Overheating

Please tell us the precise details of your conversion, most importantly, what pack voltage you have. I am wondering if it is over voltage (compared to the original) at all if this may be the problem? MW

I was reading the Zero motorcycle forums elsewhere and they mentioned controller temperatures of 150F and more as the threshold for overheating. I think what you are seeing is normal under hard riding. Is it good? Can't comment on that.

riding at 68mph is very energy intensive - the MC will get hot (or rather it's heatsink will)

I suspect that the reason I managed to damage two IGBT modules internally was due to overheating by riding my vectrix at 68mph for 30mins continuous twice a day

interesting that it happened after just 1min at 68mph

I wouldn't worry about your batteries unless they're getting to 50 deg C

Hi Elevatorguy,

From your posts I gather your overheating issue lies with the battery not the MC? Obviously, fixing the problem initially relies on an accurate diagnosis of the fault.

The manual says the dash 'High Temp Telltale' light (HTTL) illuminates when '…the battery or key system components exceed safe operating temperature.' Does your BMMS monitor battery temperature? I'm just wondering if the HTTL is coming on do to something else, e.g. the MC getting too hot? Maybe the MC fan isn't working?

If it is the battery, did you install the original Vectrix battery temp sensors back into the LiFePO4 battery terminal bolts? Or did you just tape them up and tuck them out the way somewhere? Obviously if it's the latter then perhaps either they are getting too hot where they are or maybe they are partially shorting or something?

If you reconnected them, does the HTTL light work in a way that tallies with any other battery temperature monitoring you have (i.e. BMMS or CA) etc?

TS cells should cause no problems with overheating either during charging or discharging due to the relatively low amps being drawn during each case.

Which firmware are you using at the moment? You say "lion65", but where's it from and what are its characteristics?

The Laird has just this week sent me a firmware file which works very well for my 42 x 40AH CALB conversion - you could ask him for something similar for yours?

Battery warning light = low pack voltage. Was the pack voltage low?

"...It was only 100F according to the sensors…" What sensors and where/to what are they mounted? If you know the battery temperature is not excessive (from your other monitoring systems) and the bike is showing an over temp battery issue then clearly the bike's hardware/firmware is not woking correctly.

According to the trouble shooting guide (in the manual) ;-
1/ Flashing battery light AND flashing HTTL = battery temp > 50C OR battery temp sensor data error. You stated your cells were at 100F = 37C i.e. no-where near a battery temperature issue ergo - faulty battery temp sensor(s).
2/ Flashing battery light AND flashing HTTL AND flashing wrench = 'Battery air plenum' - whatever that means!

I think you may have a case of the old faulty temperature sensor thing. A search on VIFV for this problem may help but I think your first job is to hitch up the peak cable and see if there are any errors logged in the diagnostic software. Depending on the result of that, I'd consider trying to do away with the sensors either one at a time, all together, temporarily or permanently - I believe there is a version of the firmware that works without them connected (I may be wrong on that so don't get your hopes up). Failing that, you'll have to try and find out which sensor is defective and replace it.