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Zero Motorcycles Forum | 2013+ / Re: 2015 FX: Random cut-offs that need power-cycling, problems with Zero Europe
« on: May 06, 2019, 09:03:25 PM »
Hi,
I have the same problem. It appeared shortly after I purchased my 2015 FX last summer (in July 2018).
Looking at the log files, it appears that the voltage of one of the two battery modules drops faster than the other and when the difference in voltage exceeds a certain limit, the bike disables the throttle. You then have to power cycle the bike to restart it.
The bike has been at the workshop on several occasions. Zero Europe updated the firmware the first time (it did not solve the issue). Then Zero replaced one of the BMS. It solved the issue for a few hundred km, but now the problem is back again
I tested each battery independently and realized that one battery is more powerful than the other (despite having both been manufactured the same year, in 2014). I get the feeling that the BMS or system that manages both BMS is unable to handle major differences in power/behavior between the two battery modules. What I do not understand is why Zero does not just put the bike in limp mode (e.g. isolate one of the two batteries and let the bike run in limp mode on just one battery - ideally the healthier one of the two.)
I am brining the bike back to the workshop. I am hoping that Zero will be able to find a definite solution to the problem as the unexpected throttle disable events can be dangerous if it happens in heavy traffic or at a critical junction, for instances. I love the FX, but have naturally lost confidence in it as a result.
Will keep you posted on progress.
Here are the details of the logs. You can see the voltage drop on one module (106V vs. 109V). It can happen at any SoC, at any load, in ECO or SPORT mode. Totally random.
07817 04/15/2019 06:47:51 WARNING: Max allowed voltage difference is 500mV
07818 04/15/2019 06:48:42 Riding PackTemp: h 22C, l 19C, PackSOC: 80%, Vpack:109.442V, MotAmps: 84, BattAmps: 57, Mods: 11, MotTemp: 35C, CtrlTemp: 24C, AmbTemp: 22C, MotRPM:2448, Odo:11159km
07819 04/15/2019 06:49:42 Riding PackTemp: h 23C, l 19C, PackSOC: 79%, Vpack:109.372V, MotAmps: 103, BattAmps: 84, Mods: 11, MotTemp: 38C, CtrlTemp: 24C, AmbTemp: 20C, MotRPM:2956, Odo:11159km
07820 04/15/2019 06:50:42 Riding PackTemp: h 23C, l 19C, PackSOC: 78%, Vpack:109.360V, MotAmps: -25, BattAmps: -14, Mods: 11, MotTemp: 39C, CtrlTemp: 22C, AmbTemp: 20C, MotRPM:2071, Odo:11160km
07821 04/15/2019 06:51:42 Riding PackTemp: h 23C, l 19C, PackSOC: 78%, Vpack:109.319V, MotAmps: 16, BattAmps: 7, Mods: 11, MotTemp: 40C, CtrlTemp: 22C, AmbTemp: 19C, MotRPM:2565, Odo:11161km
07822 04/15/2019 06:52:42 Riding PackTemp: h 24C, l 19C, PackSOC: 77%, Vpack:109.270V, MotAmps: 155, BattAmps: 62, Mods: 11, MotTemp: 40C, CtrlTemp: 21C, AmbTemp: 19C, MotRPM:1375, Odo:11162km
07823 04/15/2019 06:53:30 DEBUG: Module scheme changed from Running mode to Stopped mode
07824 04/15/2019 06:53:30 DEBUG: Module mode Change Does Not Require Disconnect
07825 04/15/2019 06:53:34 DEBUG: Module scheme changed from Stopped mode to Running mode
07826 04/15/2019 06:53:34 DEBUG: Module mode Change Does Not Require Disconnect
07827 04/15/2019 06:53:42 Riding PackTemp: h 24C, l 19C, PackSOC: 77%, Vpack:109.250V, MotAmps: 0, BattAmps: 0, Mods: 11, MotTemp: 42C, CtrlTemp: 21C, AmbTemp: 19C, MotRPM: 0, Odo:11162km
07828 04/15/2019 06:53:45 Power Off Key Switch
07829 04/15/2019 06:53:45 Sevcon Turned Off
07830 04/15/2019 06:53:45 Module 00 Opening Contactor vmod: 109.249V, batt curr: 0A
07831 04/15/2019 06:53:45 Module 01 Opening Contactor vmod: 106.418V, batt curr: 0A
07832 04/15/2019 06:53:45 INFO: Disabling External Chg 0 Charger 2
07833 04/15/2019 06:53:45 INFO: Disabling External Chg 1 Charger 3
07834 04/15/2019 06:53:46 CPU Soft Reset: Power Down Interrupted by Key On
07835 0 DEBUG: Reset: Software
07836 0 BMS Reset Software
07837 0 Key On
07838 0 DEBUG: Module scheme changed from None mode to Stopped mode
07839 0 Module 00 Opening Contactor vmod: 0.000V, batt curr: 0A
07840 0 Module 01 Opening Contactor vmod: 0.000V, batt curr: 0A
07841 0 DEBUG: Module scheme changed from Stopped mode to Running mode
07842 0 Module 01 CAN Link Up
07843 0 Module 01 Registered serial: 14sg0908, vmod: 106.435V
07844 04/15/2019 06:51:29 Module 00 CAN Link Up
07845 04/15/2019 06:51:29 Module 01 CAN Link Down
07846 04/15/2019 06:51:29 Sevcon Turned On
07847 04/15/2019 06:51:29 Module 00 CAN Link Down
07848 04/15/2019 06:51:29 Module 01 CAN Link Up
07849 04/15/2019 06:51:29 Module 00 CAN Link Up
07850 04/15/2019 06:51:29 Module 00 Registered serial: 14sg0870, vmod: 109.296V
I have the same problem. It appeared shortly after I purchased my 2015 FX last summer (in July 2018).
Looking at the log files, it appears that the voltage of one of the two battery modules drops faster than the other and when the difference in voltage exceeds a certain limit, the bike disables the throttle. You then have to power cycle the bike to restart it.
The bike has been at the workshop on several occasions. Zero Europe updated the firmware the first time (it did not solve the issue). Then Zero replaced one of the BMS. It solved the issue for a few hundred km, but now the problem is back again
I tested each battery independently and realized that one battery is more powerful than the other (despite having both been manufactured the same year, in 2014). I get the feeling that the BMS or system that manages both BMS is unable to handle major differences in power/behavior between the two battery modules. What I do not understand is why Zero does not just put the bike in limp mode (e.g. isolate one of the two batteries and let the bike run in limp mode on just one battery - ideally the healthier one of the two.)
I am brining the bike back to the workshop. I am hoping that Zero will be able to find a definite solution to the problem as the unexpected throttle disable events can be dangerous if it happens in heavy traffic or at a critical junction, for instances. I love the FX, but have naturally lost confidence in it as a result.
Will keep you posted on progress.
Here are the details of the logs. You can see the voltage drop on one module (106V vs. 109V). It can happen at any SoC, at any load, in ECO or SPORT mode. Totally random.
07817 04/15/2019 06:47:51 WARNING: Max allowed voltage difference is 500mV
07818 04/15/2019 06:48:42 Riding PackTemp: h 22C, l 19C, PackSOC: 80%, Vpack:109.442V, MotAmps: 84, BattAmps: 57, Mods: 11, MotTemp: 35C, CtrlTemp: 24C, AmbTemp: 22C, MotRPM:2448, Odo:11159km
07819 04/15/2019 06:49:42 Riding PackTemp: h 23C, l 19C, PackSOC: 79%, Vpack:109.372V, MotAmps: 103, BattAmps: 84, Mods: 11, MotTemp: 38C, CtrlTemp: 24C, AmbTemp: 20C, MotRPM:2956, Odo:11159km
07820 04/15/2019 06:50:42 Riding PackTemp: h 23C, l 19C, PackSOC: 78%, Vpack:109.360V, MotAmps: -25, BattAmps: -14, Mods: 11, MotTemp: 39C, CtrlTemp: 22C, AmbTemp: 20C, MotRPM:2071, Odo:11160km
07821 04/15/2019 06:51:42 Riding PackTemp: h 23C, l 19C, PackSOC: 78%, Vpack:109.319V, MotAmps: 16, BattAmps: 7, Mods: 11, MotTemp: 40C, CtrlTemp: 22C, AmbTemp: 19C, MotRPM:2565, Odo:11161km
07822 04/15/2019 06:52:42 Riding PackTemp: h 24C, l 19C, PackSOC: 77%, Vpack:109.270V, MotAmps: 155, BattAmps: 62, Mods: 11, MotTemp: 40C, CtrlTemp: 21C, AmbTemp: 19C, MotRPM:1375, Odo:11162km
07823 04/15/2019 06:53:30 DEBUG: Module scheme changed from Running mode to Stopped mode
07824 04/15/2019 06:53:30 DEBUG: Module mode Change Does Not Require Disconnect
07825 04/15/2019 06:53:34 DEBUG: Module scheme changed from Stopped mode to Running mode
07826 04/15/2019 06:53:34 DEBUG: Module mode Change Does Not Require Disconnect
07827 04/15/2019 06:53:42 Riding PackTemp: h 24C, l 19C, PackSOC: 77%, Vpack:109.250V, MotAmps: 0, BattAmps: 0, Mods: 11, MotTemp: 42C, CtrlTemp: 21C, AmbTemp: 19C, MotRPM: 0, Odo:11162km
07828 04/15/2019 06:53:45 Power Off Key Switch
07829 04/15/2019 06:53:45 Sevcon Turned Off
07830 04/15/2019 06:53:45 Module 00 Opening Contactor vmod: 109.249V, batt curr: 0A
07831 04/15/2019 06:53:45 Module 01 Opening Contactor vmod: 106.418V, batt curr: 0A
07832 04/15/2019 06:53:45 INFO: Disabling External Chg 0 Charger 2
07833 04/15/2019 06:53:45 INFO: Disabling External Chg 1 Charger 3
07834 04/15/2019 06:53:46 CPU Soft Reset: Power Down Interrupted by Key On
07835 0 DEBUG: Reset: Software
07836 0 BMS Reset Software
07837 0 Key On
07838 0 DEBUG: Module scheme changed from None mode to Stopped mode
07839 0 Module 00 Opening Contactor vmod: 0.000V, batt curr: 0A
07840 0 Module 01 Opening Contactor vmod: 0.000V, batt curr: 0A
07841 0 DEBUG: Module scheme changed from Stopped mode to Running mode
07842 0 Module 01 CAN Link Up
07843 0 Module 01 Registered serial: 14sg0908, vmod: 106.435V
07844 04/15/2019 06:51:29 Module 00 CAN Link Up
07845 04/15/2019 06:51:29 Module 01 CAN Link Down
07846 04/15/2019 06:51:29 Sevcon Turned On
07847 04/15/2019 06:51:29 Module 00 CAN Link Down
07848 04/15/2019 06:51:29 Module 01 CAN Link Up
07849 04/15/2019 06:51:29 Module 00 CAN Link Up
07850 04/15/2019 06:51:29 Module 00 Registered serial: 14sg0870, vmod: 109.296V