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[DonTom]

I went to stop the charge so I can see if it will start the charge gain normally. But I was too late, it charged up to 100% SOC.


I will start putting the bike back together and ride enough to discharge it and then try to charge again.  I see no reason to take it apart again, I got all the info. I wanted already.


I will post here the results after some riding and then try to charge again.


-Don-  Reno, NV

[DonTom]

I put the bike back together and tried to charge using the "extended range charging". Same old problem.


The one time it charged was just a fluke. But I now have the bike at 100% SOC so I will ride it around a little tomorrow and try to charge it up again after a few miles.


My guess is there is something flakey in the BMU, but I cannot prove it.


-Don-  Reno, NV

[princec]

Unlikely the BMU itself has managed to fail all on its own. Much more likely to be a little bit of corrosion and / or moisture on a critical connector, which happens when things get left alone for months. Make sure your 12V battery is fully charged too, which apparently can also cause init problems.

Cas

[DonTom]

Unlikely the BMU itself has managed to fail all on its own. Much more likely to be a little bit of corrosion and / or moisture on a critical connector, which happens when things get left alone for months. Make sure your 12V battery is fully charged too, which apparently can also cause init problems.

Cas

My 12V battery is at 13.0VDC after the bike not being on for a day. It is at 13.22 VDC when the DC2DCC is active (when bike is keyed on, 13.30  when trying to charge).


I already did remove every connector I could get to and looked inside for issues and then reseated them.


The BMU always has voltage on it, even when the DC2DCC fuse is removed and the 12v battery disconnected. The LED on it can blink even when the contactor is open. I assume that is normal, getting it's voltage from the HV battery somehow, but at a very low voltage.  The LED on it can light up full even when the contactor has been open for hours. So just sitting, it is somewhat active. And a capacitor can dry out internally or whatever to give problems. While I expect a bad BMU, I have no known way to prove it. I could buy one and see what happens and then simply have a spare BMU if I still have the same problem. I assume such a module has no programming info inside to match my bike and I can simply replace it.


I never counted the blinks for the error that it gives after a failed charge. It does NOT repeat, so I need to count the blinks the first time or try to charge and wait again for the failure.


I will do that later today and see if I can get more info.


I was was ready to do that yesterday--but that was the time the bike charged up.


-Don-  Reno, NV

[TheRan]

Error 31 means battery module ineligible, whatever that means, but I would take that to mean the fault lies within the battery and not the charging. I would also assume this wouldn't allow the bike to ride, did you try this?

[DonTom]

Error 31 means battery module ineligible, whatever that means, but I would take that to mean the fault lies within the battery and not the charging. I would also assume this wouldn't allow the bike to ride, did you try this?

The bike rides fine, but so far, I only rode it a very short distance, from my driveway back into the garage just to test that it runs.


The battery seems to be fine (both of them). I did mange to charge it to 100% soc one time yesterday. But it started out a little flakey at 3.3 KW until a couple of minutes and then went to the full 6.6 KW. Why it charged one time after this problem is a mystery. But still didn't seem to charge correctly for the first couple of minutes.


I will start doing a little more testing in a few minutes. And then go for a ride of several miles and then try to charge again. Perhaps I will ride it to Reno's Zero dealer to see what the price is of a new BMU.




I will not ride far enough to need a charge before coming back home.


-Don-  Reno, NV

[DonTom]

I normal the bike up to count the red blinks from the MCU. 22 reds, but I could have miscounted, so I do it again, changing nothing at all. One difference, I also got an error 27 besides the error 31. But just one time. 27=12V Low Voltage Fault. It measures as 13.5 VDC across the 12V battery just seconds after this fault. Makes no sense to me.


Second try to count the blinks . . . I cannot do it, as then it starts charging (I am at 101% SOC, so this is the extended range charging).


I stop the charge and try again. It starts charging again. And again, and again and again.


I can no longer get the bike to fail to charge after many tries to try to make it fail.


It is only charging at 2KW, but I think that is normal for when above 100% SOC, isn't it?


I read somewhere that the BMU prevents charging to very unbalanced cells to help protect the battery.


I have been wondering if my battery cells got way out of balance from sitting, but not more than enough to show the imbalance error  code, but enough imbalance for the BMU to stop the charge.


Unfortunately, only the Zero dealers can check the balance MV numbers on the DSR/x, unlike gen two bikes where the owners can check it. The Zero DSR/X models only give an error code, so I cannot tell if I am on the edge of an acceptable balance or not.


My understand is near the top of the charge is the best cell balancing and best is the lowest useable charge current so it takes longer to give more time to balance better. Balancing takes time near the end.


So I unplugged my 240 VAC and plugged in a 120 VAC 1.2 KW unit.  The bike charges up again just fine, but now at 1.2 KW.


I still am not sure about anything, so I do NOT trust the bike to charge. I will not take it far enough to charge for quite a while. And for the time being, I will only home charge with 120 VAC to give it more time to balance the HV battery cells.


-Don-  Reno, NV

[DonTom]

I now have my bike charged up to 110% SOC. So all I can do from here is put it back together to ride it.

BTW, the green LED on the Zero DSR/X  BMU never stops flashing. Bike is off, 12V battery disconnected. DC2DCC fuse removed, MMB fuse removed, and the LED flashes bright green about one time per second, non-stop.  There has to be voltage for the key to close the contactor and perhaps that is where it gets its voltage. Even when the bike is sitting for months, that green LED I assume must be flashing one time per second.

Not a real issue when from an 17 KWH battery, just interesting that it never shuts off.

The BMU is easy to get to. Just remove both fuses in the HV battery, disconnect the 12V negative to the 12 volt battery and remove the small top front battery cover. Two screws. The BMU is seen on the very top, but still below the orange connector going to the charger that you will NOT see unless looking up inside above the BMU.

Be sure to remove both connectors when reinstalling or else it can get stuck in there and take a while to get back out. You can guess how I know. Be sure it is fitted into the two grommets.

There is a reset button on the BMU. in case you get red lights flashing when playing around checking other things or just after putting things back to normal.

This is the first time I dug into my Zero DSR/X. I now have a rough idea where everything is at and how to get to it. I took more of the bike apart than was necessary just to find things and check connecters, etc.

See below for when  was working on the bike and when back to normal with the green light on.  I timed the camera just right each time to show it with the key out. And then green after the reset.

-Don-  Reno, NV

[DonTom]

I am now  in Verdi, 15 miles west of Reno on the CA boarder where they have free to use Tesla Destinaion Charge  Stations.


I selected extended range charging again, and now at 101% SOC it charges at 5.5 KW with a Tesla tap.


My gut feeling is the BMU did like the cell blanace and there was really nothing else wrong,  Nothing I can prove, but it sure looks like it is all back to normal for no reason other than a good long 120 VAC (1.2 KW DC) charge to the very top 110% to give it extra time to balance the cells after the long sit.


Perhaps my BMU is just being  too sensitive to cell balance and turns off before I can get the cell unbalance message, It's a bummer that only the Zero dealers can looking at the cell balance in the DSR/X.


I decided I will ride this bike to my Auburn house in the morning. 99.0 miles. I have several places on the way where I can recharge. Just in case, I will make sure I can make it all the way there--or back to Reno in case of any charging problems.


BTW, one thing I forgot to check. I think the app shows log files. I never looked at that.  Perhaps that should have been the first thing to do.


-Don-  Verdi, NV

[eglatzer]

You can download the log fiels with the app.
They are binary and you can analyze them with https://ernstgl.github.io/ZeroGen3LogParser
You can see the voltages of highest and lowest cells.

[DonTom]

You can download the log fiels with the app.
They are binary and you can analyze them with https://ernstgl.github.io/ZeroGen3LogParser
You can see the voltages of highest and lowest cells.

Thanks, I will look into it. I have never used the parser before. I knew it existed, but this is the first time I really want to know what was going on by looking at log files. Perhaps that is the first thing I should have done. But now I am glad I worked on the bike so I know how to get to things. The 12 volt fuses are in a real stupid location in the DSR/X.


Anyway, even though I did nothing to break the bike, I also did nothing when it decided to fix itself. It now charges fine every time I try it.


But I cannot say I trust it 100% yet, I will be careful how far I go on a charge for a while to make sure I can get to one of my houses. Going between here in Reno and Auburn is a perfect test as there are many places to charge up on the way. I will keep it charged up to make sure I can make it all the way there or back, in case of another charge issue. I could make the trip in a single home charge otherwise.


-Don-  Reno, NV

[DonTom]

I have now charged the bike several times without the slightest issue.


Here is an interesting area of the log files. I have to main questions about below:
l
1. What does "no cell type" mean?
2. And how can the date before these errors be in year 1970?

70	76	1/2/1970 7:32:04 AM	558000	47	84835		0	0	0	0	3652	3652	3655	43	138	25	51	0	255	1	0	0	7	102303	0	18	25	26	47	138	3	162	0	143811	0	3	0
53	253	1/2/1970 7:32:04 AM	327000	24	86197																				Saving stats, hibernating for 86400 sec
31	253	9/29/2025 6:10:12 AM	180000	0	86228																				Exiting Hibernate
83	253	9/29/2025 6:10:12 AM	180000	1	86311																				Board was reset. Source: Hib Wak n, Power-On, Supply WD, Power Val
42	253	9/29/2025 6:10:12 AM	181000	2	86353																				Entering ZERO_BMS_STATE_IDLE
31	253	9/29/2025 6:10:12 AM	181000	3	86384																				Discharge enabled
63	253	9/29/2025 6:10:12 AM	182000	4	86447																				ERRO eroBmsManagePackIo returned ZERO_RET_FAIL
45	253	9/29/2025 6:10:12 AM	341000	5	86492																				Entering ZERO_BMS_STATE_STANDBY
52	75	9/29/2025 6:10:13 AM	21000	6	86544		0	0	0	32	3785	0	3793	0	0	21	51	0	120	0	0	0	3	106104	13	2
64	253	9/29/2025 6:10:13 AM	64000	7	86608																				1000000 baud: Could not read eeprom from cellbox 0
64	253	9/29/2025 6:10:13 AM	79000	8	86672																				1000000 baud: Could not read eeprom cellbox 1
96	253	9/29/2025 6:10:13 AM	102000	9	86768																				400000 baud: cellbox_id 0 CRC invalid. value: 0x02, crc_read: 0x20, crc_calc: 0x0E
96	253	9/29/2025 6:10:13 AM	122000	10	86864																				4000 aud: cellbox_id 1 CRC invalid. value: 0x02, crc_read: 0x20, crc_calc: 0x0E
39	253	9/29/2025 6:10:13 AM	152000	11	86903																				cellbox_id 0: 0x16 (22MY)
39	253	9/29/2025 6:10:13 AM	222000	12	86942																				ellbox_id 1: 0x16 (22MY)
38	253	9/29/2025 6:10:13 AM	222000	13	86980																				Cell type detected: 22MY
56	253	9/29/2025 6:10:13 AM	222000	14	87036																				Latching 12V Output ON, lowest cell:3785mv
45	253	9/29/2025 6:10:13 AM	222000	15	87081																				Fault set: INVALID/NO CELL TYPE
49	253	9/29/2025 6:10:13 AM	225000	16	87130																				Fault cleared: INVALID/NO CELL TYPE

[/t]

[DonTom]

I do not know why the date shows as 1970, but I think this is really when the problem first started to show up with no charging:

63	253	1/2/1970 2:43:40 AM	192000	4	75929																				ERROR: ZeroBmsManagePackIo urned ZERO_RET_FAIL
45	253	1/2/1970 2:43:40 AM	332000	5	75974																				Entering ZERO_BMS_STATE_STANDBY
52	75	1/2/1970 2:43:40 AM	733000	6	76026		0	0	0	32	3654	0	3657	0	0	28	51	0	120	0	0	0	3	102366	6	14
65	253	1/2/1970 2:43:40 AM	733000	0	76091																				1000000 baud: Could not read eeprom from cellbox 0
64	253	1/2/1970 2:43:40 AM	802000	8	76155																				1000000 baud: Could not read eeprom from cellbox 1
96	253	1/2/1970 2:43:40 AM	802000	9	76251																				400000 baud: cellbox_id 0 CRC invalid. value: 0x02, crc_read: 0x20, crc_calc: 0x0E
96	253	1/2/1970 2:43:41 AM	39000	10	76347																				400000 baud: cellbox_id 1 invalid. value: 0x02, crc_read: 0x20, crc_calc: 0x0E
39	253	1/2/1970 2:43:41 AM	108000	11	76386																				cellbox_id 0: 0x16 (22MY)
39	253	1/2/1970 2:43:41 AM	148000	12	76425																				cellbox_id 1: 0x16 MY)
38	253	1/2/1970 2:43:41 AM	148000	13	76463																				Cell type detected: 22MY
56	253	1/2/1970 2:43:41 AM	148000	14	76519																				Latching 12V Output ON, lowest cell:3654mv
45	253	1/2/1970 2:43:41 AM	150000	15	76564																				Fault set: IN D/NO CELL TYPE

[/t]

[TheRan]

January 1st 1970 is when Unix time started, which is basically the zero point from where all computers count from to know what the time is. It's why in many calendar apps you can't scroll back before then, because to the computer that time doesn't exist. Being the first entry in the logs it can be assumed it writes that before it does the count to figure out the actual date and time.

[DonTom]

January 1st 1970 is when Unix time started, which is basically the zero point from where all computers count from to know what the time is. It's why in many calendar apps you can't scroll back before then, because to the computer that time doesn't exist. Being the first entry in the logs it can be assumed it writes that before it does the count to figure out the actual date and time.

Thanks for the info. I assume that means it is expected and normal to start with a date of 1970.  So then for me to see the real date, I need to look at the date where it first changes.


Does anybody here see an issue in those logs why my bike would not charge the other day? All seems to be well now, charges every time.


I even had the opportunity to recharge it 67% SOC and all was fine yesterday. It was at 67% when I first had the issue the day before.


-Don-  Auburn, CA