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1
Zero Motorcycles Forum | 2012 and older / Re: 2010 Zero DS Charging Issue
« on: June 17, 2020, 02:50:18 PM »
Ah nice. 44V is still ok, but indeed does mean it's almost empy. Assuming all cells are balanced, that would be about 3.14V per cell.

The charger needs to see this voltage in order to start, so that seems to be ok. But indeed, 6 flashes will be a problem.
I'm sure you tried removing the charger from AC for a while?

Where are you located?

2
Zero Motorcycles Forum | 2012 and older / Re: 2010 Zero DS Charging Issue
« on: June 17, 2020, 02:48:43 AM »
Will the bike still turn on (does the dash light up)?

If you can measure a voltage on the chare connector of the battery, you can see what the battery's voltage is. It might be possible that it's way too low, and the MBB is refusing to charge.
It's possible to force the onboard charger to charge the battery, but I would only recommend doing that for a very short period and only if the voltage is maybe in the ~30V range.

3
Zero Motorcycles Forum | 2012 and older / Re: 2011 Zero DS Random Cut-Outs
« on: June 17, 2020, 02:42:52 AM »
I don't know what events might trigger a software reset on an MBB, apart from resetting it by hand via the terminal.

The canbus errors might trigger a software reset. The only canbus connection is going to the battery, via the multipin connector. I would check that connector first.

4
Buy Sell Trade / Re: 2011 Zero DS Battery for Sale
« on: September 22, 2019, 10:06:49 PM »
Changed the title from 2012 to 2011: It's a 2011 battery pack.
Below a picture of the inside:



5
Buy Sell Trade / 2011 Zero DS Battery for Sale
« on: July 08, 2019, 06:20:09 PM »
Hi,

I've decided to do away with the original battery, and go for something bigger and crazier.

The battery is completely original, I could do a 40 km max range, and I've measured a usable capacity of around 2.5 kWh (3.9 kWh original).
Let me know if anyone is interested.

I'm located in the Netherlands, Zaltbommel area and regularly visit Amsterdam/Rotterdam.

Pictures will follow.

 

6
Zero Motorcycles Forum | 2012 and older / Re: 2011 Zero DS - Diagnosing throttle issues
« on: December 28, 2018, 06:38:06 PM »
I did solve it. I tested the motor controller on it's own, with a different motor. Whenever it's led said it was ready, it simply didn't do anything. I replaced it with a Kelly 72V regen controller with a direct throttle.

7
Zero Motorcycles Forum | 2012 and older / Re: Options for rebuilding a 2010 zero DS
« on: October 24, 2018, 06:45:16 PM »
I believe the 2010 comes either with the PERM 132 motor or the Agni 95R, both are DC permanent magnet motors with brushes.

Your battery pack should contain a contactor, but the stock one is only rated at 200A.

I believe they all have the same AXE controller: AXE4855.

What exact model do you have? Any pictures?

8
Zero Motorcycles Forum | 2012 and older / Re: 2011 Zero DS - Diagnosing throttle issues
« on: October 23, 2018, 05:43:06 AM »
I followed https://zeromanual.com/wiki/How_to_build_a_cable_to_access_the_MBB.
It works with a 3V3 TTL serial converter, for instance https://uk.rs-online.com/web/p/interface-development-kits/7676200/

Mine's baudrate is at 9600N1 instead of the 38400N1 from the manual.

9
Zero Motorcycles Forum | 2012 and older / Re: 2011 Zero DS - Diagnosing throttle issues
« on: October 23, 2018, 02:41:13 AM »
Okay,

I've measured the throttle signal when the bike wasn't responding.
It measures only 3100 mV at the pin going to the Alltrax when I open the throttle.

This seems to be configurable with the scale setting in the MBB. If I load the default, the scale setting is 63%. If i turn that to 33%, the throttle outputs 1600mV or so, and 5000 mV at 100%.
So by default, this bike is only running at ~60% power. Or at least, the controller is only ever getting a 63% throttle input by default.

Today, the controller has decided to work. When I disengage the kill switch, I hear a slight "clunk" from the motor. (Not the relay, it sounds different...)
I can repeat this all day long.
Whenever it decides to not respond to throttle, I get no clunk sound. I do hear the contactor engage when I power the bike off and on, but no subsequent clunk.

In both cases, the green LED on the Alltrax is a single blink, and then a solid green.

So, I'm suspecting the Alltrax is at fault here.

When it decides to cut out again, I'll check if the controller is actually getting battery power. I'm 99% sure it should not turn green if it isn't.

I couldn't find anything about the scale setting. Has everyone just silently tuned this up to 100%?

10
Zero Motorcycles Forum | 2012 and older / 2011 Zero DS - Diagnosing throttle issues
« on: October 18, 2018, 03:23:36 AM »
Hi all,

I've recently acquired an old 2011 Zero DS which was sold to me with the promise of having intermittent throttle cutouts.
I can confirm.

I'm hoping someone has one lying around in 'factory' condition and can help me confirm some of the behavior I'm seeing.

I've tied together one of those ODBII debug cables to check if the MBB has anything to say for itself:

Code: [Select]
ZERO MBB> DEBUG: EepromFindNextAvailableEventLogEntrySlot Timeout


*************************************************************
*                                                           *
*            Zero Motorcycles Main Bike Board               *
*                                                           *
*                  Board Rev : 01.00                        *
*               Firmware Rev : 01.11                        *
*                      Built : Nov  9 2011 17:44:00         *
*                  Bike Type : S and DS                     *
*                 Serial Num : 05262                        *
*************************************************************
 - Reset Source: POR BOR
 - Running Self-Test.... Passed
 - Establishing CAN connection to BMS....  Passed
 - Precharging.... Passed

PASSWORD> 1.21gigawatts
*************
 - Logged in
Today, after startup, it responded to throttle a few times, and now it has cut out.
There are no errors in the MBB, the log doesn't say anything of consequence.

If I check the inputs page, the kill switch is in run and the stand is up.

If I open the throttle, the out value according to the MBB is 3100 mV.

Code: [Select]
ZERO MBB> inputs
inputs
****************************************
*              All Inputs              *
****************************************

  - Pack Voltage              :  56927 mV (844 ADC)
  - Precharge Voltage         :  54589 mV (841 ADC)
  - Battery Throttle En       :  49137 mV (712 ADC)
  - Contactor Enable          :  8161 mV (121 ADC)
  - Contactor Coil Voltage    :  48766 mV

  - Raw Kill Switch           :  0 mV (0 ADC)
  - Kill Switch Pos           :  Run
  - Raw Kickstand Switch      :  1333 mV (410 ADC)
  - Kickstand Switch Pos      :  Up

  - Medium Speed Switch       :  Off
  - Low Speed Switch          :  Off

  - Raw Throttle0 Position    :  688 ADC
  - Raw Throttle1 Position    :  1021 ADC
  - Normalized Thr Position   :  1023 ADC
  - Final Throttle Position   :  99%
  - Throttle Out              :  3105 mV (636 ADC)

  - Board Temp                :  22 C  (551 ADC)
  - Motor Temp1               :  18 C  (583 ADC)
  - External Temp 1           :  1021 ADC
  - External Temp 2           :  1021 ADC
  - External Temp 3           :  1021 ADC

  - Motor Speed Pin           :  0
  - Motor Speed Counter       :  0
  - Motor Speed RPM           :  0
  - Bike Speed MPH            :  0
  - Motor Current Sense 0     :  0 A  (22 ADC)
  - Motor Current Sense 1     :  -1 A  (20 ADC)
  - Motor Current VREF 0      :  2429 mV (747 ADC)
  - Motor Current VREF 1      :  1173 mV (361 ADC)
  - Motor Current Raw 0       :  2412 mV (480 ADC)

If the MBB outputs a voltage signal, I would expect the AXE controller to be in a 0-5V mode instead of a 0-5k potentiometer mode.

My AXE controller starts up with one green blink (which should mean 0-5k) and then a solid green for run.

Can anyone confirm that the AXE should start up with a single green blink?

And: Can someone show me a comparable MBB log?

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