reviving a dead BionX battery

[krazykraut3711]

Hi guys, I hope this is the right place to ask. I got a full BionX kit (PL350 motor, 36 V Battery, charger, no controller or cables) for a good price on eBay. The battery hasn't been charged in a few months, and the charger doesn't recognize it anymore (just a solid red led). From what I understand, the battery must have a minimal charge before the charger will recognize it. What is the best strategy here? Please help.

- Krazykraut

 

[tude647]

Glad I came across this thread.
I have a Bionx battery pack, 11S3P. The voltage on the battery pack was ZERO.
The original charger has a microprocessor in it, which seems to monitor the voltage and drive the charging current accordingly.
When it detects such a low voltage, it supplies current on and off. The voltage went up to 8V after 2 days of trickle charge at around 35mA.
I bought a DC power supply to try and revive the battery at 200mA like you did. Will post an update here in a few days.

 

[marty]

Im not Sure how to put the battery into Regen if I cannot get it to turn on can someone please help me with this how do I regen the battery?

3.) this method doesn't work for you. but here is instruction. Put the entire bike/system onto training stand, pedal it and regen the battery, once the voltage is up, you can then use normal charger to charge it.

Ken

If you try to regen it, then you don't have open up the battery, but you will need a training stand. It will be a good workout for you.

Ken

 

[tude647]

Glad I came across this thread.
I have a Bionx battery pack, 11S3P. The voltage on the battery pack was ZERO.
The original charger has a microprocessor in it, which seems to monitor the voltage and drive the charging current accordingly.
When it detects such a low voltage, it supplies current on and off. The voltage went up to 8V after 2 days of trickle charge at around 35mA.
I bought a DC power supply to try and revive the battery at 200mA like you did. Will post an update here in a few days.

My lab power supply arrived.

I set the current limit at 0.2A and hooked it up to the battery. A couple hours later the voltage is around 34V.
YAY!
I briefly connected the original charger. It charges like a beast, and I can hear the cooling fan running, but batteries run a bit hot, so i decided to revert to the lab PS and give it 200mA until I reach 40V.
Thanks to everyone who contributed to this thread!

 

[Grumps]

three methods to recover bionx battery
1.) open up the battery and use a very low amp charger, like 200mAh, it will takes 2 days to recharge the battery very slowly
2.) open up the battery and use 42v adapter, not charger. Because normal charger will not charge when the voltage is too low
3.) this method doesn't work for you. but here is instruction. Put the entire bike/system onto training stand, pedal it and regen the battery, once the voltage is up, you can then use normal charger to charge it.

Ken

Hello I’m new to this forum (any forum for that matter) and I’m not sure how to ask a new question so I’m jumping in here albeit 12 years later. I inherited my mother in laws bionx system bike. Battery was missing. I bought a rebuilt. Brought it inside for winter. I suspect I left it on charger too long. Started making noise. Now red tail light will not turn off and will not charge, or at least the charger will not charge only red led cones on. No Amber no green. I’ve tried lifting the bike with charger plugged in and pedaling for 20 seconds it did not kick start the charging. Do I need to do this longer? If I ride the bike will it regenerate enough to solve problem? Also between the port wher charger plugs in and port where controller plugs into battery rack there are to thin black wires with male and female leads. When I plug them together the bike pedals harder. What is this connection? I can send picture. Sorry lots to say explain But might be better if I respond to direct question on what additional info you need. Thanks for any help anyone can offer.

 

[99t4]

Which battery is it?
Where did you find a rebuilt replacement?
What kind of noise? Kind of like an obnoxious muffled intermittent buzzing?

 

[Grumps]

Which battery is it?
Where did you find a rebuilt replacement?
What kind of noise? Kind of like an obnoxious muffled intermittent buzzing?

Hi thanks for replying. The battery is an 01-2090. I bought it from Nethers batteries. Battery worked well until I neglected it and then overcharged it last winter. Last wi ter I hooked it up and forgot about it. I heard it making noise and I can’t recall the noise but I do recall after I disconnected it the red tail light came on and now it won’t turn Now the charger will not charge it. I can ride it and get the control to turn on for about 20 seconds and then it cuts out. While the control is on it gives the speed and shows no charge. It will show assist and regenerate but it does not affect the peddling. I cannot figure out what the two lose wires are. Can I post a picturr?

 

[offGridDownUnder]

You mention you 'overcharged the battery'. Do you know this, and how? Is this just speculation because a problem arose? The details of how you know this will be helpful.

'Overcharge' - by time (you left it on charge for a while), or by voltage, or by some other measure?

You mention this happened last winter - we don't know where you are, is this 6 months ago or 1 year ago (it's winter in the Southern Hemisphere now)?

When did you buy this replacement battery - you used it since then and it's helpful to know how old it is. 'Rebuilt' - how? Were new cells used, or did the supplier select used cells they thought were good? Do you know the manufacturer of the cells?

Overcharging (depending on what that means) is a way to damage Li-ion batteries which leads them to ignite at an unknown later time. Used cells are always unknown and can't be guaranteed - both for physical abuse and for electrical abuse.

 

[Grumps]

I used the charger that came with the refurbished battery. It made by high power” and is from China. It looks like a knockoff of pictures I’ve seen of the chargers sold by boons. The reason I believe I overcharged it is what I gave learned researching this issue. I left it on the charger for a month. I read it takes 5 hours to charge and should be removed from the charger upon charging. The rebuilt battery came with new cells according to the guy who sold it to me who was helpful and seemed conscientious. I live in the state of Minnesota. I put the battery on the charger last January probably and took it off in February or March. In an effort to get the tail light to turn off I’ve had it on the charger many times since. I bought the replacement battery in 2022. We used the bike some and then it was unused for over a year. I neglected the battery during that time period. Now trying to resurrect. The tail light will not shut off. Is that an indication of something fatal

 

[offGridDownUnder]

I read it takes 5 hours to charge and should be removed from the charger upon charging. The rebuilt battery came with new cells according to the guy who sold it to me who was helpful and seemed conscientious. I live in the state of Minnesota. I put the battery on the charger last January probably and took it off in February or March. In an effort to get the tail light to turn off I’ve had it on the charger many times since. I bought the replacement battery in 2022. We used the bike some and then it was unused for over a year. I neglected the battery during that time period. Now trying to resurrect.

Thanks.

If you read that in the manual for the battery or charger, then they acknowledge that it's unwise to leave it on (I know you already know this) - which means they probably aren't trumpeting the 'smarts' in their charger. If that's just something you read generally, it's still true, except the 5 hours is too specific for a general statement. Depends on battery capacity, amps charger can deliver (or what is chosen), etc.

You used it some and then none for a year - was it on charge for that year? If it wasn't charged at all for an entire year I'd expect the battery went to 0v due to internal leakage.

If a Li-ion battery goes below a level (depends on the chemistry, but all values are above 2v) it will be damaged, and for many batteries, there are circuits that will shut the battery down so it can't be charged if it goes below that level because...

A cell that has gone below that level may fail by bursting into flames and spewing gasses toxic enough to keep you from making it out the door if you are asleep in the same room. That's why the cut-off circuit:
Is draining a Li-Ion to 2.5 V harmful to a Li-ion cell?
Minimum and Maximum Voltage Range of 18650 Cells - Cell Saviors
https://ehs.mit.edu/wp-content/uploads/2019/09/Lithium_Battery_Safety_Guidance.pdf

 

[offGridDownUnder]

Grin’s perspective of Ebike fires

 

[99t4]

I had a BionX 48V battery rebuilt by Nethers Battery in 2020. Well done, with genuine Samsung 35e. He had the programs and knowledge to unbrick the BMS.

The BionX BMS in their 48V batteries are very picky about the user keeping the battery charged above a specific minimum limit. When it reaches a soft minimum limit it starts an intermittent muffled buzzer. Easy to miss if the battery is in a location that is not visited often. As the buzzer and BMS itself continue to drain the battery it will soon reach the hard minimum voltage limit which then bricks the BMS.

Unfortunately Nethers Battery is no longer in business. I am not aware of any other battery rebuilder that has the equipment and knowledge to unbrick the BionX 48V battery BMS.

 

[marty]

Wondering if this guy / girl? itselectric is still with us. The web site in his signature seems to be dead. I also have a dead BionX battery.

Going to send him a private message to see if he would be interested in BoinX battery repair / rebuilding.

Search with Google. Here is another option.

BionX battery repair or refurbish

EbikeBC can repair or refurbish BionX batteries as well as all other electric bicycle batteries.We will have various solutions for older ebikes battery replacement including BionX battery; either by installation of cased battery packs or refurbishing the existing battery case. You need to send...

ebikebc.com

My BionX was reliable and worked great till the battery died. Once rode it in the rain till my underwear was wet. Water is a good test of a e bike kit.

 

[marty]

Another place for BionX parts.

BX Legacy

BX Legacy

www.bx-legacy.com