How to recell Bosch Powerpack batteries?

Batteries, Chargers, and Battery Management Systems.
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edrift.eu   1 W

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How to recell Bosch Powerpack batteries?

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

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 10:55am

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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edrift.eu   1 W

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Re: How to recell Bosch Powerpack batteries?

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

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 2:07pm

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 5:46am

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.
Last edited by Joachim on Mar 21 2018 1:57am, edited 1 time in total.

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Re: How to recell Bosch Powerpack batteries?

Post by Nickster » Dec 01 2017 8:04am

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 12:27pm

Yes you can use thin wires on the smal bms conector.
Last edited by Joachim on Mar 21 2018 1:32am, edited 1 time in total.

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Re: How to recell Bosch Powerpack batteries?

Post by Cepi » Mar 02 2018 4:32am

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?

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Re: How to recell Bosch Powerpack batteries?

Post by Whitehawk » Apr 17 2019 7:23pm

Same issue here, bosch powerpack 500 with dead BMS, no way to replace it ? :lowbatt: :pancake:
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Re: How to recell Bosch Powerpack batteries?

Post by flippy » Apr 18 2019 4:51am

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.
Lithium beats liquid dinosaurs.

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Re: How to recell Bosch Powerpack batteries?

Post by Whitehawk » Apr 19 2019 4:09pm

Holly shit :lol:

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 :roll: )
Kona Coiler - GNG 650w @ 4.5kw
Giant DH Team - RH205S @ 5.5kw
LMX 81 @ 3kw 14S6P GA
Trampa board - e-toxx dual 6374 170kv - 10S10P 30Q- Escape VESC6
LMX 161-H unlocked :bolt:
Onewheel+ XR

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Re: How to recell Bosch Powerpack batteries?

Post by Stax » Jul 30 2019 2:02pm

flippy wrote:
Apr 18 2019 4:51am
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.

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flippy   1 MW

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Re: How to recell Bosch Powerpack batteries?

Post by flippy » Jul 31 2019 6:02am

Stax wrote:
Jul 30 2019 2:02pm
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.
Lithium beats liquid dinosaurs.

Stax   1 µW

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Re: How to recell Bosch Powerpack batteries?

Post by Stax » Jul 31 2019 10:33am

flippy wrote:
Jul 31 2019 6:02am
Stax wrote:
Jul 30 2019 2:02pm
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?

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