Okay, this is what I did so far:
Step 1: Cable and SoftwareI have built a diagnosis cable for the battery modules. With the
very good instructions Corbin Dallas has pointed me to I was able to finally get it running.
My lessons learned out of this:
I knew fresh from start that the Brammo/Victroy SW requires a LabView Runtime installed, which I did upfront. When I started the Victory Battery Diagnostics it wouldn't start, saying it could not find CVIRTE.DLL. First I thought it is only that one DLL - searched & found it and put in the same folder as the battery diagnostics executable. Again the diag did not start, this time with an undefined error.
It took me some time to figure out that cvirte.dll belongs to another Runtime from NI which is called CVI RT. Either I overlooked this bit of info or you guys have a much deeper understanding of the overall setup. Downloading and installing that one did the trick.
Also, I made the installation procedures initially with the latest available version (you can choose the year of the SW modules when you choose what to install from NIs homepage). Since I got an older laptop that can stay in my garage as exclusive diagnostice I reinstalled all the Runtimes and Softwares once again but this time using versions from 2014. That is definitively a good hint as those packages were much slimmer and faster with the installation process - and still work as intended.
Next, building the diagnosis cable: That step was an almost* straight forward process. I have ordered an adapter from Amazon Germany (since I am German):
DSD TECH SH-U11 USB zu RS485 RS422 Konverter mit FTDI FT232R Chip.
*almost, because I ran into two issues: (i) the cable colors were different compared to what is given in the Brammo document 75165465_A.00 CABLE M12-PICOSPOX 1M.pdf. Simple measuring each cable resolved this. (ii) my adapter does not have D+ and D-, instead A+ and B-. Well, you can guess it: Use the plusses and the minusses. Also, I almost overlooked the comment in the post about PIN6 / Interlock_2/ and PIN5 / Interlock_1 / green wire. So read the post careful and you know how to do it!
Step 2: The batteriesWhen I picked up the bike, the seller mentioned it does not charge. Batteries are dead since 2023. Then I connect the charger, the bike does fire up but reports SYSTEM FAULT C3 and SEVERE UNDERVOLTAGE.
Okay, lets tackle the undervoltage first. Reading the log file showed that the lowest cell is at 2.6xxV - which is in a standard 18650 LiIon cell NOT beyond repair. The modules used in the E+ BPM 44-70 are using a different chemistry LiNiCoMnO2 where I could not find a threshold value (but I was not looking with too much energy).
I diassembled the bike with the intention to take out both batteries in order to be able to open them. But since the LOG file indicated voltages between 2.6 and 3.0V I simply connected a battery to a lab power supply, setting the voltage to 38V at 1A and allowed it to sit for a while (thanks to KaFr for your comments on Facebook Messenger!!! This was the right motivation and some guidance I needed!).
So disassembly was not really required - apart from taking the rear frame off to get better access to the main battery interconnection and the diagnostic connectors. Slimg agile fingers and a straight diag cable might even render that disassembly as not required.
Back to topic: After stable 38V were achieved and the battery diagnostic tool showed acceptable 0.050V imbalance, I applied 42V and 2A, afterwards 48V and 5A. The whole charginc process took almost three days as I was waiting for the current to get below 100mA for eacht target voltage. Same procedure then applied for the second battery.
The battery diagnostics tool still reported several errors but I dismissed them as being acceptable, like imbalance above 0.015V, temp sensor deviation readouts and others.
Strangely, it also reported 0% SOC until ca. 47V were achieved and it ended up with only 19%SOC at 48V. Also, the diag SW reportet an error here as values between 78 and 95% would have been expected.
I did not know and still don't how to interprete this and finally decided also to dismiss this low SOC.
Finally I reassembled the bike and fired it up immediately! SOC from the dashboard was showing 90% SOC. Yeah!!! I allowed the bike to sit for another 24hrs. Finally, I took it out for a test ride (the bike is not registered nor insured, so I did it late night at not s crowded streets and also just around the block - I felt like a 14-yr old doing somting forbidden). The bike did take looooong way to accelerate until 80kmph/50miles and it would have gone beyond but the street took some turns and did not allow much more.
Unfortunately I cannot plug in the diag cable again without dismounting the rear frame again, so I cannot verify if the diag tool still shows 19%SOC.
One problem still remains: A new system fault C2 - a generic charger fault. The charger gets warm, I can hear relais clicking and the dashboard reports the bike is in charge mode - but the batteries would not take any charge. KaFr has again provided some hints of what to check, so this story will probably continue!
I am hoping this provides some help or motivation for those out there who are undecided! Just go for it!!
