Battery communication service cable

[new-brammo-guy]

Hi All, Does anyone know where I could find the "Brammo Battery Communication cable" also know as the "Brammo Enertia powercycle service adaptor" (see pic)? Anyone interested in selling theirs? Thanks a lot

[Brammofan]

I think this may be the thing that connects to the back of the speedometer?  I hope you have luck finding one. I don't have any leads on it, though.

[new-brammo-guy]

I believe it connects directly to the battery. Happy to pay someone for theirs if they no longer need it...

Or did anyone have luck making one? I saw this past thread about making one:
https://brammoforum.com/index.php?topic=3696.msg26581#msg26581

Thanks all!

[KaFr]

The Brammo service adapter is difficult to obtain. You'll probably have to make it yourself. Try writing a PM to someone in this forum who can do it.

[new-brammo-guy]

Thanks all. Has anyone been able to make one? I have or can purchase parts, solder, etc. as needed.

[hackshack]

I'm making one.

I haven't received the parts yet, so I don't have anything to show for it. I've collected what I've found in the forums plus my own searching. Thanks to people on the forum, especially nunux59, Brammofan, and frodus. Here are my notes on the cable and diagnostic tools:

Relevant links
Get these 3 while they're up!
Victory Battery Diagnostics:
http://environ-systems.de/mediapool/132/1325968/data/64956043_02_Battery_Diagnostics-1.0.11.41.exe
The Brammo-Stuff.zip archive (top toolbar > Download as ZIP): https://mega.nz/#F!V6J1nArS!siHe7eJkhPL-9cjuYVa7cQ
The Brammo technical docs collection ("Brammo.pdf"): https://brammoforum.com/index.php?topic=3701.msg26113

Relevant threads:
* Another thread on the forum about this: https://brammoforum.com/index.php?topic=3696
Note the Polaris Digital Wrench software is not used for this bike.
* Replacement parts thread. https://brammoforum.com/index.php?topic=3502.0

For the RS-485-to-USB transceiver:
From what I've read on this forum, the official Brammo cable appears to use an FTDI chip.
See FTDI document reference FT_000117: https://mouser.com/datasheet/2/163/DS_USB_RS485_CABLES-16812.pdf
The Brammo doc dump ("Brammo.pdf") may have further reference to this but I kinda just skimmed it.
I'm substituting Amazon ASIN B010KJSCR8 for the "brains" of the cable as it uses a genuine FTDI part.

For the battery end of the cable:
The round connector is Molex 120079-0310, according to Brammo document 75165465_A.00 CABLE M12-PICOSPOX 1M.pdf. The series catalogue (page S-34) calls it an "Ultra-Lock" connector: https://www.farnell.com/datasheets/1271388.pdf
Its Mouser stock number is 538-1200790310; it's not in stock (May 2021); minimum order USD $2,847.00 for a quantity of 100.
Molex has a drawing of the receptacle here (it's the 8-pole connector): https://www.molex.com/pdm_docs/sd/1200845098_sd.pdf
I don't need the cable to be weatherproof, so I'm planning on 3D printing this connector.

Wiring things up:
The above Brammo document ("75165465...PICOSPOX 1M.pdf") shows the pinout for the adapter cable. I won't post the image but will describe it. Looking at the cable's Molex connector, there are 7 pins within a shell, and an 8th pin in the center. The shell has a notch in it. Holding the connector so the notch is at 7-o'clock position to you, pins 1-7 run clockwise.
Pin 1 - to the right of the notch. About 6-o'clock position. No connection.
Pin 2 - to the left of the notch. About 9-o'clock position. RS-485_D+_1.
Pin 3 - 10-o'clock. RS-485_D-_1.
Pin 4 - 12-o'clock. RS-485_UNUSED_1.
Pin 5 - 1-o'clock. RS485_INTERLOCK_1.
Pin 6 - 3-o'clock. RS485_INTERLOCK_2.
Pin 7 - 5-o'clock. RS485_+12V_1.
Pin 8 - center. RS485_GND_1.

MiBa from the forum mentioned:
PIN6 / Interlock_2/ brown wire / is connected to GND (or PIN8)
PIN5 / Interlock_1 / green wire / is somehow open or not connected, I can't find any connection to somewhere

Software:
There are 2 versions of Battery Diagnostics software that I've found:
* 1.0.10.40 - Brammo branded. Part of "Brammo-Stuff.zip" on mega.nz. In my tests, this program always displays the message, "No COM ports were detected. Check your serial port module connection and restart the application." Even if you install the LabVIEW driver, it does not work. I tried using an Arduino Leonardo with a custom USB VID/PID, plus Zadig to replace various USB drivers, but nothing worked.
* 10.0.11.41 - Victory branded. This one sees all COM ports! Requires LabView 32-bit runtime (2020 works fine) - you need to register on NI's site for a free account - download the offline installer to be future-proof - it's the small text in the lower right: https://www.ni.com/en-us/support/downloads/software-products/download.labview-runtime.html
* If this ever takes off, I recommend getting something like a used ASUS M80TA - VivoTab Note 8 - off eBay as your dedicated "Brammo service computer." Something cheap and portable from the era of basic Windows 8 tablets. You'll need a USB-OTG adapter. It also won't charge and use USB at the same time.

[Brammofan]

Wow... You've done your homework. Can't wait to see how it all comes together.

[sunchaser]

I agree.  Also a very detailed and well written post.  Looking forward to seeing your progress on this.  This forum needs all the resourceful people we can get!

Good luck.

[nunux59]

Indeed I gathered all the parts but never build the cable. This topic give me motivation to finally do it.

Regarding the Molex connector I bought it on Aliexpress, the magic keyword is GX16 I test fit it in a battery module to validate that it was the right connector.

Hackshack forgot to mention that you also need a 12V power supply but I think he can be forgiven regarding his really detailed post 

Good luck

[hackshack]

Quick update on connectors.
I've received various RS-485 and CANbus transceivers to test out. I have the "brains" of the cable - all I need is the circular battery connector that carries the RS-485 data. I decided not to 3D print one, because the goal of this project is for regular Empulse owners to be able to build a cable by themselves.

I ended up cheating and bought a spare Empulse battery-to-battery cable on eBay. I will cut it in half to get one male and one female connector.
This is not sustainable for us owners, though. We need a source of new connectors. I spent 3 days researching this connector.

I measured the female plug part of the connector; the insulating black plastic is exactly 8.0mm in diameter.

It appears to be a smaller version of a type of connector widely used in industrial automation. Specifically, it appears to be an "M8"  connector, with 8 pins. I specify pin count because the M* refers to the outer thread diameter, not pin count. M12 seems to be the common connector in use for industrial automation, and indeed the Brammo drawing references "M12" several times, but the plug is too large (I ordered a few). Information is surprisingly hard to find on the exact pin and shell measurements for M* style connectors. In addition, pin count varies in both number and geometry.

M8 connectors are not nearly as common as M12. M8 connectors with 8 pins are hard to find.

nunux59, regarding connectors: care to share the specific Aliexpress listing, or provide a photo of that GX16 connector next to one of the Brammo ones? Issue I see is that the GX** numbering seems to refer to the tip-to-tip distance on the outer nut securing it to the panel (!) and I cannot find good measurements of the internal plug in the GX** postings. I also saw these referred to as "aviation connectors." I was looking at GX12 as well, but vendors seem to focus on the external dimensions and not provide data on the diameter of the internal plug.

[nunux59]

I measured the connector that I ordered and tested and I can confirmed that the thread is 12mm. I found the exact item that I bought : https://fr.aliexpress.com/item/32844548144.html?spm=a2g0s.9042311.0.0.27426c37nPUxEw
I took a "straight", "8 pin", "female".

Sorry it was not GX16 but 12 ! Finally the good keyword was more M12 cable or M12 connector.

[new-brammo-guy]

I made a battery service cable and communicated using the Victory Battery Diagnostics software. I soldered the wires + heatshrink. With the software installation it took about 1 hour total. I was pleasantly surprised it just worked without debugging.

I followed the directions posted in this thread including the LabView 32-bit runtime software, wiring, etc. (thanks hackshack and others!)

I used this USB to RS485 dongle (3.3v): https://www.waveshare.com/usb-to-rs232-485-ttl.htm

I also have this one and it worked too (and cheaper!): https://www.waveshare.com/usb-to-rs485.htm

I needed a 12V power supply (blue wire, Pin 7) and used the same ground from the power supply as the connector ground (orange wire, Pin #8). See attached image.

I used the same colors as Brammo in their wiring diagram (except I used brown for the ground going to the power supply, which isn't consistent, should be orange).

To find the plug into the battery (Molex 120079-0310), I had a spare from another Brammo battery harness. I just cut it and the colors are all correct per the drawing linked in this thread (75165465_A.00 CABLE M12-PICOSPOX 1M.pdf).

The above is a test for the Brammo modules, though I ordered the connectors for the Victory Empulse TT and will try that too (I'm getting the B40 error on my Victory Empulse because of the failed temp sensors in the lower module).

[EV promise]

Hi, you're doing a great job. I was pleased to see the image of the connections. I bought the parts a while back but never made them up. I'll download the LabView software as I don't have that. I didn't realize it was required!!  Update - I do have it. It's called NI Max on my laptop and it contains the LabView software.
When do you expect to connect your Victory Empulse tt' battery?

[Korbin Dallas]

Thanks for the picture. Is this your power supply? https://www.extech.com/products/382260 .Can you use this to charge the individual Brammo batteries?
Also since we need 12v power supply for the rs-485 can we use this for the brammo and the victory batteries to communicate with the bms? https://www.electromaker.io/shop/product/usb-to-rs232-rs485-ttl-industrial-isolated-converter?gclid=Cj0KCQjwxveXBhDDARIsAI0Q0x2QjE_EQdDlBzDfaLC7gLqnwr_p4DdEB-HiZCLn3hfDAZvWBEYi910aAhjPEALw_wcB.
Thank you for your work on this and putting it out there for the benefit of all.

[new-brammo-guy]

Yes, that's the Extech benchtop power supply I'm using to provide +12v to the blue wire (RS485_+12V_1, Pin 7). Yes, you could also charge each individual Brammo battery module with that same power supply, though the current is limited to 3 or 5 amps.

This is the dongle I used to communicate to the BMS via RS485: https://www.waveshare.com/usb-to-rs232-485-ttl.htm

I ordered the connectors for the Victory Empulse - will post when I have them and working.

Happy to chat over the phone if you're having issues with the DIY service cable - just PM me (I'm central time, USA)