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extract from service manual
<onlyinclude>
The controller's configuration implements a number of Zero features:
* Speed calculations.
* Distance calculations.
* Over-voltage limits to protect the battery by cutting out regen or refusing to operate.
* Under-voltage limits to protect the battery charge state.
* Current limits to protect the battery.
* Delay before regen toggles on or off.
* Driving modes like Eco/Custom/Sport which include speed and torque limits and speed ramping limits to prevent wheel lockup.
;References
: [http://www.sevcon.com/products/low-voltage-controllers/gen4/ Sevcon Gen4 product page] (formerly at [http://www.sevcon.com/ac-controllers/gen4%E2%84%A2.aspx])
: [http://www.sevcon.com/media/78433/gen4_size_2_4_6_may_2016.pdf Gen4 data sheet] (no longer available without request form with contact details)
: [http://www.thunderstruck-ev.com/Manuals/Gen4_Product_Manual_V3.0.pdf Gen4 reference Manual]
; Configuration
: Some MBB settings direct the Sevcon controller; look to the MBB first.
: The MBB can also provide a dump of Sevcon diagnostics and logs.
: DVT software to maintain the Sevcon programming is available but recent versions require a license and the cabling is not cheap. The older unlicensed versions may have trouble maintaining newer programming by Zero.
; [http://electricmotorcycleforum.com/boards/index.php?topic=4297 Direct diagnostics]
: For those interested in better understanding your Zero's motor controller setup, you'll need some specific cables and software.
:: These will allow you to browse the current controller configuration as well as make changes such as increasing regeneration rates, customising sport or eco modes etc.
: This is what you'll need:
:# An IXXAT CAN-USB compact adaptor v1.5 (v1.01.0087.10100) or v1.6
:#:approx USD300 but you may find it cheaper on eBay or borrow/rent it from another forum member or dealer.
:#: You cannot buy these anymore, you must get them off ebay or part of a [http://www.thunderstruck-ev.com/sevcon-gen4-pc-based-programming-kit.html Thunderstruck EV $900 kit].
:#: You cannot use a new version of the IXXAT CAN-USB either as it will not work with an unlicensed copy of the software. And to get a license you have to own a business.
:# A DB2 female to OBDII male cable with a specific pin mapping (not the most common one).
:#:[http://www.easysync-ltd.com/ Easysync] make a [http://www.easysync-ltd.com/product/577/obd-m-db9-f-es.html DB9 female to OBD male cable] that has the correct pin configuration - about USD25
:# Sevcon DVT Customer software
:#:It has to be version 1.03c or lower to use unlicensed (Google is your friend, as is Dropbox in this case).
:#:Good luck saving your DCF files with it.
:#:You need to write down your settings before making big changes.
:#:Even if you bought the new version and got a license you would have to use a NEW IXXAT USB-CAN as the old one isn't compatible.
:#:The Sevcon software will run on Windows XP, 7 and 8.
:#:There are manuals and getting started guides on the Internet (Google again) on how to use the DVT software including one at [https://www.thunderstruck-ev.com/images/DVT%20Tutorial.pdf Thunderstruck EV].
: {{Warning| Do not link any files as they have been removed multiple times in the past.}}
:* One of the dropbox links you will find will have at least 3 different versions.
:* If you install any new versions completely remove everything from the previous versions.
:* If you find the program wont start up and it isn't 1.02 then install a "merge" installation of TCL and it should work.
: {{Warning|You can brick your controller temporarily by making changes.}}
:: It would be nice to have a backup but these online versions of "free" sevcon software all have issues with saving.
:: I have tested 1.00 1.01 1.02 (which never ran) and 1.03c so far.
:: If you brick your device you will need someone to give you a DCF file to return your device to working order.
:: But good luck getting it from a form member who doesn't work for a dealer as stated it is next to impossible to export the file.
: Sevcon is very much against this use of their product and software, and have issued takedown notices for publicly available files.
: You will not get official support and people will be reluctant to post details publicly.
:: Get the 200 page DVT / SEVCON GEN 4 manual from the manufacture's webpage and read it a couple times.
:: Try contacting knowledgeable people privately.
: You really need to understand what you are doing when you start to make changes.
:: This isn't a toy you are going to be remotely piloting, it is a vehicle you are risking your life on!
: Zero has specific programming to customize the Sevcon controller.
:: So it is not clear whether customer customization is achievable beyond basic modification of settings or performing an alignment using DVT.
; Recovery
: [https://endless-sphere.com/forums/viewtopic.php?f=30&t=88205&p=1287062#p1287062 DoctorBass has documented a backdoor method of recovering a Sevcon controller if its firmware is in an unusable state]
: Using the IXXAT connection, issue the following command:
can send "0x7FA 0x48 0x65 0x79 0x73 0x6c 0x69 0x70"
: This byte sequence is also apparently available as "BD" (for "backdoor", presumably).
</onlyinclude>
[[Category:Advanced Modification]]
The controller's configuration implements a number of Zero features:
* Speed calculations.
* Distance calculations.
* Over-voltage limits to protect the battery by cutting out regen or refusing to operate.
* Under-voltage limits to protect the battery charge state.
* Current limits to protect the battery.
* Delay before regen toggles on or off.
* Driving modes like Eco/Custom/Sport which include speed and torque limits and speed ramping limits to prevent wheel lockup.
;References
: [http://www.sevcon.com/products/low-voltage-controllers/gen4/ Sevcon Gen4 product page] (formerly at [http://www.sevcon.com/ac-controllers/gen4%E2%84%A2.aspx])
: [http://www.sevcon.com/media/78433/gen4_size_2_4_6_may_2016.pdf Gen4 data sheet] (no longer available without request form with contact details)
: [http://www.thunderstruck-ev.com/Manuals/Gen4_Product_Manual_V3.0.pdf Gen4 reference Manual]
; Configuration
: Some MBB settings direct the Sevcon controller; look to the MBB first.
: The MBB can also provide a dump of Sevcon diagnostics and logs.
: DVT software to maintain the Sevcon programming is available but recent versions require a license and the cabling is not cheap. The older unlicensed versions may have trouble maintaining newer programming by Zero.
; [http://electricmotorcycleforum.com/boards/index.php?topic=4297 Direct diagnostics]
: For those interested in better understanding your Zero's motor controller setup, you'll need some specific cables and software.
:: These will allow you to browse the current controller configuration as well as make changes such as increasing regeneration rates, customising sport or eco modes etc.
: This is what you'll need:
:# An IXXAT CAN-USB compact adaptor v1.5 (v1.01.0087.10100) or v1.6
:#:approx USD300 but you may find it cheaper on eBay or borrow/rent it from another forum member or dealer.
:#: You cannot buy these anymore, you must get them off ebay or part of a [http://www.thunderstruck-ev.com/sevcon-gen4-pc-based-programming-kit.html Thunderstruck EV $900 kit].
:#: You cannot use a new version of the IXXAT CAN-USB either as it will not work with an unlicensed copy of the software. And to get a license you have to own a business.
:# A DB2 female to OBDII male cable with a specific pin mapping (not the most common one).
:#:[http://www.easysync-ltd.com/ Easysync] make a [http://www.easysync-ltd.com/product/577/obd-m-db9-f-es.html DB9 female to OBD male cable] that has the correct pin configuration - about USD25
:# Sevcon DVT Customer software
:#:It has to be version 1.03c or lower to use unlicensed (Google is your friend, as is Dropbox in this case).
:#:Good luck saving your DCF files with it.
:#:You need to write down your settings before making big changes.
:#:Even if you bought the new version and got a license you would have to use a NEW IXXAT USB-CAN as the old one isn't compatible.
:#:The Sevcon software will run on Windows XP, 7 and 8.
:#:There are manuals and getting started guides on the Internet (Google again) on how to use the DVT software including one at [https://www.thunderstruck-ev.com/images/DVT%20Tutorial.pdf Thunderstruck EV].
: {{Warning| Do not link any files as they have been removed multiple times in the past.}}
:* One of the dropbox links you will find will have at least 3 different versions.
:* If you install any new versions completely remove everything from the previous versions.
:* If you find the program wont start up and it isn't 1.02 then install a "merge" installation of TCL and it should work.
: {{Warning|You can brick your controller temporarily by making changes.}}
:: It would be nice to have a backup but these online versions of "free" sevcon software all have issues with saving.
:: I have tested 1.00 1.01 1.02 (which never ran) and 1.03c so far.
:: If you brick your device you will need someone to give you a DCF file to return your device to working order.
:: But good luck getting it from a form member who doesn't work for a dealer as stated it is next to impossible to export the file.
: Sevcon is very much against this use of their product and software, and have issued takedown notices for publicly available files.
: You will not get official support and people will be reluctant to post details publicly.
:: Get the 200 page DVT / SEVCON GEN 4 manual from the manufacture's webpage and read it a couple times.
:: Try contacting knowledgeable people privately.
: You really need to understand what you are doing when you start to make changes.
:: This isn't a toy you are going to be remotely piloting, it is a vehicle you are risking your life on!
: Zero has specific programming to customize the Sevcon controller.
:: So it is not clear whether customer customization is achievable beyond basic modification of settings or performing an alignment using DVT.
; Recovery
: [https://endless-sphere.com/forums/viewtopic.php?f=30&t=88205&p=1287062#p1287062 DoctorBass has documented a backdoor method of recovering a Sevcon controller if its firmware is in an unusable state]
: Using the IXXAT connection, issue the following command:
can send "0x7FA 0x48 0x65 0x79 0x73 0x6c 0x69 0x70"
: This byte sequence is also apparently available as "BD" (for "backdoor", presumably).
</onlyinclude>
[[Category:Advanced Modification]]