Creo 2 Remote Buttons not working on a ride (Solved)

[Allan47.7339]

My Creo with a Mastermind TCU started to not respond to the road remote buttons during a ride yesterday. It would erratically go into the micro tune mode and finally switched to the OFF mode and not respond further. Fortunately it was on the flat section almost at the end of the ride. It continued to not respond the remote buttons and with a Mastermind it's the only control. I took the TCU out and tested the buttons for continuity which they were good. I noticed a slight bit of moisture when I unplugged one of the remote wires. I attached the remote button junction box from my other Creo and everything worked again. I found a tiny bit of moisture on the jack plug which is why I tried the other junction box. I found in the Creo 2 manual on page 18, they show a piece of tape used to keep the wire more vertical after it enters the cable port through the frame. This would be in effect a "drip leg" like you would use on house wiring entering the building. I will try to dry the junction box before I order new remotes. The remote I am using has been plugged/unplugged a few times and the seal may not be as tight when new. I was riding in the rain the previous day but it was dry on the day the malfunction manifested itself.

Edit: I dried the junction box in the oven and it seems to work again. I will reinstall with a drip loop with a zip tie and add a little silicone to the outside of the inserted plugs.

Edit 2: Might be something in the lights. If the Y-connector is in place, they don't work. I need to test ride to see if motor is actually working.

Edit 3: I found two very small nicks in the 24 gauge (.5mm) wiring from the Lupine front light. Lupine uses a single insulated cable with the two wires encapsulated in a rubber outer. I must have nicked them when stripping for connectors. It's been good for a year but there must have finally been enough moisture to make a connection and disrupt the shifting.

 

[Allan47.7339]

The error started to repeat on last Sunday's ride. I finished the ride by leaving it set in whatever assist level that would stay on. I knew I could open up the TCU and remove the Y-splitter and disconnect the lights. I found when I got home the buttons would not work with the Y-splitter in-line with or without lights attached. Just the pass through the splitter was enough to keep the buttons from signalling the TCU. I've ridden a few days without the lights connected but after this evening's ride I plugged a USB-C charger to the TCU and now buttons and lights work. I have been seeing an occasional low Creo battery alert on my Garmin which is what led me to try charging the TCU. I'll check my light connections to make sure they are all solid and polarity correct and keep riding. I'll check if the shop keeps any spare TCU's on hand. If it suddenly gives up I would rather order one to have on hand than waiting a week. The shop has to install the TCU and program it but that is probably a same day appointment.