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[StoneAgeMan]

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

Code: [Select]

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


[Specter]

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

[TheRan]

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.

[StoneAgeMan]

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(?):

Code: [Select]

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):

Code: [Select]

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

[StoneAgeMan]

Posting with attached trimmed log

[StoneAgeMan]

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. 

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:

Code: [Select]

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