How to recell Bosch Powerpack batteries?

Batteries, Chargers, and Battery Management Systems.
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edrift.eu
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How to recell Bosch Powerpack batteries?

Post by edrift.eu » Mar 04, 2017 4:16 am

Does anyone know how to successfully repair (replace the cells) on Bosch ebike batterypacks?

Ive heard someone on this forum ( Omikron ) bought a refurbished pack on ebay and another one mentioned that you can send it to china to have it recelled. Also e-bike-vision.de are selling after market replacements.

The older bosch batterier only has 3 pins so they should be easier then the newer ones (2014+) with 5 pins.

Has anyone tried to replace the BMS? Since it uses "Flexible flat cable" that are very hard to remove without damaging then replacing the BMS seems to be only option. Right?

Any recommendations, links and sources are very helpfull! ive read all post regarding Bosch Powerpack on this forum and what little i can find on google.

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Re: How to recell Bosch Powerpack batteries?

Post by Speady » Mar 04, 2017 10:55 am

Guess you're located in Europe.
You can get your Powerpack re-celled at akkuplus.de in Germany.
There's two options of battery capacity to choose from.
If you want to swap the cellblock yourself, you can buy a bare cellblock and save some shipping expenses.
https://akkuplus.de/Akkupack-fuer-Bosch ... lbsteinbau
But don't try to replace the BMS, the Drive unit does not work with some noname BMS.

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Re: How to recell Bosch Powerpack batteries?

Post by edrift.eu » Mar 04, 2017 1:06 pm

Thanks for the info Speady. that was speedy!

The problem is the "Flexible flat cable" that are extremely hard to remove an resolder. The pack for selfinstallation seem to be only the cells, glues together and and welded. That is the easy part.

Have you tested this service or what is your experience with them?

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Re: How to recell Bosch Powerpack batteries?

Post by Speady » Mar 04, 2017 2:07 pm

It would be useful to mention what version of Bosch Powerpack you have, is it Classic or Performance?
Did you already open the plastic casing?
I don't own any overpriced Bosch crap myself, but in Germany it is very popular.
Maybe the threads on german pedelecforum can guide you, at least the pics.
Classic battery:
http://www.pedelecforum.de/forum/index. ... 72/page-30
Performance Powerpack
http://www.pedelecforum.de/forum/index. ... 771/page-2

Kepp in mind, industry wants you to buy new things every couple years. Swapping cells isn't planned in the first place and takes some time and effort.

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Re: How to recell Bosch Powerpack batteries?

Post by Joachim » Mar 05, 2017 5:46 am

edrift.eu wrote:Does anyone know how to successfully repair (replace the cells) on Bosch ebike batterypacks?

Ive heard someone on this forum ( Omikron ) bought a refurbished pack on ebay and another one mentioned that you can send it to china to have it recelled. Also e-bike-vision.de are selling after market replacements.

The older bosch batterier only has 3 pins so they should be easier then the newer ones (2014+) with 5 pins.

Has anyone tried to replace the BMS? Since it uses "Flexible flat cable" that are very hard to remove without damaging then replacing the BMS seems to be only option. Right?

Any recommendations, links and sources are very helpfull! ive read all post regarding Bosch Powerpack on this forum and what little i can find on google.
Perfromance line i rebuild thes with succes and original cell holders-good brand cells(panansonic pf for the 400 and sanyo GA for the 500 packs).
The classic line i,am wurking on...and yes the hard part are these tiny flat flexible sense cables.
I,am sorting out the pins for minus-B1+2+3+...10+ and the two lines for the temp sensor...the bms looks the same and they have 3 smal wires for can usb to the motor controlller.
ebikevision/beltrona are crap!i sold 3 of them and 1 is death and the range from a 460wh pack is les as a original bosch 400 pack!i dont sell these anymore.
The germany company in the link you buy just a ordinary hot gleu pack for 300Euro :shock:
The cel holders and configuration are the same in the classic and performance line bosch packs.
I will try to make a new connector with normal wires @that point rebuilding the classic line bosch is just as easy like the newer bosch packs.
When done you can get this original replacement incl the wires and right connector in 400 are 500
Image

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Re: How to recell Bosch Powerpack batteries?

Post by Nickster » Dec 01, 2017 8:04 am

Do you have an update on this project? I too am interested in the transition from flat cable -> normal wires.

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Re: How to recell Bosch Powerpack batteries?

Post by Joachim » Dec 01, 2017 12:27 pm

Yes you can use thin wires on the smal bms conector..wurks perfect.My company fietsaccuspecialist already rebuils 30+ of these bosch packs :mrgreen:
I put some smal fusses on each ballans wire-battery side to be sure there never be shorts between cells&ballans/sense wires.

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