp:-100C, AmbTemp: 1C, MotRPM: 0, Odo: 8580km
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Let it warm up, at least past 35 deg F or so, see what it does.
If it has an internal heater for the battery, may have ran itself dead trying to keep battery warm.
Once it warms up, preferably in a warmer garage etc, slow charge it up, give it a good charge IF it takes it and see how it does.
Aaron
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Well the logs show that the battery is actually at 114V so that's a good sign. It shouldn't have run down a significant amount in 10 days especially not to 0V, unless there was a parasitic drain (there shouldn't be, that would mean your contactor is stuck shut somehow) that would probably take like a year or more. Wherever you're getting a 0V reading from that must just be because the contactor is open when you're taking it.
Letting things warm up and trying again would be a good idea, the bike should function at that temp (I've been riding around at below that the last couple weeks) but perhaps it's causing an issue somewhere with condensation or something like that. I don't know enough to say for sure but my best guess would be a faulty controller.
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Wherever you're getting a 0V reading from that must just be because the contactor is open when you're taking it.
Thanks for your response! I'm not actually "taking" a measurement, that's what shows on the dash (Console) when key is on, a double 00 next to an empty battery icon. The dash display goes through its normal startup process, then shows the double 00.
I had pulled off the little round covers from over the BMS (MBB?) LEDs and the two BMS reset buttons and there was No BMS LED activity (all were off). There was also no response (in the LEDs) to soft reset (right) nor hard reset (left). I do see a 'Software Reset' in the log (attaching seems to stall posting).
That makes me wonder if the BMS is simply not getting power somehow. Is it fused somewhere?
I don't know enough to say for sure but my best guess would be a faulty controller.
The controller had worked for charging on the 3rd, but it clearly is in a non-responding (frozen) state. Some of the logged values seem like from an un-powered input giving bogus readings. For example, PackTemp: h 156C, l 156C and Mods: 00, MotTemp:-100C,. Also the dates are missing after the Jan 3rd shutdown (so from the 16th on).
I had plugged it to charge (on 240v) later that day. It showed the green Charging LED but flashed the red triangle (continuously I think). Here's the log snippet showing that failed, I'm guessing that the incrementing numbers are elapsed milliseconds maybe(?):
08207 0 DEBUG: Reset: Power-On, External
08208 0 Power On Onboard Charger
08209 0 CAN0 FORM error. count=1
08210 0 DEBUG: Resetting CAN0 due to error passive mode
08211 0 Calex 720W Charger 0 Connected
08212 0 Calex 1200W Charger 1 Connected
08213 0 DEBUG: Module scheme changed from None mode to Charging mode
08214 0 Module 00 Opening Contactor vmod: 0.000V, batt curr: 0A
08215 0 Module 01 Opening Contactor vmod: 0.000V, batt curr: 0A
08216 4 Unknown Charger 5 Connected
08217 5 Entering Hibernate
08218 10 Charging PackTemp: h 156C, l 156C, AmbTemp: 4C, PackSOC: 0%, Vpack:114.451V, BattAmps: 0, Mods: 00, MbbChgEn: Yes, BmsChgEn: No
08219 186 Calex 720W Charger 0 Disconnected
08220 186 Calex 1200W Charger 1 Disconnected
08221 210 Calex 720W Charger 0 Connected
08222 210 Calex 1200W Charger 1 Connected
08223 610 Charging PackTemp: h 156C, l 156C, AmbTemp: 2C, PackSOC: 0%, Vpack:114.333V, BattAmps: 0, Mods: 00, MbbChgEn: Yes, BmsChgEn: No
08224 620 Entering Charge Standby Mode
08225 625 Module 00 Opening Contactor vmod: 0.000V, batt curr: 0A
08226 625 Module 01 Opening Contactor vmod: 0.000V, batt curr: 0A
08227 12/31/1969 23:31:29 Calex 720W Charger 0 Disconnected
08228 12/31/1969 23:31:29 Calex 1200W Charger 1 Disconnected
Beiow is the charging cycle from the last charge (Jan 3rd):
08066 0 DEBUG: Reset: Power-On, External
08067 0 Power On Onboard Charger
08068 0 CAN0 FORM error. count=1
08069 0 DEBUG: Resetting CAN0 due to error passive mode
08070 0 Calex 720W Charger 0 Connected
08071 0 Calex 1200W Charger 1 Connected
08072 0 DEBUG: Module scheme changed from None mode to Charging mode
08073 0 Module 00 Opening Contactor vmod: 0.000V, batt curr: 0A
08074 0 Module 01 Opening Contactor vmod: 0.000V, batt curr: 0A
08075 2 Module 00 CAN Link Up
08076 2 Module 00 Registered serial: 16qd2748, vmod: 101.997V
08077 01/03/2024 21:22:25 Sevcon Turned On
08078 01/03/2024 21:22:25 WARNING: Max allowed voltage difference is 500mV
08079 01/03/2024 21:22:26 Sevcon CAN Link Up
08080 01/03/2024 21:22:27 Unknown Charger 5 Connected
08081 01/03/2024 21:22:27 DEBUG: Sevcon Contactor Drive ON.
08082 01/03/2024 21:22:27 Battery module 151 contactor closed
08083 01/03/2024 21:22:27 Module 00 Opening Contactor vmod: 101.993V, batt curr: 1A
08084 01/03/2024 21:22:27 Module 01 Opening Contactor vmod: 0.000V, batt curr: 0A
08085 01/03/2024 21:22:27 Sevcon Turned Off
08086 01/03/2024 21:22:27 DEBUG: Sevcon Contactor Drive OFF
08087 01/03/2024 21:22:30 Sevcon Turned On
08088 01/03/2024 21:22:30 Sevcon CAN Link Down
08089 01/03/2024 21:22:31 Sevcon CAN Link Up
08090 01/03/2024 21:22:32 DEBUG: Sevcon Contactor Drive ON.
08091 01/03/2024 21:22:32 Module 00 Closing Contactor vmod: 102.058V, maxsys: 102.058V, minsys: 102.058V, diff: 0.000V, vcap: 90.875V, prechg: 89%
08092 01/03/2024 21:22:32 DEBUG: Module 00 Contactor is now Closed
08093 01/03/2024 21:22:32 INFO: Enabling Calex 720W Charger 0
08094 01/03/2024 21:22:32 INFO: Enabling Calex 1200W Charger 1
08095 01/03/2024 21:22:32 INFO: Enabling External Chg 0 Charger 2
08096 01/03/2024 21:22:32 INFO: Enabling External Chg 1 Charger 3
08097 01/03/2024 21:22:32 INFO: Enabling JIB Chargetank Charger 5
08098 01/03/2024 21:22:32 INFO: JIB Chargetank Charger 5 preemptively enabling
08099 01/03/2024 21:22:32 INFO: Disabling Calex 720W Charger 0
08100 01/03/2024 21:22:32 INFO: Disabling Calex 1200W Charger 1
08101 01/03/2024 21:22:32 INFO: Disabling External Chg 0 Charger 2
08102 01/03/2024 21:22:32 INFO: Disabling External Chg 1 Charger 3
08103 01/03/2024 21:22:33 Charging PackTemp: h 19C, l 18C, AmbTemp: 14C, PackSOC: 46%, Vpack:101.990V, BattAmps: 1, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08104 01/03/2024 21:22:40 INFO: Charge Tank Voltage 220VAC with input current = 10 Amps
08105 01/03/2024 21:22:40 Unknown Charger 5 Disconnected
08106 01/03/2024 21:22:40 INFO: Disabling JIB Chargetank Charger 5
08107 01/03/2024 21:22:40 INFO: Enabling Calex 720W Charger 0
08108 01/03/2024 21:22:40 INFO: Enabling Calex 1200W Charger 1
08109 01/03/2024 21:22:40 INFO: Enabling External Chg 0 Charger 2
08110 01/03/2024 21:22:40 INFO: Enabling External Chg 1 Charger 3
08111 01/03/2024 21:22:41 Unknown Charger 5 Connected
08112 01/03/2024 21:22:41 INFO: Enabling JIB Chargetank Charger 5
08113 01/03/2024 21:32:33 Charging PackTemp: h 19C, l 18C, AmbTemp: 13C, PackSOC: 51%, Vpack:103.458V, BattAmps: -22, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08114 01/03/2024 21:42:33 Charging PackTemp: h 19C, l 18C, AmbTemp: 14C, PackSOC: 53%, Vpack:103.801V, BattAmps: -18, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08115 01/03/2024 21:52:33 Charging PackTemp: h 20C, l 18C, AmbTemp: 15C, PackSOC: 56%, Vpack:104.359V, BattAmps: -24, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08116 01/03/2024 22:02:33 Charging PackTemp: h 20C, l 19C, AmbTemp: 16C, PackSOC: 59%, Vpack:104.935V, BattAmps: -24, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08117 01/03/2024 22:12:33 Charging PackTemp: h 20C, l 20C, AmbTemp: 17C, PackSOC: 62%, Vpack:105.693V, BattAmps: -21, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08118 01/03/2024 22:15:25 CAN0 FORM error. count=2
08119 01/03/2024 22:22:33 Charging PackTemp: h 21C, l 20C, AmbTemp: 17C, PackSOC: 65%, Vpack:106.407V, BattAmps: -24, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08120 01/03/2024 22:32:33 Charging PackTemp: h 21C, l 21C, AmbTemp: 18C, PackSOC: 69%, Vpack:107.287V, BattAmps: -21, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08121 01/03/2024 22:42:33 Charging PackTemp: h 22C, l 21C, AmbTemp: 18C, PackSOC: 72%, Vpack:108.197V, BattAmps: -18, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08122 01/03/2024 22:52:33 Charging PackTemp: h 23C, l 21C, AmbTemp: 19C, PackSOC: 76%, Vpack:109.306V, BattAmps: -19, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08123 01/03/2024 23:02:33 Charging PackTemp: h 23C, l 22C, AmbTemp: 19C, PackSOC: 80%, Vpack:110.365V, BattAmps: -18, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08124 01/03/2024 23:12:33 Charging PackTemp: h 23C, l 22C, AmbTemp: 19C, PackSOC: 83%, Vpack:111.227V, BattAmps: -18, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08125 01/03/2024 23:22:33 Charging PackTemp: h 24C, l 22C, AmbTemp: 19C, PackSOC: 86%, Vpack:112.047V, BattAmps: -17, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08126 01/03/2024 23:32:33 Charging PackTemp: h 24C, l 22C, AmbTemp: 20C, PackSOC: 88%, Vpack:112.909V, BattAmps: -20, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08127 01/03/2024 23:42:33 Charging PackTemp: h 24C, l 22C, AmbTemp: 20C, PackSOC: 91%, Vpack:113.768V, BattAmps: -21, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08128 01/03/2024 23:52:33 Charging PackTemp: h 25C, l 22C, AmbTemp: 20C, PackSOC: 95%, Vpack:114.615V, BattAmps: -15, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08129 01/03/2024 23:55:57 CAN0 BIT1 error. count=1
08130 01/04/2024 00:02:33 Charging PackTemp: h 25C, l 22C, AmbTemp: 20C, PackSOC: 98%, Vpack:115.564V, BattAmps: -17, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08131 01/04/2024 00:12:33 Charging PackTemp: h 25C, l 23C, AmbTemp: 20C, PackSOC:100%, Vpack:116.127V, BattAmps: -8, Mods: 01, MbbChgEn: Yes, BmsChgEn: No
08132 01/04/2024 00:18:43 Calex 720W Charger 0 Disconnected
08133 01/04/2024 00:18:43 Calex 1200W Charger 1 Disconnected
08134 01/04/2024 00:18:43 INFO: Disabling Calex 720W Charger 0
08135 01/04/2024 00:18:43 INFO: Disabling Calex 1200W Charger 1
08136 01/04/2024 00:19:12 Unknown Charger 5 Disconnected
08137 01/04/2024 00:19:12 DEBUG: Module scheme changed from Charging mode to Stopped mode
08138 01/04/2024 00:19:12 DEBUG: Module mode Change Does Not Require Disconnect
08139 01/04/2024 00:19:12 INFO: Disabling JIB Chargetank Charger 5
08140 01/04/2024 00:19:12 Power Off Onboard Charger
08141 01/04/2024 00:19:12 Sevcon Turned Off
08142 01/04/2024 00:19:12 Module 00 Opening Contactor vmod: 116.141V, batt curr: 0A
08143 01/04/2024 00:19:12 Module 01 Opening Contactor vmod: 0.000V, batt curr: 0A
08144 01/04/2024 00:19:12 INFO: Disabling External Chg 0 Charger 2
08145 01/04/2024 00:19:12 INFO: Disabling External Chg 1 Charger 3
Let it warm up, at least past 35 deg F or so, see what it does.
If it has an internal heater for the battery, may have ran itself dead trying to keep battery warm.
Once it warms up, preferably in a warmer garage etc, slow charge it up, give it a good charge IF it takes it and see how it does.
Aaron
Thanks for your response too! I don't think that there is any battery heater. It was refusing a charge yesterday, I'll try again tonight.
Steve
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Posting with attached trimmed log
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So, I have an update on this problem, because it came back this year, during a "freeze" (~28F, -2C). Basically the bike is no-go at key on, dash reports 00 for battery and has a large set of the 4X Error codes showing No CanBus. What had fixed it last year was putting it on a trailer and taking it to the dealer (it worked right there on the trailer). That was after about 6 days of non-freezing weather at home with no response.
The fix this year was done without a trailer, although there was still a 5-day down phase (with non-freezing but cold weather) :-). I had power-cycled the bike to On about every work-day while going by, to no success.
Today (day off) I plugged in my 1500 watt "shop" heater and directed it at the battery bottom, with a bit on the front. After about 40 minutes, I turned the key and the Battery was back at 100% :), no 4X error codes.
So all is well again (for now), I guess I'll have to get the baby a heated blanket or other block heater. 8)
For fun, I captured the BMS and MBB logs (note that the BMS logs were NOT retrievable for the above week until the fix). As the battery-savvy folks likely know, the only real clue in the MBB log entries was the "Invalid" (maxxed-out or all zero) BMS-related values like Pack Temp Hi/Low, Vpack, Mot Temp, etc.
Here's the key line. Note the Hi and Lo PackTemps are the same AND are on-fire:
08044 10 Disarmed PackTemp: h 156C, l 156C, PackSOC: 0%, Vpack:113.979V, MotAmps: 0, BattAmps: 0, Mods: 00, MotTemp:-100C, CtrlTemp:-100C, AmbTemp: 3C, MotRPM: 0, Odo:13176km
If anybody knows of a nice electric blankie or similar, let me know!
Thanks,
Steve