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Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: Walker on April 16, 2018, 09:21:50 PM
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Hi, I am new here, having my SR MY2018 for a week. First impression - AWESOME !
But... during my trip back home I rode the battery to 0% and had 175km with 48Wh/km = 8,44kWh used. Well, the dealer said it will go up after few battery cycles. After 2 more cycles nothing happened, I am able to get 8,5kWh from the battery only. Is that normal? Are they right?
Second problem is a noise comming out of the belt, more precisely from the gear of the motor. They are also telling me it will get better...right?
Third and the most serious problem - the bike makes restart when I stop at the lights. Does not make it every time, but very often. Don´t have to tell you how dangerous it is ! Does anybody know where is the problem? I went through the log and found this error coming up during the restart again and again:
06558 04/16/2018 16:29:23 Throttle Disabled: Sevcon Starting Up,
06559 04/16/2018 16:29:24 DEBUG: Module 00 Contactor is now Open
06560 04/16/2018 16:29:26 Sevcon Turned On
06561 04/16/2018 16:29:27 Sevcon CAN Link Up
06562 04/16/2018 16:29:27 DEBUG: Sevcon Contactor Drive ON.
06563 04/16/2018 16:29:27 Module 00 vmod: 108.84 maxsys: 108.84 minsys: 108.84 diff: 0.000 vcap: 100.062 prechg: 91%
06564 04/16/2018 16:29:27 DEBUG: Module 00 Contactor is now Closed
06565 04/16/2018 16:29:33 SEVCON CAN EMCY Frame Error Code: 0x2000, Error Reg: 0x02 Sevcon Error Code: 0x54c3, Data: 0x00 0x00 0x54 0x40 0x05 , Unknown
06566 04/16/2018 16:29:33 SEVCON CAN EMCY Frame Error Code: 0x2000, Error Reg: 0x02 Sevcon Error Code: 0x54c5, Data: 0x00 0x00 0x54 0xff 0x05 , Unknown
06567 04/16/2018 16:29:33 SEVCON CAN EMCY Frame Error Code: 0x2000, Error Reg: 0x02 Sevcon Error Code: 0x54c7, Data: 0x00 0x00 0x54 0xfc 0x05 , Unknown
06568 04/16/2018 16:29:33 DEBUG: Sevcon Contactor Drive OFF
06569 04/16/2018 16:29:33 DEBUG: Sevcon Has Turned Off Contactor Drive
06570 04/16/2018 16:29:33 Module 00 vmod: 108.821V, batt curr: 1A
06571 04/16/2018 16:29:33 Module 01 vmod: 0V, batt curr: 0A
06572 04/16/2018 16:29:33 Sevcon Turned Off
Thank you for your ideas...
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I will say the wh/mile that the bike calculates is always way too low to multiply it out to get your full battery capacity. Not even the nominal capacity. Not sure how it's being calculated but it is definitely off. You can use it with precision to measure one ride carefully to another, just the number itself isn't accurate.
Not sure about the belt noise, just make sure your rear axle is straight at the same marks on both sides to make sure the belt is tracking straight.
And the faults look like there is a problem. Did it rain the day you rode the 175 km? Or did the dealer wash it with a hose before you bought it? hopefully that's all it is and it goes away once it dries out.
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Thank you Terry.
So how can I learn the real capacity of my battery?
I´ll try to align the belt, but is seems to be ok.
There was no rain since I got the bike so water is not the issue... :(
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Thank you Terry.
So how can I learn the real capacity of my battery?
I´ll try to align the belt, but is seems to be ok.
There was no rain since I got the bike so water is not the issue... :(
I think the Zero app is fairly accurate regarding total battery kWh capacity when fully charged. It seems to correlate fairly well when recharging and connected to a Kill-A-Watt meter. The meter will show about a 5% larger draw from the wall outlet, but I chalk that up to the charger's inefficiency that turns some of the electrical power into heat. Plus, the cheap Kill-A-Watt device is probably not perfectly accurate.
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I had serious problems with Zero App version 1.6.71 which gave me bad data.
I reverted to version 1.6.50 which works much better (at least with my bike: FXS 2016 with firmware 47).
Perhaps you could try this version...
You can get it from here: https://downloadapk.net/down_Zero-Motorcycles.html
See other post here http://electricmotorcycleforum.com/boards/index.php?topic=7720.15
Of course, it will not solve the problem that you seem to have with your bike (third problem in your list)!
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Maybe a bad contact within the keyswitch? due to water ingress or defective build. If it repeats under "dry" condition, it should be replaced by dealer.
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So I am in a contact with my dealer and with ZERO Europe HQ and they call me to have it repaired. They say that the errors are referring to the communication between the MBB and the controller, probably have to change it. How could this pass the factory tests?
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So the controller is being changed... :(
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As for the belt noise, loosen up the belt a little bit. I always keep mine looser than the factory spec calls for without any issues. Adjust the rear wheel so that you have at least 1/16" gap between the belt and the outer lip of the sprocket. Spray some silicone on the belt and on the motor sprocket area. That should quiet it down. The noise will also diminish over time.
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Ok, I´ll try. And what is the default "belt frequency" for 2018 model, 42,5 - 73,6Hz or 96,3 - 124Hz ?
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Sorry, but I have no idea what you are referring to by belt frequency. Maybe someone else reading this thread does.
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Ok, I´ll try. And what is the default "belt frequency" for 2018 model, 42,5 - 73,6Hz or 96,3 - 124Hz ?
42,5 - 73,6Hz , per page 6.20 of my 2018 Zero S manual.
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Thank you, I tunned it to 70Hz. Few day ago I got my bike back from the dealer. They changed the controller unit and made some "calibration". Now the bike does not restart and runs fine. But I am still woriied about the range and usefull capacity of the battery, Richard230 or someone else with MY2018, how much energy can you get from your 14.4kWh battery pack? I am still at some 9,5kWh (last trip 216km at 44Wh/km). I also got a notice from the dealer about battery-controller learning proces - see attached file.
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Nice. I have noticed myself that using my bike for long rides will improve the expected range. But if you're on the road and "quick" charging it the expected range will deviate more. On my FX atleast.
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Thank you, I tunned it to 70Hz. Few day ago I got my bike back from the dealer. They changed the controller unit and made some "calibration". Now the bike does not restart and runs fine. But I am still woriied about the range and usefull capacity of the battery, Richard230 or someone else with MY2018, how much energy can you get from your 14.4kWh battery pack? I am still at some 9,5kWh (last trip 216km at 44Wh/km). I also got a notice from the dealer about battery-controller learning proces - see attached file.
Before Zero's latest BMS and MMB version 31 updates, my 2018 "16.6" kWh S was showing 15.183 kWh capacity on the Zero app when fully charged. However the latest version 31 updates have eliminated that information. >:( I assume that this was done to keep Zero owners from asking questions like yours. ::) Now the only way you can check your battery condition via the app is by checking voltage and cell balance (which on my bike varies between 2 and 3 mV right now) - and of course relying on the percentage shown on your instrument display or cell phone app. Apparently, Zero is slowly reducing the amount of battery condition information available to their customers via the app. Kind of makes you wonder why. ::)
My thought is that Zero is slowly reducing the battery high and low voltage parameters in order to extend battery life. My 2014 S (which showed 13.38 kWh when fully charged and when new - if I recall correctly) originally would show 117 volts when fully charged and 0% represented a completely discharged battery (no reserve). However, the 2018 model originally was showing 116 volts when fully charged, but with the new firmware update it is now showing 115 volts fully charged. I have no idea what will be going on as the battery pack reaches 0%, since I have not taken my battery below 25%. However others have reported that at 0% on the display, you can still ride another 20 miles, or so.
When my 2014 S first had its "power tank" installed by my dealership, it also showed something like 9.5 kWh, so I complained. As it turned out, a Zero tech came to the shop to analyze what was going on and determined that the power tank was defective and that its individual BMS was not communicating with the bike's MMB. He replaced the power tank module and everything has been fine ever since - other than the total battery pack, after three years of working perfectly, started to stop charging the battery to 100% and now stops charging at 92% and 113 volts. :(
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Today I rode the battery to 0% and then some 5km more (the power and torque were limited) but the bike did not stop. I was out of time so I stopped playing with the bike and set on the charger. App told me, that I used 9.44kWh - I am still missing some 2kWh of energy. I´ll try to install an old version of the app on my phone to see the overall battery capacity.
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There is an issue with the firmware which miscalculates the battery amp hours. Download the Zero Voltage app from the android store to see this information. Also you can watch your voiltage using this app which is always correct.
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There is an issue with the firmware which miscalculates the battery amp hours. Download the Zero Voltage app from the android store to see this information. Also you can watch your voiltage using this app which is always correct.
Zero solved that problem with the latest version of their "smart" phone app. ::) They deleted the battery amp hour capacity information. :( At least the current voltage and cell balance are still displayed. But will even that survive with the next firmware update? ::)
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The voltage of my empty battery was 94Volts is it correct? I thought it should go lover, to some 90V.... ?
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The voltage of my empty battery was 94Volts is it correct? I thought it should go lover, to some 90V.... ?
Something like 97Vdc is actually "0%" SoC on the bike display. It goes pretty quickly down from there, and from what I've seen, depending on cell balance (what is the voltage of the lowest voltage cell) you could end up with anything from 92Vdc to 96Vdc showing on the App when the bike cuts out the motor but your lights will keep working for a while.
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Does anyone know, where to get an old version of Zero app for Android - need to se the battery capacity... thanks!
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So I think the battery finaly settled down and I can get a range about 200km when I keep speed with the traffic. I do not care anymore about the capacity but I know I can use max. 10kWh from the battery (if the onboard kWh consumption meter is right). The only thing I am still not satisfied is the strange sound of the belt. It vibrates and creaks in some speeds and when decelerating. I was trying to change the tension (now about 100Hz) and the alignment, also applied dry silicone on it, but it helped just for a while... :( any idea?
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Try checking the belt tension at 10 to 15 points in the wheel rotation. With a perfectly-concentric rear pulley obviously all measurements should be identical, but that may not be the result you get.
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There is a lot of information in the Zero Unofficial Manuals on belt noise and maintenance. I've found it is best to keep the belt at the lowest range of the tension specification. Also make sure the belt is centered on the rear sprocket.
How many miles is on your bike? It took about 1,000 miles on my 2017 DSR for the belt to quiet down. I'm now at 1,300+ miles and the belt is very quiet.
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I have got 2 700 miles on it. What tension do you mean, 42Hz ?
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I don't go by frequency. I use the Gates gauge and go by tension in kg. I set mine around 23 - 25 kg. Your bike uses the wide belt with a range of 26 - 75 kg.
Recommended Belt Tension
Belt Type Years Resonant Frequency Tension Range
Narrow 2013-2016 42.5 Hz – 73.6 Hz 20 – 30kg
Wide 2017+ (except S 13.0) 96.3 Hz – 124 Hz 26 – 75kg
PS - I don't remembering experiencing any noise when the belt was newer upon deceleration. Only upon starting from a stop up to a certain mph. I ride in custom mode with motor regen set to 0%. When I'm coasting down a hill and tucked behind my windscreen, all I hear is a little tire whin. You might want to try that and see if your still hear the noises and make sure it's coming from the belt.
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Yesterday I tried a new setup - 65Hz and centered the belt on the rear sprocket (was too close to the outer edge). I also washed the belt with water and used a dry silicone spray. Seems good after 40km so far...