Bosch range extender

[Batteryrepair]

I'm thinking of developing a bosch range extender battery.

Using the original Bosch system and BMS, fooling the bike into thinking it's being set up as a normal dual battery with 2x a powerpack or powertube, but in reality it's a custom pack, cheaper, lighter, no need to carry a 2nd battery in a backpack or bag, no need to stop and swap batteries. Less wear on both batteries because the load is shared.

I'm considering using either 180Wh or 360Wh. 15A peak LG 21700 cells, 5Ah.

If you have a 500Wh battery and drive below 18mph/25kph, what size of range extender would you prefer?

The 180Wh could be under the saddle in t a small case or on the bottle mount points. The 360Wh could only be on the bottle mounts. The weight would be ca. 1kg for the 180Wh, double for the 360Wh. Easy to use on the frame battery models and rack models, a little more wiring needed for the powertubes.

 

[Batteryrepair]

Does anyone know if you need to update the batteries to the most recent version? Bosch don't allow me on their online system since I do repairs on their circuitboards and they don't like that.

 

[shanesnr]

Does anyone know if you need to update the batteries to the most recent version? Bosch don't allow me on their online system since I do repairs on their circuitboards and they don't like that.

Hi ive a friend who made a second battery from a powerpack 500 with a standard same value battery.since u know yourway around the battery circuits have u tried with controller boards? Youd do extremely well if so! Think of all the motors lying in sheds all because of a faulty board hundreds of thousands

 

[jbalat]

Hi just wanting to join in. I have the 2018 powerfly with the Bosch 500 power pack. I did read somewhere that one guy was able to plug his own pack in parallel but I can’t find it at the moment. The prerequisite was that they were both fully charged and you couldn’t plug into the charge socket since it goes into charge mode

 

[Waynemarlow]

I'm lead to believe that the later motors and displays ( from about 2020 ) using a Bosch Y Splitter cable and connector will work. A friend of mine has done this on his Trek and it works a charm. I think on some manufacturers bikes you have to get the local Bosch agent to toggle a software command to allow the two batteries.

Bosch DualBattery: info about mounting it right | E-Bike Blog

More battery capacity means longer riding fun. Here you can learn which Bosch batteries are compatible with each other and how to attach an additional battery.

www.ebike24.com

My dilemma is that I don't want another 3KG ( 400Wh ) battery, I need only about 150Wh's.

Anybody tried taking a Bosch battery apart and reducing the cell count with a reduced casing perhaps. The OP idea is great and badly needed and any tips on how would be welcome.

Have a look at the UK Trail Watts for further info.

https://www.emtbforums.com/threads/trail-watts-booster-battery-systems.3731/

 

[Batteryrepair]

I'm lead to believe that the later motors and displays ( from about 2020 ) using a Bosch Y Splitter cable and connector will work. A friend of mine has done this on his Trek and it works a charm. I think on some manufacturers bikes you have to get the local Bosch agent to toggle a software command to allow the two batteries.

Bosch DualBattery: info about mounting it right | E-Bike Blog

More battery capacity means longer riding fun. Here you can learn which Bosch batteries are compatible with each other and how to attach an additional battery.

www.ebike24.com

My dilemma is that I don't want another 3KG ( 400Wh ) battery, I need only about 150Wh's.

Anybody tried taking a Bosch battery apart and reducing the cell count with a reduced casing perhaps. The OP idea is great and badly needed and any tips on how would be welcome.

Have a look at the UK Trail Watts for further info.

https://www.emtbforums.com/threads/trail-watts-booster-battery-systems.3731/

You're correct, it works! I had to use a Bosch BMS though. Also, you can just make a small pack and connect the bosch bms to it, it'll adjust it's range automatically. Just make sure it can handle 20A.