FXS breakdown. July 2021.
French version of this document
Discussion and solution in electricmotorcycleforum.com : finally, it was a failure of the controller and it has been repaired by a Zero dealer.
In brief :
The bike is a 2016 FXS ZF 6.5, with two removable battery packs.
The bike was running fine until these days. On July 7th 2021, I have charged the bike during night using a manual timer. The bike charged from 58% to 73% in 1h 30min. Until there all seemed OK.
But when I tried to use the bike the day after, the bike did not start.
Abnormal behavior :
- Bike does not start
- Bike does not charge
- No "click" when keying or attempting to charge
- Dash is flashing 1min 30s after keying or after attempting to charge
- The red triangular indicator on the dash does not behave the same way when side stand is up or down
- When side stand is up, the red triangular indicator says "Contactor error", according to the manual
- The dash indicates these errors :
- 25 Contactor open warning
- 27 Precharge error
- 48 SEVCON startup disabe (only once, not cycling)
- 49 Contactor open disable
- 58 BMS sensor warning
- When trying to charge, the BMS LEDs indicate that the bike is balancing, instead of indicating the SOC
It
does not seem to be a problem with the BMS and the batteries, since I
have made soft and hard resets of the BMS, tried to operate the bike
with only one battery (in case one of the battery had a problem). I
have tested separately both batteries in the rear position, then in the front position (with the
"blanking plug" in the free position).
As
a result, since the contactors are in each of the batteries, it is
almost impossible that the contactors themselves are faulty (they could
not both have failed at the same time).
It is therefore a problem upstream of the contactors.
More details :
What seems abnormal is in red.
When keying on the bike, no "click". After 1min 30s the headlight turns off and the screen starts flashing.
July 8th: with the bike on the side stand => the red indicator flashes are not described in the manual
July
9th: with only one battery, and since the day before, I have made a
soft RESET on the battery BMS (but it has not changed anything)
When I plug in the charging cord: no "click". After 1min 30s the screen starts flashing. The bike is on the side stand.
The bike is a FXS model 2016, with original firmware:
Serial number
2016_mbb_ca1a29_02158
VIN
538XXAZA1GCJ06548
Firmware rev.
47
Board rev.
3
Model FXS
Logs :
Note that I have almost all the logs for the entire life of my FXS. Detail here. I have also all the logs transformed in text files using the parser. These files are indexed, in such a way that I can easily find any text string in these files.
It
was difficult to get the last log since when the screen start flashing
the transmission of the log crashes. After several attempts I got it.
Log file in .bin format
Log file converted in .docx format using this parser and segmented at each restart of the bike.
Seems
abnormal (appears 3 times in this log, all 3 after the bike failure.
But I checked that these lines appear several times in older logs, so
they are perhaps not directly related to the present failure):
DEBUG: Reset: Software
BMS Reset Software
Errors on the dash :
|
Error
|
2016 manual
|
2017 manual
|
|
25
|
Contactor open warning
|
|
|
27
|
Precharge error
|
|
|
44
|
Kill switch disable
|
|
|
45
|
Kickstand switch disable |
|
|
48
|
SEVCON startup disable
|
|
|
49
|
Contactor open disable
|
|
|
58
|
not in the manual !!!
|
BMS sensor warning
|
Batteries and fuses
My bike has 2 removable batteries.
On
July 8th, while batteries removed from the bike, I pushed on the left
(gauche) RESET button of both batteries. According to https://zeromanual.com/wiki/BMS_Reset_Procedure, it should have done a "hard reset". But I do not understand if
this works while the batteries are removed from the bike. Anyway, it
does not seem to have changed anything.
On July 9th, I have made soft RESETs, but it
does not seem to have changed anything.
Video of the resets.
Numbering of the BMS LEDs according to the manual: 1 red, 2 green, 3 green, 4 green.
When the batteries are inside the bike:
Rear battery: the LEDs are visible from the bottom of the bike.
Front
battery: the LEDs are hardly visible by removing the saddle, and
visible when removing the front left plastic fairing.
I have checked all the 5A and 10A fuses.
BMS LEDs
I
have checked in several modes that the LEDs of the 2 batteries are
flashing perfectly synchronous. It means that both batteries
communicate with some central system.
Short link to this page: https://bit.ly/FXSbreakdown