B40 error tackling

[Brammofan]

Man I really do hate the fule Size limited on these outdated forum platforms.

Lol... I guess you get what you pay for. 
I was recently considering whether I should shut the forum down because it has been pretty quiet here for several weeks. I'm glad it's still running so we can try to help folks.

[acceler]

I'm just joking. Lol
I was on this back in like 2018ish when my first elpulse went all b40 on me. It's a wealth of knowledge. I'm really glad it was still up and active.

[EV promise]

Hi, I've opened the files. Had some dificulty posting due to size, so here is an extract. Modules 4 and 7 are the troubled ones. Humidity at 100 per cent with the rest at about 50 per cent.
Hope this posts.

[EV promise]

The reason for the B9 and the B40 is the RH gap is greater than 30 per cent. Also module 4 PCB temp is to low/different to the others and this will also flag a fault. The two are likely to be related to damage on the pcb, only inspection will resolve this I suspect. Hope this helps.
ps I use the Victory software on Win 10 64bit to open the files.

[acceler]

So I got the usb downloaded but all I see is drv and chg files.
Can someone read these and help me with me figure out what pack is faulty

[empulsefan]

Hello, I had to unzip archive-8c05.zip and start to get the program working!
hope this helps,

greeting,gerry

[Haplo]

Hi, I've opened the files. Had some dificulty posting due to size, so here is an extract. Modules 4 and 7 are the troubled ones. Humidity at 100 per cent with the rest at about 50 per cent.
Hope this posts.

Hi,.. thanks for opening my files, analysing them and sharing it... I took a look, but could it be that youre mistaken and actually mean Modules 4 and 6 are the troubled ones? See screenshot?

Also: can you share the program with which you are converting the files? I understand your CSV is just an extract. I would like to look at the full data. It seems to also help Acceler, who has also downloaded his (or her??) files but can't convert them.. Thanks!

[EV promise]

Hi, yes modules 4 and 6. It was late and that was my third attempt to post the information. I will add more files.
In general, the Brammo programs ( motor alignment, battery module program and motorcycle diagnosis)  and the file opening program need to be run on a Windows xp machine in 32bit.
I'm happy to open the files.  For my use I save the files as Excel files and not csv files as this keeps the formatting eg. column widths and I freeze the top line so I always have the headers.
Diagrams for the two Brammo Empulse service cables are on this forum. Motorcycle diagnosis requires the ixxat interface. Battery diagnosis requires a  FTDI FT232RL USB to RS485 Converter. I have updated firmware in the modules.
Victory software can be found on the Polaris website. I'm not good a posting live links. Others are.
Happy to help.

[EV promise]

Hi, the files above are complete. I just selected some of the smaller ones.
Module 4 is the one in clear trouble. The low temperature reading brings on all the battery heaters and the temperature difference between that and the others sets the fault code. The Empulse service manual shows how to remove each module.

[acceler]

Just the last few files off the USB
Can someone do anything with those?

[EV promise]

Hi acceler, I've attached the .drv file you posted. The .chg files were sadly to small, something the same or larger than the .drv file would be great.
Looking at the .drv file (posted in full below) I can see communication has been lost with module 7. In the 'module exists' column 7 is not there!!  Some data is missing from 5,6 and 7 but as they are linked this will be a symptom. Module charge level is only 18 per cent ish.
Let me know your thoughts.

[acceler]

I got the bottom pack pulled already.  I'm guessing packs 5,6 and 7 are in the bottom?
Been trickle charging it back up at .5 amps. Already got it up from 42.25v to 44.v  that's how we "save" our scooter and ebike 1860 cell packs when they "go to sleep".
I've posted some bigger files also one from January. Which is when I'm guessing the last time the bike actually ran but idk 🤷‍♂️.

[EV promise]

Hi acceler, I've looked at your file from January and it does have errors sadly. I will post it once my laptop is available.
Module 7 has no relative humidity value, hence the B9 code. Also the real time clock was showing a V78 error although the file is date and time stamped. So maybe rtc battery low.
All cell voltages and temperatures look good.
I don't think there's anything else to be found in the files. Disassembly is the only way forward I believe. Check the cells and circuit board.
Sounds as if you agree and are making progress.

[Haplo]

Happy to help.

Your help is very much appreciated, EV Promise!

I took Module 4 apart as you suggested. However, couldn't find much damage there. It was moisty, sure! So that was not OK of course, but apart it didn't look bad at all. The bolts connecting the PCB to the cells were corroded and there was some wear visible around the pouch-connections. Also some rust on the PCB around the BUS connectors. I will post some pictures.

[Haplo]

And some more pictures: