ElectricMotorcycleForum.com
Makes And Models => Zero Motorcycles Forum | 2012 and older => Topic started by: JESSinSD on February 26, 2019, 07:37:00 AM
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Hi Zero folks. I have a 2016 FXS and it has nothing but issues since I bought it.
Now, it is barely out of warranty and when I went to plug it in, it wouldn't charge. I was told that the charging module was bad. (Green Watt Power EVC-116-720). Found a new one on eBay and it started charging just fine. But after about 20 minutes, it will shut off. I reset the BMS on the batteries as per the AMAZING Unofficial Zero Manual at https://zeromanual.com/wiki/Unofficial_Service_Manual#Charger.
Now, it won't charge at all.
Any advice is most appreciated.
Jessica in San Diego
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I'm glad the unofficial manual helped out. Have you checked the logs? Are there any other symptoms, maybe with the 12V system?
The DC-DC converter sometimes triggers charger failures.
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Thanks for the response. Yes, the manual is incredible. SO MUCH GOOD STUFF! I owe that guy a steak dinner and a beer.
I downloaded the logs today and currently in the process of parsing the logs and analyzing the data. However, being a bit of a newbie on electric bike repair, I am not certain what I am looking at. I am sure the answer (or a clue) is in there somewhere. I noticed that the charger heated up quite a bit. I am wondering if there is a bad or dirty contact somewhere. I also noticed that there was very little dialectic grease in one of the battery modules whereas the other one is packed.
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I'm the main editor of the unofficial manual, so thanks.
Log interpretation is an arcane skillset, for sure. You can forward those logs to Zero for advice, although I admit often enough they'll just tell you to go to a dealer with no real guidance. And it could be that they don't know, either.
Uploading the logs to the forum for others to check might help if you're comfortable with that. The vehicle's VIN and some other information will be in there.
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Wow.. Great job!! ;D You are right. Zero Customer Service has all but ignored me and/or just told me to bring the bike to the dealer. But I am an "unofficial" Electrical Engineer so I am going to take a crack at it and do my best to decipher some of the data. It is actually well time stamped and intuitive. As I trip over some of the acronyms and nomenclatures, I may resort to this thread and your manual for advice. Stay tuned.
I want to get this bike running again. Again, thanks for your wealth of knowledge and documentation. Without it, I would be absolutely blind. Now, because of your manual, I have hope and troubleshooting ammunition.
Cheers,
jess
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No problem. You've probably found the FX wiring diagram which I did not develop, notably, since I've only had a DS+DSR, personally.
You'll find that others have posted logs in the forum. It's possible that a message of note near the time when the error occurs can be found by a search (here or via Google, etc).
Also, one vague recommendation is to look for patterns, and see whether a sequence of events that normally happens is missing some critical event when things go wrong. This recommendation works better when you can compare a working bike with a broken/glitchy one...
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How do you download the logs and view them?
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Connect to the bike with Bluetooth according to instructions in the owner's manual, then there is an option in the app to download and email the logs to a specified address.
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Here is the link to parse the binary code so you can read the logs: http://home.hasslers.net/zerologparser/log_parser.php
Here is a link with a wealth of knowledge: http://home.hasslers.net/zerologparser/
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Hi Brian. So I downloaded the logs from yesterday's charging attempt. It would charge for a few minutes, then quit. The charging module got quite warm. Almost to hot to touch. I think the clue is in here somewhere, I have the whole log but didn't want to inundate you.
08879 02/25/2019 11:24:54 Exiting Hibernate
08880 02/25/2019 11:24:54 DEBUG: Entered Idle State
08881 02/25/2019 11:24:54 System Turned On
08882 02/25/2019 11:24:54 DEBUG: Entered Standby State
08883 02/25/2019 11:24:55 DEBUG: CAN Link Is Up
08884 02/25/2019 11:24:55 DEBUG: Entered Charging State
08885 02/25/2019 11:24:56 Discharge level 010 AH, SOC: 60%, I: 0A, L:3697, l:3692, H:3703, B:006, PT:012C, BT:012C, PV:103602, M:Charge
08886 02/25/2019 11:24:56 SOC:8974,21913,10711,26000,59,57,60,0
08887 02/25/2019 11:24:56 Contactor drive turned on Pack V: 103616mV, Switched V: 90308mV, Duty Cycle: 39%
08888 02/25/2019 11:24:56 Contactor was Closed Pack V: 103616mV, Switched V: 90308mV, Prechg Pct: 87%, Dischg Cur: -698mA
08889 02/25/2019 11:24:56 DEBUG: CAN Receiving Syncs
08890 02/25/2019 11:32:19 DEBUG: Entered Standby State
08891 02/25/2019 11:32:19 DEBUG: CAN NOT Receiving Syncs
08892 02/25/2019 11:32:20 System Turned Off
08893 02/25/2019 11:32:21 DEBUG: CAN Link Is Down
08894 02/25/2019 11:32:21 DEBUG: Entered Idle State
08895 02/25/2019 11:32:21 Contactor was Opened Pack V: 104409mV, Switched V: 103030mV, Prechg Pct: 98%, Dischg Cur: 0mA
08896 02/25/2019 11:32:24 System Turned On
08897 02/25/2019 11:32:24 DEBUG: Entered Standby State
08898 02/25/2019 11:32:25 DEBUG: CAN Link Is Up
08899 02/25/2019 11:32:25 DEBUG: Entered Running State
08900 02/25/2019 11:32:26 Discharge level 010 AH, SOC: 60%, I: 0A, L:3722, l:3705, H:3727, B:005, PT:013C, BT:020C, PV:104303, M:Bike On
08901 02/25/2019 11:32:26 SOC:8976,21913,10347,26000,61,59,60,-2
08902 02/25/2019 11:32:26 Discharge cutback 70%
08903 02/25/2019 11:32:26 181A
08904 02/25/2019 11:32:26 DEBUG: CAN Receiving Syncs
08905 02/25/2019 11:32:27 Contactor drive turned on Pack V: 104297mV, Switched V: 94129mV, Duty Cycle: 39%
08906 02/25/2019 11:32:27 Contactor was Closed Pack V: 104297mV, Switched V: 94129mV, Prechg Pct: 90%, Dischg Cur: 0mA
08907 02/25/2019 11:33:26 Discharge level 010 AH, SOC: 59%, I: 0A, L:3713, l:3706, H:3718, B:005, PT:013C, BT:020C, PV:104037, M:Bike On
08908 02/25/2019 11:33:26 SOC:9105,21913,10347,26000,61,58,59,-1
08909 02/25/2019 11:34:26 Discharge level 010 AH, SOC: 59%, I: 0A, L:3709, l:3705, H:3715, B:006, PT:013C, BT:021C, PV:103937, M:Bike On
08910 02/25/2019 11:34:26 SOC:9125,21913,10347,26000,61,58,59,0
08911 02/25/2019 11:35:26 Discharge level 010 AH, SOC: 59%, I: 0A, L:3708, l:3706, H:3713, B:005, PT:013C, BT:021C, PV:103889, M:Bike On
08912 02/25/2019 11:35:26 SOC:9190,21913,10347,26000,61,58,59,0
08913 02/25/2019 11:36:26 Discharge level 010 AH, SOC: 59%, I: 0A, L:3706, l:3705, H:3712, B:006, PT:013C, BT:021C, PV:103852, M:Bike On
08914 02/25/2019 11:36:26 SOC:9200,21913,10347,26000,61,58,59,0
08915 02/25/2019 11:36:34 DEBUG: CAN Link Is Down
08916 02/25/2019 11:36:34 DEBUG: CAN Link Is Up
08917 02/25/2019 11:36:44 DEBUG: CAN Link Is Down
08918 02/25/2019 11:36:44 DEBUG: CAN Link Is Up
08919 02/25/2019 11:36:47 DEBUG: CAN Link Is Down
08920 02/25/2019 11:36:47 DEBUG: CAN Link Is Up
08921 02/25/2019 11:37:26 Discharge level 010 AH, SOC: 58%, I: 0A, L:3705, l:3704, H:3711, B:006, PT:013C, BT:021C, PV:103823, M:Bike On
08922 02/25/2019 11:37:26 SOC:9203,21913,10347,26000,61,58,58,0
08923 02/25/2019 11:37:59 DEBUG: CAN Link Is Down
08924 02/25/2019 11:37:59 DEBUG: CAN Link Is Up
08925 02/25/2019 11:38:26 Discharge level 010 AH, SOC: 58%, I: 0A, L:3705, l:3704, H:3710, B:005, PT:013C, BT:021C, PV:103803, M:Bike On
08926 02/25/2019 11:38:26 SOC:9203,21913,10347,26000,61,58,58,0
08927 02/25/2019 11:38:59 DEBUG: CAN Link Is Down
08928 02/25/2019 11:38:59 DEBUG: CAN Link Is Up
08929 02/25/2019 11:39:12 DEBUG: CAN Link Is Down
08930 02/25/2019 11:39:12 DEBUG: CAN Link Is Up
08931 02/25/2019 11:39:26 Discharge level 010 AH, SOC: 58%, I: 0A, L:3704, l:3704, H:3710, B:006, PT:013C, BT:022C, PV:103781, M:Bike On
08932 02/25/2019 11:39:26 SOC:9203,21913,10347,26000,61,58,58,0
08933 02/25/2019 11:40:26 Discharge level 010 AH, SOC: 58%, I: 0A, L:3703, l:3703, H:3709, B:006, PT:013C, BT:022C, PV:103763, M:Bike On
08934 02/25/2019 11:40:26 SOC:9203,21913,10347,26000,61,58,58,0
08935 02/25/2019 11:40:31 DEBUG: CAN Link Is Down
08936 02/25/2019 11:40:31 DEBUG: CAN Link Is Up
08937 02/25/2019 11:40:40 DEBUG: CAN Link Is Down
08938 02/25/2019 11:40:40 DEBUG: CAN Link Is Up
08939 02/25/2019 11:40:41 DEBUG: CAN Link Is Down
08940 02/25/2019 11:40:41 DEBUG: CAN Link Is Up
08941 02/25/2019 11:41:26 Discharge level 010 AH, SOC: 58%, I: 0A, L:3703, l:3703, H:3708, B:005, PT:013C, BT:022C, PV:103745, M:Bike On
08942 02/25/2019 11:41:26 SOC:9238,21913,10347,26000,61,58,58,0
08943 02/25/2019 11:42:26 Discharge level 010 AH, SOC: 58%, I: 0A, L:3702, l:3702, H:3708, B:006, PT:013C, BT:022C, PV:103727, M:Bike On
08944 02/25/2019 11:42:26 SOC:9383,21913,10347,26000,61,57,58,0
08945 02/25/2019 11:42:35 DEBUG: CAN Link Is Down
08946 02/25/2019 11:42:35 DEBUG: CAN Link Is Up
08947 02/25/2019 11:42:47 DEBUG: CAN Link Is Down
08948 02/25/2019 11:42:47 DEBUG: CAN Link Is Up
08949 02/25/2019 11:43:26 Discharge level 010 AH, SOC: 58%, I: 0A, L:3701, l:3701, H:3707, B:006, PT:013C, BT:022C, PV:103714, M:Bike On
08950 02/25/2019 11:43:26 SOC:9416,21913,10347,26000,61,57,58,0
08951 02/25/2019 11:43:26 DEBUG: CAN Link Is Down
08952 02/25/2019 11:43:26 DEBUG: CAN Link Is Up
08953 02/25/2019 11:43:58 DEBUG: CAN Link Is Down
08954 02/25/2019 11:43:58 DEBUG: CAN Link Is Up
08955 02/25/2019 11:44:16 DEBUG: CAN Link Is Down
08956 02/25/2019 11:44:16 DEBUG: CAN Link Is Up
08957 02/25/2019 11:44:26 Discharge level 010 AH, SOC: 58%, I: 0A, L:3701, l:3701, H:3706, B:005, PT:013C, BT:022C, PV:103702, M:Bike On
08958 02/25/2019 11:44:26 SOC:9421,21913,10347,26000,61,57,58,0
08959 02/25/2019 11:44:44 DEBUG: CAN Link Is Down
08960 02/25/2019 11:44:44 DEBUG: CAN Link Is Up
08961 02/25/2019 11:44:49 DEBUG: CAN Link Is Down
08962 02/25/2019 11:44:49 DEBUG: CAN Link Is Up
08963 02/25/2019 11:44:50 DEBUG: CAN Link Is Down
08964 02/25/2019 11:44:50 DEBUG: CAN Link Is Up
08965 02/25/2019 11:45:22 DEBUG: CAN Link Is Down
08966 02/25/2019 11:45:22 DEBUG: CAN Link Is Up
08967 02/25/2019 11:45:26 Discharge level 010 AH, SOC: 57%, I: 0A, L:3701, l:3701, H:3706, B:005, PT:013C, BT:022C, PV:103686, M:Bike On
08968 02/25/2019 11:45:26 SOC:9422,21913,10347,26000,61,57,57,0
08969 02/25/2019 11:45:34 DEBUG: CAN Link Is Down
08970 02/25/2019 11:45:34 DEBUG: CAN Link Is Up
08971 02/25/2019 11:46:26 Discharge level 010 AH, SOC: 57%, I: 0A, L:3700, l:3700, H:3706, B:006, PT:013C, BT:022C, PV:103671, M:Bike On
08972 02/25/2019 11:46:26 SOC:9422,21913,10347,26000,61,57,57,0
08973 02/25/2019 11:47:26 Discharge level 010 AH, SOC: 57%, I: 0A, L:3700, l:3700, H:3706, B:006, PT:013C, BT:022C, PV:103663, M:Bike On
08974 02/25/2019 11:47:26 SOC:9422,21913,10347,26000,61,57,57,0
08975 02/25/2019 11:48:26 Discharge level 010 AH, SOC: 57%, I: 0A, L:3698, l:3698, H:3705, B:007, PT:013C, BT:022C, PV:103647, M:Bike On
08976 02/25/2019 11:48:26 SOC:9422,21913,10347,26000,61,57,57,0
08977 02/25/2019 11:49:26 Discharge level 010 AH, SOC: 57%, I: 0A, L:3698, l:3698, H:3705, B:007, PT:013C, BT:022C, PV:103636, M:Bike On
08978 02/25/2019 11:49:26 SOC:9422,21913,10347,26000,61,57,57,0
08979 02/25/2019 11:50:26 Discharge level 010 AH, SOC: 57%, I: 0A, L:3698, l:3698, H:3705, B:007, PT:013C, BT:022C, PV:103623, M:Bike On
08980 02/25/2019 11:50:26 SOC:9422,21913,10347,26000,61,57,57,0
08981 02/25/2019 11:51:26 Discharge level 010 AH, SOC: 57%, I: 0A, L:3697, l:3697, H:3704, B:007, PT:014C, BT:022C, PV:103610, M:Bike On
08982 02/25/2019 11:51:26 SOC:9422,21913,10347,26000,61,57,57,0
08983 02/25/2019 11:52:26 Discharge level 010 AH, SOC: 57%, I: 0A, L:3697, l:3697, H:3703, B:006, PT:014C, BT:022C, PV:103598, M:Bike On
08984 02/25/2019 11:52:26 SOC:9422,21913,10347,26000,61,57,57,0
08985 02/25/2019 11:53:03 Contactor was Opened Pack V: 103592mV, Switched V: 102203mV, Prechg Pct: 98%, Dischg Cur: 0mA
08986 02/25/2019 11:53:03 System Turned Off
08987 02/25/2019 11:53:04 DEBUG: CAN NOT Receiving Syncs
08988 02/25/2019 11:53:04 DEBUG: CAN Link Is Down
08989 02/25/2019 11:53:04 DEBUG: Entered Idle State
08990 02/25/2019 11:53:11 Discharge level 010 AH, SOC: 57%, I: 0A, L:3700, l:3700, H:3705, B:005, PT:013C, BT:022C, PV:103675, M:Idle
08991 02/25/2019 11:53:11 SOC:9422,21913,10347,26000,61,57,57,0
08992 02/25/2019 11:53:12 System Turned On
08993 02/25/2019 11:53:12 DEBUG: Entered Running State
08994 02/25/2019 11:53:12 DEBUG: CAN Link Is Up
08995 02/25/2019 11:53:13 DEBUG: Entered Charging State
08996 02/25/2019 11:53:14 Discharge level 010 AH, SOC: 57%, I: 0A, L:3700, l:3700, H:3706, B:006, PT:014C, BT:022C, PV:103678, M:Charge
08997 02/25/2019 11:53:14 SOC:9422,21913,10347,26000,61,57,57,0
08998 02/25/2019 11:53:14 Contactor drive turned on Pack V: 103682mV, Switched V: 91608mV, Duty Cycle: 39%
08999 02/25/2019 11:53:14 Contactor was Closed Pack V: 103682mV, Switched V: 91608mV, Prechg Pct: 88%, Dischg Cur: 0mA
09000 02/25/2019 11:53:14 DEBUG: CAN Receiving Syncs
09001 02/25/2019 12:03:14 Discharge level 009 AH, SOC: 61%, I: -2A, L:3747, l:3719, H:3753, B:006, PT:014C, BT:025C, PV:105030, M:Charge
09002 02/25/2019 12:03:14 SOC:8647,21913,9862,26000,63,60,61,-4
09003 02/25/2019 12:04:22 DEBUG: Entered Running State
09004 02/25/2019 12:04:22 DEBUG: CAN NOT Receiving Syncs
09005 02/25/2019 12:04:23 Discharge level 009 AH, SOC: 61%, I: 0A, L:3734, l:3717, H:3737, B:003, PT:014C, BT:025C, PV:104583, M:Bike On
09006 02/25/2019 12:04:23 SOC:8668,21913,9807,26000,63,60,61,-3
09007 02/25/2019 12:04:23 Discharge cutback 64%
09008 02/25/2019 12:04:23 166A
09009 02/25/2019 12:04:24 DEBUG: CAN Receiving Syncs
09010 02/25/2019 12:05:23 Discharge level 009 AH, SOC: 61%, I: 0A, L:3725, l:3719, H:3728, B:003, PT:014C, BT:024C, PV:104330, M:Bike On
09011 02/25/2019 12:05:23 SOC:8751,21913,9807,26000,63,60,61,-1
09012 02/25/2019 12:06:21 Contactor was Opened Pack V: 104239mV, Switched V: 102912mV, Prechg Pct: 98%, Dischg Cur: 0mA
09013 02/25/2019 12:06:22 System Turned Off
09014 02/25/2019 12:06:22 DEBUG: CAN NOT Receiving Syncs
09015 02/25/2019 12:06:23 DEBUG: CAN Link Is Down
09016 02/25/2019 12:06:23 DEBUG: Entered Idle State
09017 02/25/2019 12:06:29 Current Sensor Zeroed old: 2519mV, new: 2519mV, corrfact: 237
09018 02/25/2019 12:06:30 Discharge level 009 AH, SOC: 61%, I: 0A, L:3724, l:3720, H:3727, B:003, PT:014C, BT:024C, PV:104317, M:Idle
09019 02/25/2019 12:06:30 SOC:8763,21913,9807,26000,63,60,61,0
09020 02/25/2019 12:06:35 System Turned On
09021 02/25/2019 12:06:35 DEBUG: Entered Running State
09022 02/25/2019 12:06:35 DEBUG: CAN Link Is Up
09023 02/25/2019 12:06:36 Discharge level 009 AH, SOC: 61%, I: 0A, L:3722, l:3719, H:3726, B:004, PT:014C, BT:024C, PV:104255, M:Bike On
09024 02/25/2019 12:06:36 SOC:8763,21913,9807,26000,63,60,61,0
09025 02/25/2019 12:06:37 DEBUG: CAN Receiving Syncs
09026 02/25/2019 12:06:37 Contactor drive turned on Pack V: 104249mV, Switched V: 91923mV, Duty Cycle: 39%
09027 02/25/2019 12:06:37 Contactor was Closed Pack V: 104249mV, Switched V: 91923mV, Prechg Pct: 88%, Dischg Cur: 0mA
09028 02/25/2019 12:07:11 Contactor was Opened Pack V: 104203mV, Switched V: 102793mV, Prechg Pct: 98%, Dischg Cur: 0mA
09029 02/25/2019 12:07:11 System Turned Off
09030 02/25/2019 12:07:12 DEBUG: CAN NOT Receiving Syncs
09031 02/25/2019 12:07:12 DEBUG: CAN Link Is Down
09032 02/25/2019 12:07:12 DEBUG: Entered Idle State
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IAW the KISS principle and the issue with the CAN bus link going up and down - check for loose cable, socket, or maybe a bent pin.
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Great advice. Thank You. I think it could just be a bad charger. I bought the second one on eBay. Hoping and waiting for DigiNow to come out with a better solution.
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Hi Jessica,
I am the owner of a 2016 FXS too. I think I am having a similar problem to yours. I am stuck at a simpler step though, which is finding the BMS reset buttons. Would you be able to tell me where they are located on the bike? I've spent 45 minutes looking for them and can only find the "big" com plug.
Thank you in advance :)
Did changing the charger a second time solve your issue?
Best