How to recell Bosch Powerpack batteries?

[edrift.eu]

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.

[Speady]

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.

[edrift.eu]

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?

[Speady]

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.

[Joachim]

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
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.

[Nickster]

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

[Joachim]

Yes you can use thin wires on the smal bms conector.

[Cepi]

Joachim, I have my BMS damaged and want to replace it. Do you know which one can I take? So far I know, Bosch BMS's are customized for their system. What are this 3 small wires exactly for? Where can I get this information?

[Whitehawk]

Same issue here, bosch powerpack 500 with dead BMS, no way to replace it ?

[flippy]

BMS''s from these packs, especially the newer ones seem to die a lot.

as fas as i see the newer BMS from the flat models tend to self destruct if you disconnect the wires to the cell pack.
you need to hook up a fake pack in parralel while doing the swap so the bms doesnt commit suicide.
prehaps it does not kill itself but every pack i have tried never came back from a complete power loss.
i am missing the magic trick to reset the bms.
what i have found out is that the 300Wh flat models have LG cells and have the same physical capacity as the 400Wh packs with PF cells in them. but the BMS activly limits the capacity to 300Wh in the "smaller" pack, so recelling a capped bms might give interesting results. it would be pretty shitty if you put a 500+Wh cell pack in it and you are artificially limited to 300Wh...
i have found this out while havng the battery connected to the bike with the system on and draining the battery at the motor connector.

[Whitehawk]

Holly shit

Finally my battery is 400wh and my BMS looks OK, I will try to replace my 12 dead cells to resurrect it (only 3 years old and 500kms .. so maybe 10 charges )

[Stax]

you need to hook up a fake pack in parralel while doing the swap so the bms doesnt commit suicide

Is there a tutorial on how to do this?
I have an external power source that can generate 36v. But I have no idea how I should connect it to the bms in parallel.

[flippy]

Is there a tutorial on how to do this?
I have an external power source that can generate 36v. But I have no idea how I should connect it to the bms in parallel.

you dont need a single power supply, you need 10 of them, all isolated from each other.

[Stax]

Is there a tutorial on how to do this?
I have an external power source that can generate 36v. But I have no idea how I should connect it to the bms in parallel.

you dont need a single power supply, you need 10 of them, all isolated from each other.

Ok. And how am I supposed to do that?
How do you connect a parallel battery pack to the bms?

[bombadero]

Did the OP successfully re-cell his powerpack? I have a couple of 2017 Powerpack 500s I want to recell but keep running into rumors and anecdotes about the BMS suicide chip. These are somewhat older batteries, like I said, dating to 2017. I've posted about this here recently myself. What year did they add that chip? I've seen people re-celling the Classic+ by just desoldering it from the board, no tricks or anything were used. But then maybe they are using an expensive battery tester to revive the BMS? They never actually show it on the bike, what the capacity is, et cetera, just that it lights up when plugged into a charger after the swap.

[flippy]

its not a rumor, its very real.

the bms has all its programming in RAM, not ROM/flash memory. removing the board from the batteries will cut the power to the ram and then all the programming is gone instantly.

large recellers simply have a specilized 10 output power supply to keep the bms active during the swap. they also dont have the programming from bosch.