Gen2/Main Bike Board
From Unofficial Zero Manual
< Gen2
The Main Bike Board (MBB) controls the overall system, implements safety interlocks, and directs the controller.
- It is also the entry point for configuring these systems, performing diagnostics, and examining operational events.
- When referring to "the firmware", or "the logs", people are referring to this board primarily, and possibly the BMS.
- It is enclosed within a fully-potted plastic-like container with multi-pin connectors along the top side.
- Location (S Platform)
- Below the front area of the seat under cable runs.
- It is located aft of (and above) the DC-DC 12V Converter with a bracket sandwiched between them.
- Location (X Platform)
- Below the front modular battery (or front half of a longbrick battery) in the triangular bay above the controller.
- Mounting (S Platform)
- Two socket head bolts with washers fasten the enclosure to a vertical plate.
- The bolts enter the plate in the forward direction but offer very limited clearance for manipulating them.
- NOTE: on the right, the cables from the controller to the motor run past.
- A very small angled 3mm Allen Key wrench is best for unmounting the board.
- Diagnostics
- When using the OBD2 port, the board's application firmware supplies the interactive console.
- Playing with the 2012 MBB shows Doctorbass' transcript using 2012 firmware.
- 2013 models' interface differs quite a bit from this but the general logic and experience are the same.
- Protections
- The board appears to be permanently sealed and potted within the enclosure to protect it from dust and a certain amount of moisture ingress.
- Interlock Troubleshooting
- Use careful electrical isolation measures when troubleshooting electrical switches used as inputs for interlocks enforced by the firmware.
- Replacement
- The board must have its firmware setup specific to the bike in question.
- Major firmware difference exist across model years such that the firmware binary in question must be selected to prevent major problems on replacement.
- NOTE: Apparently only the manufacturer can perform this provisioning (probably imaging the base kernel, userland, and application-container management).
- A dealer must select the correct and latest applicable application firmware to apply to the bike per its basic parameters:
- Year
- Model
- Battery configuration
- Information from the bike's VIN is necessary to select the right programming by the dealer or manufacturer.
- This information may not be sufficient, if it requires coding in the presence of a Power Tank or Charge Tank.
- The board settings require model information to be set per above, and the BMS must agree about this information.
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