Project empulse

[Gio]

hi empulse owners my name is gio and I just bought a empulse r. It's a defective bike it wouldn't charge anymore. That's how I came to this forum. I was a mechanic for 20 years and mechanical/elektric runs though my vains. When I diagnose the bike I realize one of the seven batteries wouldn't charge (top front). The rest of them voltage I could get 14,5+. So I took the battery out and opened it up. First I opened the bottom part and saw that some cells were bloated. That's problem nr1 After that I opened the top and saw that it had some corrosion damage one 3 transistors. I will bring the print plate to a specialist for repair. After this I could pull the top of to seperate the cell pouches. It was a little hard because they were bloated. Cut some fingers while doing so. But it all worked out. I measured all cells and they were flat. So I'm looking for new cells. The specs I found were 10ah 3.7volt 3/5c li-on pouches. I found some suppliers in China who could make them. But I'm still looking for something closer to the Netherlands /Europe. My plan is to leave the battery as much as original. I will try and upload some pictures of my progression when I'm on my computer. Don't know how this works on my phone.

[Brammofan]

Welcome to the forum Gio. There is another project going on with an Empulse in this subforum. Good luck to you.

[Gio]

Yes I just saw it I will keep an eye out on that one as well!
I removed the pouch cells already.
Will post some pictures soon

[Korbin Dallas]

Welcome to the forum Gio

[Haplo]

Hi Gio,.

Welcome to the forum and great to see work on another Empulse.. And it seems you are in the Netherlands? So am I, and also working on an Empulse I bought a while ago.

I see you already looking at replacement pouches. I can recommend you to first readout the memory-stick which in the bike. It might give a clue to where to look for more specifically. I had some idea's to fix the bike when it first broke, but since I had the data of the memory stick and know where to look for, the plan got much clearer. I'm getting confident I will get it running again.

Good that you are also focussing on repairing the PCB. When you won't get that working, buying replacement pouches wont help much.

[EV promise]

Hi Gio, welcome here. As mentioned above you really need the remove the usb data stick from inside the orange sleeve under the seat and post a couple of the .chg or .drv files (20 to 100k size).
It's likely the bike developed a fault, then was not used resulting in the batteries becoming faulty. There is a link on this site to a program to convert the files to Excel or you can just attach a couple and we'll feed back the information and converted file for you to read.
Hop that helps

[Leander]

welkom! dit project klinkt als een hele uitdaging!

[Gio]

so today i feeled a little bit better i was sick for a week and started to look at the empulse again.
i charged 6 of the 7 batteries ( one is bloated as seen in pictures below).
The all hold there voltage so it seems that i only got one faulty battery.
I didnt get the pcb back yet and i also didnt find the wright size pouches.
The pouches i need are Lithium NCM pouches 10ah 3.7 volts with a dimension of 2450x158x10 these are realy hard to find.
Most of the pouches are lipo or lifepo , if i replaced all packs then i would try the lipo but i only want to replace one for now i still need to look if the empulse doesnt have more defaults.
If someone knows someone with a complete oem battery or good poouches please let me know.

I also downloaded the files of the usb to my pc but it seems that the converter isnt working on my pc and i cant get it to work.
Last file registerd was from 4-2022.
I will ad a link of the last few files on the bottom the complete file is 3gb.

someone who can convert it for me here?

File link:
https://file.io/JUzoQO2uvzwS

[EV promise]

Hi Gio,  I have hopefully attached some of the smaller files below. The modules are numbered on the top row with 1 at the back and 4 near the steering head and on the lower row 5 at the front and 7 by the motor.
I open the file in Excel, freeze the top row so I'm able to read the headers.
Module 5 shows the highest relative humidity so should be looked at. These seem often to collect moisture. Difficult to say if it's condensation from changing temperature and weather or if rain drips off the tank, lands on the modules and creeps in.
No serious errors are shown that shutdown the bike, however bloated cells will need dealing with.
Have a read and see what you think. I hope other members will comment also

[Korbin Dallas]

The logs are interesting. very cold on the last one. Even with the B9 humidity fault was the bike still drivable? I would like to see the back of the circuit board in the picture. Did you say you found someone to repair the boards? My guess is that is why the bike wont charge. As far as the cells in the picture...all the swollen ones should not be used. We would love to find a reliable source for new cells. I know that Brammo made some different batteries for other markets (golf carts and backup power supplies) The swollen cells also cracks the plastic parts of the case which will make it harder to keep the moisture out in the future. please continue to update us on your progress, we are all learning. Thank you Gio.

[patrick]

so today i feeled a little bit better i was sick for a week and started to look at the empulse again.
i charged 6 of the 7 batteries ( one is bloated as seen in pictures below).
The all hold there voltage so it seems that i only got one faulty battery.
I didnt get the pcb back yet and i also didnt find the wright size pouches.
The pouches i need are Lithium NCM pouches 10ah 3.7 volts with a dimension of 2450x158x10 these are realy hard to find.
Most of the pouches are lipo or lifepo , if i replaced all packs then i would try the lipo but i only want to replace one for now i still need to look if the empulse doesnt have more defaults.
If someone knows someone with a complete oem battery or good poouches please let me know.

I also downloaded the files of the usb to my pc but it seems that the converter isnt working on my pc and i cant get it to work.
Last file registerd was from 4-2022.
I will ad a link of the last few files on the bottom the complete file is 3gb.

someone who can convert it for me here?

File link:
https://file.io/JUzoQO2uvzwS

Hi Gio, I'm buying mines from here, direct replacement

https://a.aliexpress.com/_EIfa7sh