2016 Victory Empulse TT - with code B40 - Free.. if I can't fix it.

[KaFr]

Hi EV Promise,
when the battery was almost 100% charged, error B40 was triggered because the temperature sensor on PCBA #5 reported an extremely low temperature (TOO COLD) unlike the other PCBA temperature sensors. Then the B8 error started. Subsequently, the battery reported a too high temperature (TOO HOT).

[EV promise]

Hi KaFa, yes I see the other faults now. Thanks for the information. A more recent file than the ones I was looking at.
Hi Bob, I believe you should disconnect the battery safety connection by the headstock urgently. It's clear to me, the lower module needs to come out and apart to dry off but as for repair I'm at a loss. I've attached an image of what you're probably going to find. Also to the top left, is what I believe to be the humidity/temperature sensor U14 with two dimples in it. Maybe not.
I don't know what to say to help. Sorry

[KaFr]

I would definitely try to reduce the charge percentage to at least 90% before disconnecting the main battery contact.

Before removing the bottom package, it is necessary to drain and dismantle the motor cooling circuit and also the motor controller. A lifting device must be used for safe handling of the package. There are lifting eyes on the package, because the package is very heavy.

The Polaris workshop manual, where the entire procedure and necessary equipment is described, would certainly help.

[EV promise]

Hi, having had time to ponder the issue, a possible first step came to mind. The battery modules on a Brammo Empulse have small clear oval covers protecting the battery power screws. See image. I don't have an image of a Victory battery module but if these exist and can both be removed  the moisture would vent and the circuit board dry out. A small heatsink fan would help to push air through. Caution is still required even with the battery disconnect parted.
Just a thought.

[Korbin Dallas]

Ok here we go.. I picked up the bike from Bob for a price I could not refuse. Here is the link to what I have found so far.

https://photos.app.goo.gl/S9ibfnEZdczwvGPXA

Please let me know if you can see these.

[new-brammo-guy]

Korbin, you're my hero! I'm in a similar situation with temp sensor errors -> B40. I've connected to the CANbus and RS485 to update software. Let me know if you need any help with the service software. Please keep us posted!

[EV promise]

Wow, amazing work and images. I think U14 is the humidity and temperature sensor, hiding under the terminal where you wrote the ID numbers. Boards look in great shape but are clearly hiding something on the module 5 board. I'm impressed. We want it to work again.
Can you describe the seal and case corrosion please.

[KaFr]

Excellent work, Korbin! It will certainly be very useful to other Victory Empulse TT owners. I looked through all the photos and learned a lot. 

It looks like the chemistry is leaking from the cells, running down the lid of the module and drying out at the bottom, right?

It's also nice that the transparent cap can be unscrewed, which I think could reduce the humidity, what do you think?. Is this cover on both sides of the module?

The BMS boards look like new, is there any corrosion on the cell connections?

Is it possible to find the place on the board where the temperature sensor is connected?

[Korbin Dallas]

These are my best guesses as of right now. bottom battery is upside down in the bike. water is coming in the "bottom" of the battery somehow and pooling up at its lowest point. which is the top of the case. The battery had a very strong chemical odor when we opened it. There is a Vaseline type substance on the seals on the battery case. Google says this " Deposition corrosion" is what I suspect until I can remove the cells. https://fractory.com/aluminium-corrosion/. I think the smell was from the interaction of the chemicals and the aluminum case. hopefully not from cells breaking down. The case top is aluminum and I don't know if you can see it in the picture but it has eroded almost thru the case. (white powder on the case). That is after I cleaned off the jelly like substance. I believe the cells and the bms to be good, everything looks new in there. I want to hook the bms upto the computer and see if there is anyway to tell if the temp sensor is reporting. I have not made the cable for this or the Brammo battery yet.

[new-brammo-guy]

Do I read it correctly that the main faults were:
SYSTEM FAULT B8  : Battery Fault: Temperature Sensor Failure | SYSTEM FAULT B40  : BMS Back in Idle Mode | BATTERY TOO COLD  : Battery Fault: Battery is too cold to charge

Thus the only logged issues:
Module 5 PCBA Temperature (C) = -50C

and Battery Min. Temperature (C) = -40C (in cell 19, which I think is Module 5 - see attached)

Though in Module 5 the voltages look good (same as others):
Module 5 Cell 1 Voltage (V)   Module 5 Cell 2 Voltage (V)   Module 5 Cell 3 Voltage (V)   Module 5 Cell 4 Voltage (V)
4.125   4.151   4.112   4.130

And the Module 5 cell temps look good (same as others):
Module 5 Cell Temperature (C) = 19C

These change frequently in the data, which seems odd - why wouldn't they stay the same?
Battery Max. Temperature (C)   Battery Min. Temperature (C)   High Cell Num   Low Cell Num

[Korbin Dallas]

Repair moved to this thread.

https://brammoforum.com/index.php?topic=4244.0