Bosch charging or battery problems

[billadie]

Several years ago I bought a Lapierre with a Bosch Active 400 drive and battery. I never got on with it so sold it to a neighbour. After years of local running it has now decided not to power up. The Intuvia display shows 60% charge, the assistance level function works and the odometer, max speed etc records are all there. The light switch doesn't work.
Turning to the battery, pressing the battery button achieves nothing, no LEDs lit. Plug in charger, again no LEDs. Leave charger connected for several hours - no change. The bike was last charged a couple of weeks ago, and last used last week. The overall mileage is about 2500.

A multimeter across the + and - terminals of the charger gives 0.4V. I don't know whether this is as it should be. There is a third connection which I guess is some form of handshake/controller.

Any suggestions? Other than never sell anything to anyone within 50 miles.

 

[matthewslack]

2500 miles is nothing, and it has been working recently, so hopefully fixable.

I would start by removing the battery from the bike and inspecting all contacts between it and its mount. Same for any other accessible connectors, including at the display. Just disturbing them might be all it needs.

The charger output will not turn on until communication is established with the battery, so I would not immediately worry about the 0.4V.

Is there a remote charge port on the bike or is it direct to the battery? Another area to check and wiggle.

A friendly dealer with a battery and a charger might be the best problem solving tool.

 

[saneagle]

The problem is that it's difficult to do any DIY test of the battery, since it needs the comms to switch on, and the same with the charger. You can only test them with Bosch equipment that dealers have.

You can open the battery to test it with a meter, but it takes a bit of leverage to get the two halves of the case apart after removing the screws, which normally leaves a few prise marks.

Unless you want to repair the battery yourself, you're pretty well limited to buying a new one. There are repairers, but to do a proper repair would probably cost more than a new one.

Any Bosch dealer should be able to test the battery for about £40, but I can imagine that they're only going to confirm that it isn't working properly, which you already know. The diagnosis is unlikely to lead to a quick or simple fix.

 

[billadie]

Thanks Saneagle. I thought as much. Unfortunately Bosch charge ridiculous prices. Electropapa do cheaper Bosch compatible, but not for the one I/she has.

 

[saneagle]

Thanks Saneagle. I thought as much. Unfortunately Bosch charge ridiculous prices. Electropapa do cheaper Bosch compatible, but not for the one I/she has.

Which battery is it? Somebody here can probably find one for you at a good price.

 

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[billadie]

Which battery is it? Somebody here can probably find one for you at a good price.

It's a Powerpack 400 rack mount. I found a 300 (which will be sufficient for what it is used for) for £350
https://fifecycles.co.uk/products/bosch-powerpack-300-rack-mounted-battery?currency=GBP&variant=54930197086595&utm_source=google&utm_medium=cpc&utm_campaign=Google Shopping&stkn=d1baa386c194&gad_source=1&gclid=Cj0KCQjwtJ6_BhDWARIsAGanmKdC1nKDCkGzwqx58L8R0R1UY74tJm-kJrua8-SsifEwvIhUHvb9c3IaAqC8EALw_wcB

 

[saneagle]

It's a Powerpack 400 rack mount. I found a 300 (which will be sufficient for what it is used for) for £350
https://fifecycles.co.uk/products/bosch-powerpack-300-rack-mounted-battery?currency=GBP&variant=54930197086595&utm_source=google&utm_medium=cpc&utm_campaign=Google Shopping&stkn=d1baa386c194&gad_source=1&gclid=Cj0KCQjwtJ6_BhDWARIsAGanmKdC1nKDCkGzwqx58L8R0R1UY74tJm-kJrua8-SsifEwvIhUHvb9c3IaAqC8EALw_wcB

This is probably as cheap as you can get it in this country and german Ebay is pretty good if you can find someone who will ship to UK:

https://winstanleysbikes.co.uk/bosch-powerpack-400-rack-type-battery-pack

https://www.ebay.de/b/Bosch-Akku-400/177814/bn_7005319543

 

[soundwave]

these use the non smart batts so soon they will no longer be made and the s,art ones wont work with older motors.

id get 2 if you can afford it

 

[sjpt]

Check with Merlin, https://www.merlincycles.com/bosch-powerpack-500wh-rack-battery-303236.html for a 500, £349
I got that one a year ago, very efficient service and all fine.

Hopefully you won't need it. As has been mentioned above, check all the connections. In particular where the battery plugs in, and the connections to the display. Also, press the battery power button after inserting to make sure it is on.

I have had problems on a similar (Motus) bike.
The rack is badly designed so it's easy to get the battery apparently in but not properly located.
The Intuvia connections are badly designed and need fairly regular cleaning. (I understand improved on later models)
It is hardly ever necessary to turn the battery on, but at random intervals it seems to be necessary.

 

[sjpt]

The Intuvia display shows 60% charge,

The Intuvia display has the odd feature that it always shows the charge level of the last battery it saw. So if you remove the battery, it may well show 60%, or if any of the connections are wrong, ditto. Also, the same if you take the display off the bike and turn it on. Occasionally useful, much more often not.

Before I learned better I (twice) set off down the hill forgetting the battery was still in the house after being charged. As it was downhill I didn't notice the lack of assist. Luckily not a very steep or long hill, the Motus is not a fun bike to pedal uphill unassisted.

 

[billadie]

Thanks.
i am fairly sure that the problem is the battery. When on charge the battery will get warm indicating a flow of current at least. Unfortunately, the battery doesn't actually charge.