Rebuild/Upgrade for Bionx d500 Battery

[BigBird]

https://www.electricrider.com/bionx-lithium-battery-upgrade-replacement-p/bionxrebuild-13.2.htm

Does anyone have any info/feedback on this?

 

[Syonyk]

That's a rebuild for the old 37V LiMn packs. They (probably) replace the cells with Sony US18650V3 cells, which are the same chemistry.

If I'm not mistaken, the D500 is a newer 48V system - so that would not apply at all.

 

[Cephalotus]

It's a 10s6p battery pack.

At 13,2Ah they use new cells with only 2,2Ah. Typically BionX consumes up to 30A and recuperation is up to -6A. Low cut of voltage is above 3,0V/cell, charging voltage depends on your charger.

BionX 37V batteries have a very simple BMS. You have 3 connections to the battery (+, ground, 10kOhm NTC to ground as a temperature sensor) and + and - to the charger with a "heat activated fuse"

Very easy to rebuild. For battery calibration you should reprogramme the BMS to the new capacity. It can be done with hacked software and CAN tools, I don't know if they have access to those tools.

In BionX world with PL, P, SL and d Motors you can mix all 37V, 41V and 48V batteries. Everything from around 2010 to 2016 is compatible if it uses the same G2 software.

In 2016 and 2017 BionX introduced new stuff like the G3 system / new color display witch uses a different software in all components and in 2017 they have new "integrated" batteries that uses different connectors.

At the BionX BAAS connectors next to the motor you can add any 36V battery capable of the current as an battery extender. You "just" have to watch correct polarity and voltage needs to be similar to the main battery pack voltage.

Regards

 

[Syonyk]

At 13,2Ah they use new cells with only 2,2Ah. Typically BionX consumes up to 30A and recuperation is up to -6A. Low cut of voltage is above 3,0V/cell, charging voltage depends on your charger.

Correct. The reason they use 2.2Ah cells is that the Sony US18650V3 is a nominal 2250mAh cell, and that's the highest capacity cell with the same spinel LiMn chemistry that will self balance on the older packs.

Very easy to rebuild. For battery calibration you should reprogramme the BMS to the new capacity. It can be done with hacked software and CAN tools, I don't know if they have access to those tools.

Do you know the details on that? The Canbus pack calibration seems to drift with time, especially on the 37V packs.