I had some strange Zilla issues once that turned out to be noise in the
RPM sensor. The sensor signals weren't being picked up properly so the
controller cut power to the motor after it detected a "stall" caused by a
faulty RPM signal. My EV would move forward a few feet before the Zilla
cut power to the motor. Foot off the pedal, back down, and the EV would
move another few feet...
Might also check to make sure the throttle isn't partially on when
starting your EV. Could be the Hairball is waiting for the throttle to go
completely off before applying power. It's at least something that could
be weather/temperature related. Having partial throttle applied can also
affect serial communications with the Hairball (at least according to the
manual). If you have serial communications, you can check the throttle
input data.
The fact that your controller stopped responding when updating your BMS
also sounds fishy. That smells like electrical interference. Maybe try
isolating the cable between the Zilla and Hairball a bit more. Does it
still have the ferrite bead?
-Adrian
On Sat, 13 Apr 2013 11:35:02 -0700, Iron Mountain Films
<ironmountainfi...@yahoo.com> wrote:
I hope the brain trust on this list can help I am sending all this
info to Manzinita Micro also.
first the good news I am back on the road after almost a year, now with
a pack of 45 CALB CA grey cells. When I can get the car to go it is
awesome, which is most of the time.
On my first attempt after install of the new pack, I tested without the
Orion BMS hooked up, motor spins; Hook up Orion BMS aux (bms)
contactor closes and motor spins; put the car down car backs up and
pulls foward, I open the gate to take it for a test drive,
then it wouldn't precharge and hairball shows error and contactor off
LEDs (I believe this is normal) Hooking up to Mac with z term original
error was newest 1111 Cleared codes and then got a 1113 EEPROM crc
error and then lost
communication Tried on pc laptop in hyperterminal but not working I
then hooked up a bulb to ck engine light and did serial port shorting
plug procedure and got a 1311 waiting for key. I then sent the Hairball
to Manzinita Micro after talking to a tech. They checked it out and
updated firmware and found no problem. I re-installed in the car, still
no worky kept getting waiting for start error, I then checked my start
signal and no start signal (hooked to starter relay on key). I bypassed
that and just put in a microswitch to give me a start signal and the car
worked. Very big Grin.
I took multiple trips without problem.
The first time it wouldn't go was after charging, the car is warm it is
about 75 or 80 degrees. The weird thing is the Orion closes its
contactor and the Zilla precharges Hairrball shows green led contactor
on, but the car wont go. this has happened 3 or 4 times. Each time I
have left the car after trying to get it to go including powering down
the zilla completely, (that actually worked one time), and after it
has cooled down or I come back to it, it fires right up. The codes I am
pulling are 1312, waiting for start, 1133 lost communication with
controller during use,either direction. (I believe this happened when
while trying to trouble shoot I sent a new profile to the bms to turn
off thermistors while driving no throttle applied, throttle stopped
responding) 1231 propulsion pack open, no contactor drop, controller
not responding; 1241 key input not on while key is asserted; 1111 no
more dtc's On Previous occasions the
error sequence was the same but without the 1133 code.
The Zilla has been very reliable I bought it in 05. I have read that
it should be in a sealed box Mine is mounted on a heat sink above the
motor not in a box. Maybe sitting around for a year it has collected
moisure?
Mike MalmbergIron Mountain Films, Inc
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