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TranzX 36V
If it does not charge, it can be reset by charging from the discharge. See photo for layout: Changing the button If you cannot see anything on the indicator, it can be because the button is water damaged. To have access, you must carefully peel off the st...
Ecoride 36V
The wish from the customer is 17.5 Ah - 50 cells need to fit into the box! I remember having done this once - and the challenge was fitting the BMS in. This time doing it with dedicated design. Original battery 325 mm tall alu housing. On both ends, it nee...
Attaching sense wires in large modular batteries
The easy case: bicycles A BMS is supposed to keep track of each and every cell group's voltage. In bicycles, this can be easily solved with n+1 wires, where n is the number os cell groups in series. This is why the BMSs we buy from China have 11 wires for 10S...
BT-E6010
Typical problems Corrosion Nothing to do, goes to recycling. Deep discharge Sometimes it survives being woken from deep discharge. Usually not. Bad BMS We cannot buy new BMS, but it is possible to swap BMS between identical batteries. ...
BT-E8010 / BT-E8014 / BT-E8016
On the E80xxs, usually the charge connector, the discharge connector, or the BMS gets fucked. If it is one of the connectors, it must be replaced with original one from a bad battery. E8010 is 14Ah - 504Wh E8014 is 11.6Ah - 418Wh E8016 - 630Wh Open SUPER C...
Making the Shimano BT-E60xx discharge machine
Github repo for the finished software: https://github.com/gregyedlik/BT-E60xx/ The process is very similar to hacking the Shimano charger, but this time a bicycle is also involved. It seems like the bicycle sends a short message, and then the battery answe...
BT-E6000 fuse replacement
Just like on the BT-E6010. First, check that the following are true: The battery is in balance and not in deep discharge, nor is it fully charged When you plug in the charger, the LEDs on the battery start blinking at least for a few seconds as if it were...
Hacking the Shimano charger
With a Raspberry pi, you can send the same code as the charger would.. and the FETs close! :) Original Spoof Python code import serial import time ser = serial.Serial('/dev/serial0') ser.baudrate=9600 ser.parity=serial.PARITY_NONE ser.stopbi...
Shimano BT-E80xx charger adapter
PowerPack 400/500 (second generation)
It is possible to transfer BMS between these batteries if done carefully. Take care that the power connectors are NOT identical on all of them! Some housings have 4 screws, other 6. They use different power connectors from the Bosch plug to the BMS, and you m...
PowerPack Classic 300/400
10S4P, straightforward, but has a nasty flex sense harness that must be handled with extreme care. We can do capacity checks only with the Bosch diagnostic tool, and we can do recell as long as the BMS is good. The adapter dongle for the charger (black) and ...
PowerTube 500/625
They have the same BMS. BMS swapping is possible and easy - more difficult if from 500 to 625 or vice versa. There are four T15 screws on each end. On the bottom end, two of them are covered by as plastic plate, that needs to be removed. It is held on by thre...
E-bike Vision Classic 458
10S5P design, 13 Ah -> 458 Wh 11 T15 screws hold it together. No flaps. Strong plastics! It has two charge ports - the second is a 4-pin XLR. Uses the same 5V enable. Recovery from deep discharge The BMS needs to be de-energised: remove B+ and the se...
Bosch charger hack
Performance Classic The middle pin is the 5V.
Derby Cycle / Kalkhoff / BMZ Impulse
The batteries are 36V, 10s5p layout, 11 to 17 Ah capacity. They go under the names Kalkhoff, BMZ, or Derby Cycle. It does communication with the bicycle, but not with the charger. However, it can be discharged without special equipment, simply by connecting to...
Producing the Bosch-compatible charging plug
Solder the middle ones first, so it will not move out of alignment. Do not solder two pins of the same tab right after one another, you might melt the helper piece. Hold the regulator down with something while soldering it in. This is the hardest part....
Battery enabler
We need to build a simplified version of this: https://www.seeedstudio.com/CANBed-FD-Arduino-CAN-FD-Development-Kit-p-4724.html We need Voltage regulator that supports up to 42V 120 Ohm termination Battery enabler hack The goal is to hack the battery...
Clean Motion Zbee
This battery was out of balance - one cell is 3.23 while the rest is all 3.33V. CALB-TUV-EN62133.pdf