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Bionx D series 48v battery problem

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Bionx D series 48v battery problem

Old 05-24-20, 12:20 AM
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Bionx D series 48v battery problem

I hope everyone is doing well and staying safe. I am wondering if anyone knows what could be causing this issue I am having with the bionx D series kit with rc3 thumb controller I have. After storing the 48v battery over the winter I put the charger on the battery to wake it up from sleep mode. instead of getting a solid green light at the end of the charging cycle I am getting a flashing green light which looks like it means overcharged. When I put it on the bike it shows full battery on the meter but I am loosing torque while the battery meter is still showing a full battery. I tried to recharge it again with the same end result flashing green light. I then rode it and drain the battery a bit more seemed to last longer this time the battery meter on the RC3 thumb controller drops two dots and charge it again but still get the flashing green light instead of the solid green light I am supposed to get at the end of the cycle.


Has anyone experienced this same issue and more importantly how do I fix this problem? Any help would be appreciated
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Old 08-02-23, 01:47 AM
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Have you resolved the issue, I'm having the same problem. Thanks.

Originally Posted by apper_on
I hope everyone is doing well and staying safe. I am wondering if anyone knows what could be causing this issue I am having with the bionx D series kit with rc3 thumb controller I have. After storing the 48v battery over the winter I put the charger on the battery to wake it up from sleep mode. instead of getting a solid green light at the end of the charging cycle I am getting a flashing green light which looks like it means overcharged. When I put it on the bike it shows full battery on the meter but I am loosing torque while the battery meter is still showing a full battery. I tried to recharge it again with the same end result flashing green light. I then rode it and drain the battery a bit more seemed to last longer this time the battery meter on the RC3 thumb controller drops two dots and charge it again but still get the flashing green light instead of the solid green light I am supposed to get at the end of the cycle.


Has anyone experienced this same issue and more importantly how do I fix this problem? Any help would be appreciated
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Old 08-04-23, 09:29 PM
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Clark W. Griswold
 
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Originally Posted by inegrin
Have you resolved the issue, I'm having the same problem. Thanks.
Considering this thread is 3 years old and the OP only made one post and the entire thread was only that one post and Bionix is long out of business it is unlikely you will get a useful response from them but there are some people on the internet who have held on to that old technology and keep it working that have posted in various places. Google will help you find it.
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Old 08-05-23, 11:18 AM
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BIONX out of business - does not matter , my 2 BIONX bikes are going strong.
It is not a problem only with BIONX.
first to reset , to recalibrate SOC battery meter you have to drain battery so the bike shut down
dont know what green flashing on charger means, never had such thing.
what I would try is to disconnect electronics inside battery pack from battery cells, those charging electronics must be depowered so the chip controlling charging and SOC curcuit can reset itself. also I would measure volage of cells pack.
there must be main terminal which connect cells to electronics inside battery
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Old 05-09-24, 06:05 PM
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Not sure if this applies to your problem, but...: I've got a 36v BionX where the battery died and couldn't be resuscitated. I liked the BionX (still do), and really didn't want to go to the work of finding another suitable system to install on my bike, but of course the BionX company itself is dead so there's no new replacement batteries available. After a LOT of looking around for alternatives, I came across Northeast Battery Systems LLC of Windsor Locks, CT (you can Google them); they were able to take my BionX battery, re-cell it (with slightly higher-capacity cells!) and get it working again.

Once I got it back on the bike, the BionX system took a couple of power cycles before it remembered how to boot, which was kind of curious, but it's been working like a champ ever since - with slightly better range than it had before, too.

If your BionX problem is battery-related, I highly recommend emailing Northeast Battery Systems and asking them if they can help.
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Old 05-10-24, 08:26 AM
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Great info; just be aware that shipping a battery without HAZMAT "certification" can result in a substantial fine if you're caught (AFAIK).
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Old 05-10-24, 10:15 AM
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Originally Posted by ohh
Not sure if this applies to your problem, but...: I've got a 36v BionX where the battery died and couldn't be resuscitated. I liked the BionX (still do), and really didn't want to go to the work of finding another suitable system to install on my bike, but of course the BionX company itself is dead so there's no new replacement batteries available. After a LOT of looking around for alternatives, I came across Northeast Battery Systems LLC of Windsor Locks, CT (you can Google them); they were able to take my BionX battery, re-cell it (with slightly higher-capacity cells!) and get it working again.

Once I got it back on the bike, the BionX system took a couple of power cycles before it remembered how to boot, which was kind of curious, but it's been working like a champ ever since - with slightly better range than it had before, too.

If your BionX problem is battery-related, I highly recommend emailing Northeast Battery Systems and asking them if they can help.
what did that cost ya?
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Old 05-10-24, 11:11 AM
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Originally Posted by CrimsonEclipse
what did that cost ya?
Somewhere around $430-450. Your mileage may vary, o'course. For mine, I described the battery via email, then they asked me to ship it to them so they could do an assessment and provide options and cost.

Oh, and for shipping, I shipped via UPS Ground, writing "Li-Ion battery" on the outside of the box, and UPS was fine with it.
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Old 05-10-24, 02:25 PM
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Originally Posted by ohh
Somewhere around $430-450. Your mileage may vary, o'course. For mine, I described the battery via email, then they asked me to ship it to them so they could do an assessment and provide options and cost.

Oh, and for shipping, I shipped via UPS Ground, writing "Li-Ion battery" on the outside of the box, and UPS was fine with it.
They must have changed their policy (or it differs depending on location). A few years ago I tried to ship a battery and they wouldn't consider it; i would need to go through a HAZMAT broker.
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Old 05-10-24, 04:35 PM
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Originally Posted by ohh

Oh, and for shipping, I shipped via UPS Ground, writing "Li-Ion battery" on the outside of the box, and UPS was fine with it.
UPS still requires a certified hazmat shipper for any lithium battery above 300wh. Only certified shippers have the software to generate shipping papers. "Li-Ion battery" label is not enough. Here is UPS flow chart, scroll down to pages 9-10 ...

https://www.ups.com/assets/resources..._batteries.pdf

I also used NE Battery Systems two years ago with success. I drove down to deliver. Kevin is now having issue with failing BionX BMS boards.

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Old 05-10-24, 05:28 PM
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The UPS info is new to me (and, it seems, also new to the people at our local UPS store, who didn't care about the battery I shipped even when I asked them specifically about it). Good information to have! Thank you!
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Old 05-13-24, 11:10 AM
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Originally Posted by ohh
The UPS info is new to me (and, it seems, also new to the people at our local UPS store, who didn't care about the battery I shipped even when I asked them specifically about it). Good information to have! Thank you!
Unfortunately most of the lower level folks at UPS, FedEx and DHL don't understand Hazmat regulations, so they want to help and I have had to tell them actually you cannot help I need your hazmat department. Shipping batteries without the proper safety precautions in place could be quite deadly and destructive. It would be nice to have a set up on the truck for LiOn and other battery stuff that is sealed and safe so shipping is a little easier. So you still have all the paperwork and such but you don't have to pack it quite as precisely and it won't run the risk of destroying the truck or hurting the driver.
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Old 05-27-24, 12:16 PM
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I've got a very early 24V Bionx kit. Not sure if this will work with the 36 & 48V systems. I opened the battery box with and separated the battery from the controller. There were only 3 wires connecting battery to controller - positive, negative and a very thin temp wire that would melt and shut system off if battery got too hot. Used an XT60 connector to connect the external battery to controller now housed in a small plastic box. For Battery, built it using SPIM08HP pouch cells in 7s. Also have another set in 7s2p. Have almost 1K miles on this setup. Hope you have good luck with our defunct Bionx system.
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