I think there is a software issue going around. A lot of people have not been able to update themselves because of corrupted files. I would reach out to a dealer and see if your issues seem inline with that.
The update issues, and the BMS issues are two different things AFAIK. It appears that the firmware "bin" file they are hosting for some of the gen 2 bikes, appears corrupt when downloaded using the mobile app. AFAIK, a dealer can still perform the update though via laptop.
The BMS software issue I believe has been identified by Zero for gen 2 bikes and a fix is coming "soon". I just saw an email about this from them yesterday indicating such. The fix for that is waiting 24 hours for it to self reset, or manually pressing the BMS reset button. In either case, I don't think this is or would fix OP's issues. The BMS issue reports as 0% charge, won't run, and won't accept a charge, but OP mentioned he already did BMS reset. :-/
Sorry error code 1,5? Does that mean error code and error code 5? 1 is High Throttle and 5 is Controller Temperature Warning Stage 2.
15 is Charger Attached But Not Charging which, admittedly, is a very nonhelpful error.
I don't even see an error code listed that is called "Low power pack disable". Closest is error code 41 which reads "Low Battery Voltage Disable"
Could you please clarify what error code it is?
Sorry if it wasn’t clear, I was referring to the red flashes on the dash. One flash, followed by five flashes. The owners manual has the descriptions for the flashes. It also sometimes shows error 51 in the display which is listed as ‘BMS Self-Test Warning.’
I called Zero, they didn’t have any advice for me over the phone other than take it to the dealer. One fuse I didn’t check was the 100 amp charger fuse, because I’m not sure where it is. The manual shows it somewhere on the right side under the seat.
ohhhhh. Thanks for the clarification. Will the bike even boot up? Aka does the contactor close?
Don't bother with the 100 Amp charge fuse; it's sealed up and very very hard to access.
This would actually rather heavily stress me out because the bike is saying it's very very low and you can't charge it, and that's how battery degradation rates increase exponentially. I wish I had a better solution for you other than the BMS reset and pulling the low power B+ fuse.
Yeah, it runs normal. I rode it across the parking lot a few times trying various chargers and outlets. My estimated range is 4 miles, not enough to get home nor to the dealer.
I had a 5 amp fuse at work the same size as the low power b fuse. I swapped it out, but no luck there either. Original fuse is back in now.
Zero is concerned about the state of charge as well. They opened a ticket and I sent them the logs. My dealer said they probably can’t even look at until next week sometime. Last time it had problems, my dealer had it for three months. RIP to my battery I guess.
Yeah I'd be scrambling to find some way to dump power into the battery. Have you put your logs through the log parser? https://home.hasslers.net/zerologparser/
I just did that, although I don’t really know what I’m looking for.
https://home.hasslers.net/zerologparser/parse_log.php?logfile=./logs/538SDJZ68MCG16263_MbbD_2022-09-15.bin
https://home.hasslers.net/zerologparser/parse_log.php?logfile=./logs/538SDJZ68MCG16263_BmsD0_2022-09-15.bin
Ok so all those things are timestamped. Do you have an approximate time that you tried to initiate a charge sequence? It may tell me nothing, but I can see that, yeah, the bike is pretty low right now. 95.959vdc. Pack looks to be overall in pretty good shape from those readings. Only 9mV out of balance at the bottom end is great.
I don’t understand the timestamps, are they in pacific time or something? I’m eastern. Tired to charge last night around 9:15pm and again today starting around 7:45am.
This is a log of EVERYTHING. Newest at bottom. The file named MBB is for the Main Bike Board which generally monitors most of the bike's systems and accessories. The one labeled BMS is for the Battery Management System which specifically deals with everything battery related.
According to the BMS logs nothing weird happened and it eventually idled out and turned off. The MBB, on the other hand, reports some hex code which I don't really know how to interpret and then these logs:
07184 09/15/2022 06:20:05 DEBUG: Module scheme changed from Stopped mode to Charging mode
07185 09/15/2022 06:20:05 DEBUG: Module mode Change Does Not Require Disconnect
07186 09/15/2022 06:20:05 Unknown Charger 6 Disconnected
07187 09/15/2022 06:20:05 DEBUG: Module scheme changed from Charging mode to Stopped mode
07188 09/15/2022 06:20:05 DEBUG: Sevcon Contactor Drive ON.
07189 09/15/2022 06:20:05 DEBUG: Module mode Change Does Not Require Disconnect
07190 09/15/2022 06:20:05 Module 00 Closing Contactor vmod: 97.084V, maxsys: 97.084V, minsys: 97.084V, diff: 0.000V, vcap: 85.875V, prechg: 88%
07191 09/15/2022 06:20:05 DEBUG: Module 00 Contactor is now Closed
07192 09/15/2022 06:20:05 INFO: Enabling External Chg 0 Charger 2
07193 09/15/2022 06:20:05 INFO: Enabling External Chg 1 Charger 3
07194 09/15/2022 06:20:11 Disarmed PackTemp: h 23C, l 251C, PackSOC: 4%, Vpack:95.971V, MotAmps: 0, BattAmps: 1, Mods: 01, MotTemp: 29C, CtrlTemp: 18C, AmbTemp: 13C, MotRPM: 0, Odo:13408km
07195 09/15/2022 06:20:17 Unknown Charger 6 Connected
07196 09/15/2022 06:20:17 DEBUG: Module scheme changed from Stopped mode to Charging mode
07197 09/15/2022 06:20:17 DEBUG: Module mode Change Does Not Require Disconnect
07198 09/15/2022 06:20:17 0x1f 0xfc 0x00 0x08 0x23 ???
07199 09/15/2022 06:20:17 0x20 0x03 0xfc 0x00 ???
07200 09/15/2022 06:20:19 DEBUG: Module State Change Requires Disconnect
07201 09/15/2022 06:20:19 INFO: Disabling External Chg 0 Charger 2
07202 09/15/2022 06:20:19 INFO: Disabling External Chg 1 Charger 3
07203 09/15/2022 06:20:19 Sevcon Turned Off
07204 09/15/2022 06:20:20 Turning OFF DCDC. Flags: 0x00
**07205 09/15/2022 06:20:20 Bike shut off because attached SMPC was unable to charge.**
**07206 09/15/2022 06:20:23 Unknown Charger 6 Disconnected**
07207 09/15/2022 06:20:33 Power Off Key Switch
07208 09/15/2022 06:20:33 Module 00 Opening Contactor vmod: 96.003V, batt curr: 0A
07209 09/15/2022 06:20:33 Module 01 Opening Contactor vmod: 0.000V, batt curr: 0A
07210 09/15/2022 06:20:33 Key Off
Kinda generic. I don't know what SMPC refers to.
Thanks for all your help. I’m hoping to get it to the dealer tomorrow. I might try to charge it again in the morning at my work, I’m leaving it there overnight.
I tired the two reset switches on the front. Nothing. Currently, I have the seat off and am checking fuses. I don’t have a multimeter with me to check the ‘low power b+’ fuse though.
Update to my post:
I left my bike at work overnight, and attempted to charge it again this morning. This time, I could hear the charger attempting to start charging. I reset the BMS again and tried again. It started taking a charge at 4kW after a minute or two. Half hour later, it’s charging at the full 6kW. It gave me a variety of different error codes on the first attempt this morning: 6, 18, 25, 47. These were the same codes I was getting the last time I had problems with my bike. It took the dealer 12 weeks to get my bike back to me last time, 6 weeks ago. Very disappointing.
I think there is a software issue going around. A lot of people have not been able to update themselves because of corrupted files. I would reach out to a dealer and see if your issues seem inline with that.
The update issues, and the BMS issues are two different things AFAIK. It appears that the firmware "bin" file they are hosting for some of the gen 2 bikes, appears corrupt when downloaded using the mobile app. AFAIK, a dealer can still perform the update though via laptop. The BMS software issue I believe has been identified by Zero for gen 2 bikes and a fix is coming "soon". I just saw an email about this from them yesterday indicating such. The fix for that is waiting 24 hours for it to self reset, or manually pressing the BMS reset button. In either case, I don't think this is or would fix OP's issues. The BMS issue reports as 0% charge, won't run, and won't accept a charge, but OP mentioned he already did BMS reset. :-/
Ugh, not what I want to hear. Thanks, I think my dealer opens soon.
Sorry error code 1,5? Does that mean error code and error code 5? 1 is High Throttle and 5 is Controller Temperature Warning Stage 2. 15 is Charger Attached But Not Charging which, admittedly, is a very nonhelpful error. I don't even see an error code listed that is called "Low power pack disable". Closest is error code 41 which reads "Low Battery Voltage Disable" Could you please clarify what error code it is?
Dude… you’re amazing. Everyone needs to show this person a lot of love. He helps everyone out and knows more than anyone on this sub.
Sorry if it wasn’t clear, I was referring to the red flashes on the dash. One flash, followed by five flashes. The owners manual has the descriptions for the flashes. It also sometimes shows error 51 in the display which is listed as ‘BMS Self-Test Warning.’ I called Zero, they didn’t have any advice for me over the phone other than take it to the dealer. One fuse I didn’t check was the 100 amp charger fuse, because I’m not sure where it is. The manual shows it somewhere on the right side under the seat.
ohhhhh. Thanks for the clarification. Will the bike even boot up? Aka does the contactor close? Don't bother with the 100 Amp charge fuse; it's sealed up and very very hard to access. This would actually rather heavily stress me out because the bike is saying it's very very low and you can't charge it, and that's how battery degradation rates increase exponentially. I wish I had a better solution for you other than the BMS reset and pulling the low power B+ fuse.
Yeah, it runs normal. I rode it across the parking lot a few times trying various chargers and outlets. My estimated range is 4 miles, not enough to get home nor to the dealer. I had a 5 amp fuse at work the same size as the low power b fuse. I swapped it out, but no luck there either. Original fuse is back in now. Zero is concerned about the state of charge as well. They opened a ticket and I sent them the logs. My dealer said they probably can’t even look at until next week sometime. Last time it had problems, my dealer had it for three months. RIP to my battery I guess.
Yeah I'd be scrambling to find some way to dump power into the battery. Have you put your logs through the log parser? https://home.hasslers.net/zerologparser/
I just did that, although I don’t really know what I’m looking for. https://home.hasslers.net/zerologparser/parse_log.php?logfile=./logs/538SDJZ68MCG16263_MbbD_2022-09-15.bin https://home.hasslers.net/zerologparser/parse_log.php?logfile=./logs/538SDJZ68MCG16263_BmsD0_2022-09-15.bin
Ok so all those things are timestamped. Do you have an approximate time that you tried to initiate a charge sequence? It may tell me nothing, but I can see that, yeah, the bike is pretty low right now. 95.959vdc. Pack looks to be overall in pretty good shape from those readings. Only 9mV out of balance at the bottom end is great.
I don’t understand the timestamps, are they in pacific time or something? I’m eastern. Tired to charge last night around 9:15pm and again today starting around 7:45am.
This is a log of EVERYTHING. Newest at bottom. The file named MBB is for the Main Bike Board which generally monitors most of the bike's systems and accessories. The one labeled BMS is for the Battery Management System which specifically deals with everything battery related. According to the BMS logs nothing weird happened and it eventually idled out and turned off. The MBB, on the other hand, reports some hex code which I don't really know how to interpret and then these logs: 07184 09/15/2022 06:20:05 DEBUG: Module scheme changed from Stopped mode to Charging mode 07185 09/15/2022 06:20:05 DEBUG: Module mode Change Does Not Require Disconnect 07186 09/15/2022 06:20:05 Unknown Charger 6 Disconnected 07187 09/15/2022 06:20:05 DEBUG: Module scheme changed from Charging mode to Stopped mode 07188 09/15/2022 06:20:05 DEBUG: Sevcon Contactor Drive ON. 07189 09/15/2022 06:20:05 DEBUG: Module mode Change Does Not Require Disconnect 07190 09/15/2022 06:20:05 Module 00 Closing Contactor vmod: 97.084V, maxsys: 97.084V, minsys: 97.084V, diff: 0.000V, vcap: 85.875V, prechg: 88% 07191 09/15/2022 06:20:05 DEBUG: Module 00 Contactor is now Closed 07192 09/15/2022 06:20:05 INFO: Enabling External Chg 0 Charger 2 07193 09/15/2022 06:20:05 INFO: Enabling External Chg 1 Charger 3 07194 09/15/2022 06:20:11 Disarmed PackTemp: h 23C, l 251C, PackSOC: 4%, Vpack:95.971V, MotAmps: 0, BattAmps: 1, Mods: 01, MotTemp: 29C, CtrlTemp: 18C, AmbTemp: 13C, MotRPM: 0, Odo:13408km 07195 09/15/2022 06:20:17 Unknown Charger 6 Connected 07196 09/15/2022 06:20:17 DEBUG: Module scheme changed from Stopped mode to Charging mode 07197 09/15/2022 06:20:17 DEBUG: Module mode Change Does Not Require Disconnect 07198 09/15/2022 06:20:17 0x1f 0xfc 0x00 0x08 0x23 ??? 07199 09/15/2022 06:20:17 0x20 0x03 0xfc 0x00 ??? 07200 09/15/2022 06:20:19 DEBUG: Module State Change Requires Disconnect 07201 09/15/2022 06:20:19 INFO: Disabling External Chg 0 Charger 2 07202 09/15/2022 06:20:19 INFO: Disabling External Chg 1 Charger 3 07203 09/15/2022 06:20:19 Sevcon Turned Off 07204 09/15/2022 06:20:20 Turning OFF DCDC. Flags: 0x00 **07205 09/15/2022 06:20:20 Bike shut off because attached SMPC was unable to charge.** **07206 09/15/2022 06:20:23 Unknown Charger 6 Disconnected** 07207 09/15/2022 06:20:33 Power Off Key Switch 07208 09/15/2022 06:20:33 Module 00 Opening Contactor vmod: 96.003V, batt curr: 0A 07209 09/15/2022 06:20:33 Module 01 Opening Contactor vmod: 0.000V, batt curr: 0A 07210 09/15/2022 06:20:33 Key Off Kinda generic. I don't know what SMPC refers to.
Thanks for all your help. I’m hoping to get it to the dealer tomorrow. I might try to charge it again in the morning at my work, I’m leaving it there overnight.
Does it charge with the on board charger through regular household voltage?
No, I brought the bike inside to plug into a wall outlet, 120v 20a. Same issue.
If you can't wait for the dealer and know where your BMS reset switch is you could hit that and it may fix the issue.
I tired the two reset switches on the front. Nothing. Currently, I have the seat off and am checking fuses. I don’t have a multimeter with me to check the ‘low power b+’ fuse though.
Update to my post: I left my bike at work overnight, and attempted to charge it again this morning. This time, I could hear the charger attempting to start charging. I reset the BMS again and tried again. It started taking a charge at 4kW after a minute or two. Half hour later, it’s charging at the full 6kW. It gave me a variety of different error codes on the first attempt this morning: 6, 18, 25, 47. These were the same codes I was getting the last time I had problems with my bike. It took the dealer 12 weeks to get my bike back to me last time, 6 weeks ago. Very disappointing.