B40 fault B8 system fault

[KaFr]

In my opinion, the biggest increase in moisture inside the pack is caused by the escaping vapors or liquid from the swollen cells when they get extremely hot.

Example: This summer I took my Victory on a trip 100km from home. I left with a fully charged battery, once on the way I charged it to about 80% and at the end I charged the battery to 75%. The last charge was around noon, it was very hot and the battery was heated to about 35 degrees Celsius. Then I parked the bike in the shade for about 5 hours. I then drove home, again with one charge on the way and one at home. When I then analyzed the data, I found that the humidity in module 5 had risen from 61% to 64% during the five hours of parking! It was completely dry and hot all day, so moisture from the surroundings was out of the question.

[new-brammo-guy]

Korbin, If you can bring your module/board back to life, it gives me hope that I could do it with mine.

Alternatively, does anyone know where we might be able to get a replacement PCB (pics from Korbin's attached)? I'm assuming the Victory module PCB is not the same as the Brammo - but does anyone know for sure? I do have some Brammo modules I could take apart.

[new-brammo-guy]

Bottom of Korbin's battery module PCB

[Korbin Dallas]

https://photos.app.goo.gl/6mZeu5DX3i5cCywu5

Here is the link to my disassembly of the 2013 empulse and battery modules
The empulse circuit board is different in the rs485 connection for sure

[Korbin Dallas]

I posted new pictures of the upper battery disassembly. I wanted to look in there to confirm that none of the cell leakage is happening in there also.
I found it to be extremely clean. no indication what so ever of either water or cell leakage. the bottom of the case even looks really clean. the only spots I found were on the corner of the end cap of the battery case which I think is some kind of assembly fluid or grease. The battery expanded by about 2 inches over night after I took off the end cap. I expected to find swollen cells but I didnt see any indication like when I took apart the empulse cells. I hope to be able to squeeze it back together with some clamps. My goal now is to get this battery back together and with the top case off connect to the bms and get some readings.

[KaFr]

Korbin, If you can bring your module/board back to life, it gives me hope that I could do it with mine.

Alternatively, does anyone know where we might be able to get a replacement PCB (pics from Korbin's attached)? I'm assuming the Victory module PCB is not the same as the Brammo - but does anyone know for sure? I do have some Brammo modules I could take apart.

The PCBs for the Victory modules are different from the Brammo PCBs as mentioned by Korbin.

It will be difficult to get them as a separate spare part.
Another Victory battery pack will have to be used as an organ donor.

I'm thinking of contacting Polaris to see if they would be willing to sell off the faulty bottom packs from the bought back Empulse TTs.
Another option is to approach a seller on ebay who is selling off a burned out Empulse TT. He recently offered the top package, he may still have the bottom package that was fire damaged on the outside, but the PCBs inside might be fine.

[KaFr]

As I understood from the photos, the largest amount of chemical liquid accumulated on module 5 on the plates connecting the contacts of the cells. Here it has flowed for a long time on the PCB in the area of ​​connecting the heaters. Over time, with the help of high humidity and the presence of electrolyte, galvanic corrosion occurred, which destroyed the solder joints on the PCB.

If this is the case, it is a systemic defect in the materials used or in the assembly of this module. For example, poor-quality surface protection of screws and or metal plates could cause this type of corrosion to develop. It reminds me a lot of the corrosion of screws and plates in the Brammo Empulse modules.

[Korbin Dallas]

I would agree but have you seen my latest pics from the upper battery

[KaFr]

Yes, I saw your photos of the top package disassembled. It looks a lot better there than in the bottom one. I can only see light traces of condensation running down the surface of the metal plate of one of the modules. Is it module 3? The other boards as well as all the PCBs look very clean.

So either it is the fault of the lower package being turned upside down, or water is leaking from the outside through some gap. What do you think?

I still have some disassembly questions. Is it possible to remove the pcb board and the metal plates connecting the contacts of the cells without having to disassemble the whole package including the cells?

Is there a gap between the PCB and the plastic partition between the cell contacts?

[Korbin Dallas]

yes the tops of all 3 of the big plates on each of the 4 modules in the upper battery had the same Staining (?).
I feel like it is less likely condensation that is causing the problem now. If it were then I would have seen indication of water sitting in the bottom of the upper battery case. Larger battery = more condensation. I still believe water to be the main problem and the inverted position of the lower battery. Contemplating installing the lower battery right side up when I go back together.
Yes you can take the module tops off without taking each module out. When you take off the bus bars the battery will spread so you will need a way to compress it back or hold it in place before removal. ( see latest pics. I graduated from RedNeck University.)
There is a gap but it is tight and if you let the module expand at the top it will aid in getting the PCB out. Mine hit the humidity sensor. I also took off these plastic hold down brackets (circled in the picture)

[EV promise]

Thanks Korbin for the new images. Looking at image IMG_4089 of the back of a circuit board it will want wires soldering in place of dissolved tracks on the top right. Also it's clear, you'll have to carefully expose some of the copper on other tracks and check them for continuity .
Has anyone found a source for these boards? What happened to factory stock on closure.
Definitely a Honeywell humidity sensor.

[Korbin Dallas]

These circuit boards?

[Korbin Dallas]

I want to thank CasaDelGato for letting me salvage some of the boards from his project.
The boards have the same part number as the victory boards but the wrong firmware
I was able to power up a board and change the module number to 5 from 1
Then i was able to load the new firmware for the empulse which i think it 15.01.03 ( i am at work now and dont have all the info infront of me)
I dont have the 15.01.06 which it shows is on the victory boards i was also able to power up
That is as far as i have gone and wont be able to get back to it for some time
The tested i did were with the boards off the battery.

[new-brammo-guy]

Whhhhhaaat?! Awesome stack of boards. Thanks to CasaDelGato! #teamwork

[Korbin Dallas]

Is there a way to take the two boards together and transfer firmware from one to the other or extract it off the board then install it?