ElectricMotorcycleForum.com

I am working on a FX Sevcon system that will not activate the contactors after making a rather dumb error. I was planning to diagnose a throttle related error. When I first fired up DVT, I skipped the part where you build a table before making edits. I made a few changes to the drive profile before I realized I messed up. Now when returning to operational, I get an error. I do not have a pre-oops backup DCF file............ The MBB log does not give much help but it does confirm that my error started after I messed up. Contactors do not pull in and motor does not spin nor track being spun. The controller blinks 10 doots. The MBB power LED gives a 2, 1 doot code (contactor error).  Plugging in the off-board charger does not activate contactors and gives error. The onboard charger was removed prior. The bike did work before I messed up, it just had some throttle issues.

When I go to Operational, I get the error "0x4682 IO INIT". Some digging gets me this:

    Controller has not received all configured RPDOs at power up
    Check PDOs on all CANbus nodes are configured correctly and match up.


The MBB Log echos the 4682 error:

    SEVCON CAN EMCY Frame      Error Code: 0x1000, Error Reg: 0x01, Sevcon Error Code: 0x4682, Data: 00 00 00, Unknown


I am no expert on CAN but I belive this error refers to the RPDO's. I have the following:

    Sync Period 40.0mS
    RPDO 1
    Cob-ID    0x00000200
    Synch Per Transmit 1

    Throttle Input Voltage  Address 0x2220,0
    Forward Switch   Address 02121,0
    Reverse Switch    Address 02122,0
    FS1 switch    Address 02123,0


There are several TPDO's listed but I don't think they would give this error?? I can provide them if needed.



What I have done so far:

    Build table (can't remember what the exact process is called) and create after the fact DCF backup file.
    Reload created DCF file. Did not fix issue.
    Delete all RPDO's. This does seem to remove the error but causes many, many other errors leading to a need to restore DCF backup.
    Tried to use my old DigiNow OBD scanner but it will not pair with my phone (none of the popular passcodes work?). Used Zero app to create log and emailed it to myself. Found nothing of value.
    Dug through as many settings as I can to verify they make "sense" to the best of my ability. Very inconclusive but I didn't notice anything blatant.


What I know:

    The MBB is alive and communicating as expected. It reports, sends, and receives data from the controller.
    The only error I get in preop is 4681 (unit is in preop) and 4682 (IO Init) in operational.
    DVT warns me that there is no contactor mapped (not an error). I assume this is ok since the controller does not control the contactors directly; the MBB does.
    When I change settings in DVT, they do upload to the controller and overwrite the current settings.

What might help:

    Someone with a 2013 FX confirm my RPDO's and other CAN settings such as addresses, time settings, and Bit/Byte values.
    Someone with a 2013 FX send me their stock DCF file. Even if I can't directly load it, I can use the built in compare function to....compare the settings.
    Someone with general knowledge/experience with Sevcon and DVT tells me what I did and how to fix it.   
    Rewiring everything to eliminate the MBB and use the contactor settings built into the controller eliminating all RPDO's


I would appreciate any advice, input, or information that may help me out of this pickle.
   

Back to the main question asked by OP.  I just got my 2015 FX back from the dealer after the mainboard died in fully discharged both of my batteries killing them. The batteries in the motherboard had to be replaced under warranty. I was able to pay the difference and get 2016 batteries as replacements for the old 2015 batteries. I've only put a few miles on the bike since I got it back but I can say that the bikes just as Petty as it was before the battery swap. I would say the new batteries have made no difference in the responsiveness of the bike.

I am looking at a 2013 FX battery that is supposedly got internal damage (collapsed cells).  I want to evaluate the battery and see what kind of damage there may be internally.  something that threw me off however was when I checked the main power connector contacts and it had 111VDC without anything being connected.  I know on my 2015 batteries the contactor must be enabled for voltage to be present at the main contacts.  Can anyone confirm if this battery is supposed to be always hot?   I looked down in the little view port where you are supposed to see the BMS LED's and there is no board in there!  It looks like the BMS board fits into an edge connector and it is gone; can this be confirmed that the 2013 battery had a BMS that fit in this location?  Also, if anyone can provide any information or pictures of the batteries internal setup before I dive in that would be much appreciated! 

i asked about that and it was an inside job with the go karts.  From what I understand it was an employee who did the gokart.

How different is the connector?  Is it something that can be changed on the 2013 bike and batteries to mate up with a 2015 or is the wiring layout too different.  are we talking connector change or connector change and rewiring?  And more importantly, how is that price?

Posted a couple weeks ago, looks like they have more still:
http://electricmotorcycleforum.com/boards/index.php?topic=5083.msg35537#msg35537

If I were you guys, I'd jump on these.

This is a good...no a great deal, and these things are not easy to find!

The way I look at it your basically guaranteed 30 miles no matter how hard you ride, if your careful you can get 80 miles.... Completely user dependent, if you drive it hard you going to get on the lower end of them at but as far as average, 40-60 ish miles really depends mostly on average speed, higher the speed lower the range

This guy here ^ knows what he is talking about.  He may seem crazy....and probably is but he has an FX with an SR motor and ESC in it.