E-Bike Battery Repair | Replacing a Dead BMS

Описание: ** SAFETY WARNINGS **
This is a summary report of a project that I did, not an instructional video. Do not attempt to replace the BMS of an e-bike battery unless you understand the components well, have the appropriate skills, and know the hazards.

I forgot to mention that I used a fuse to protect the battery pack against excessive discharge current. It is essential that you wire your battery pack through a fuse. Failure to do this presents a very high risk of causing a major fire. Look up videos of lithium battery fires. They are spectacular.

A large pack of lithium ion cells like you see in this picture is a very serious fire hazard. If you decide to do some work on a lithium battery pack, make sure to take fire precautions. For God's sake be careful when you're handling a soldering iron near these things.

DESCRIPTION
I had a Kalkhoff e-bike battery pack which was fully functional (cells very well balanced) apart from the battery management system (BMS) which was dead. As far as I know, a battery must have a Kalkhoff BMS to work with a Kalkhoff bike. Unfortunately, I was not able to source a replacement Kalkhoff BMS. However, I was able to source a generic (Vruzend) BMS, which can be used with other brands of electric bike/motot (like Bafang, in this example).

This video shows the process of installing a replacement BMS in an e-bike battery.