Ebike: Repurposing a Bionx battery case ‐ schematics

Note: Working with Lithium-ion cells is dangerous. Use this info at your own risk.

A friend of mine offered me a Bionx battery with its support because cells were weak. I do not have a Bionx system but I accepted the offer and decided to repurpose the case for my own ebike.

I took everything out: the battery pack (10s6p configuration), and the BMS. I kept the XLR connector for the charging port and the kind of DB9 connector (7w2) for the output to my controller and switch. My system does not have a CAN bus. Therefore, I have 5 free pins and used 2 to connect an external ON/OFF switch.

I have a 48VDC controller so I need to fit a 13s4p battery pack and a new BMS inside that case. There are 52 cells compared to the 60 cells in the original case; enough space to accomodate everything including wires and 2 fuse holders.

Schematics:

A few pictures showing the original battery...

and how it is going to be, obviously with new cells!

We can now move on to building the battery