Thanks for posting this. I like the crimped tab connector solution on the 3D printed version of the (deliberately unobtainable) Bosch connector. Great solution. The 5V converter is clearly overkill, as you pointed out. A tiny 5V regulator like Diodes Incorporated ZXTR2105FQ would fit under some heat-shrink tubing without the bulky case. I would recommend sticking with a proper Neutrik XLR connector to maintain the current rating but it does require a solder connection. Have you tried confirming that the BMS cuts off if you charge with more than 4.5 amps? Justin reported this in the comments on another video.
Thanks! Another thing that should probably be done is to have some sort of "fuse" that shuts off if someone accidentally outputs a voltage higher than 42V. Any ideas of a good part? I'll check the Bosch BMS charge current cut-off.
@@chrisnafis7000 I've read discussions on Endless Sphere about adding "HVC" (high voltage cut-off) protection in special cases like when someone is running a battery pack without a BMS. It was never clear to me if there's a commercially available component specifically for this purpose or if you would need to scratch-build your own circuit with a voltage detector and some kind of switch. I'm not sure it's needed here? Anyone using your approach should be instructed to only connect a 42.0V charger/solar charge controller. I believe the BMS inside the battery pack likely has over-voltage protection with monitoring for each cell group as part of the cell balancing function which should provide this protection.
@@SerendipitySue Interesting. I found this page which shows their 2A, 4A and 6A chargers and charge times for different batteries. At the bottom, it says "Charging current is limited to 4 A for the PowerPack 300 and Classic + Line batteries." so that must have been what Justin had on hand for testing. It looks like all others can take up to 6A. I would set up my Satiator with both 4A and 6A charger profiles and use the 4A one to prolong battery life and the 6A only when I'm in a big hurry. Thanks for testing. www.bosch-ebike.com/en/products/charger/
Were you able to charge your Bosch battery with 8A? Grin now sells the adapter, too. It also comes with the plug to connect it to the PC. The 230V Bosch charger is available as 6A charger but they never made one for the 120V 🙄
@@SerendipitySue do you have the current software version on the battery that allows 6A charging? If your battery is older and it's software has never been updated, it won't support the 6A.
Can you please explain how to enabler wire works? For charging and discharge on say a grin tech controller. And do you know the max amp draw the bms provides? Thank you
I figured out the bosch charger experimentally. You can up the charge current to 5.5A I think before the BMS turns off. It's been a while since I tested it. 4A works fine.
@SerendipitySue, Could you please post a wiring diagram? I didn't understand the wiring in your project. I'd appreciate it very much if you could. Thank you
The GRIN plug has a GND and +42V out. The BOSCH has a GND and +42V in. The Step-down transformer has a GND and +42V in and 5V out. Hook all the GNDs together. Hook the GRIN +42V out to the BOSCH +42V in AND the Step-down transformer IN. The connect the 5V output of the step-down transformer to the GRIN 5V input.
@@SerendipitySue I am trying to understand what is going on electrically between the Cycle satiator and the Bosch battery. From what I understand (and correct me where I am wrong), the bosche battery requires an initial voltage of 5v through its charging leads (+ and -) to click a relay inside it which then allows it to get the full voltage and amperage pumped into it? And your design gives that initial 5v, but then it switches to the 36v (or whatever profile you have set for the battery) to engage and charge the battery? Or does the bosch battery have a second circuit that you plug the 5v + and - into which must always be providing a 5v current while charging the battery? or?
I want to create a "smart" charger out of an stock bosch charger for my gen4 bosch e-bike system. I'm going to use a Arduino to switch the power to the charger on and off using a solid-state relay. I want to be able to automatically charge by battery to a set level, like 70% to preserve the battery when I don't need all the capacity. I can create a simple timer, but than you need to calculate how much the battery needs to be charge to reached the desired level. To make it more user friendly, I would like the Arduino to be able to measure the battery voltage, and than calculate the time it needs. I have the same 3 pin charger, and I believe you can't measure the battery without the 5v active? So I think I need a seperate 5v power supply to measure, than turn of the 5v power supply, and than activate the charger? No resistor needed on the 5v? And does someone knows if it's oke just to cut off the charging line, in order to measure the voltage, and connect it again to resume charging? And are there any pin-out guides?
The 5V just enables charging. It hardly draws any power. I used a Grin charge controller. It is programmable ( ruclips.net/video/YejPGydMOnw/видео.html )
@@SerendipitySue yea, I came across the grin charger. I would buy it if it was able to charge the dual battery both to a set level. Sadly, i tested the charge behavior of the Bosh dual tube battery system, and it charge one battery to 100% and only than switches to the other, no way to force this switch. Im forced to remove one from the bike, and charge both batteries on there own chargers. I bought 2x 2A bosch chargers, and I'm going to transform them into a smart dual battery charger using solidstate relays to swich the charger AC and its output voltage on and off and a voltage sensor to check the battery level.
5v присутствует на третьем выводе штекера зарядки, при всех режимах. BMS подключает батарею с достаточным остаточным напряжением к заряднику, и только после этого зарядник подаёт своё напряжение для заряда. BMS после достижения заряда отключает напряжение в самом зарядке.
Wow, great vid! I have a Ebike with the Bosch system and was thinking about using the Grin Cycle Satiator.
Thanks for video, great job, thanks from Spain friend, 1000likes
Thanks for posting this. I like the crimped tab connector solution on the 3D printed version of the (deliberately unobtainable) Bosch connector. Great solution.
The 5V converter is clearly overkill, as you pointed out. A tiny 5V regulator like Diodes Incorporated ZXTR2105FQ would fit under some heat-shrink tubing without the bulky case.
I would recommend sticking with a proper Neutrik XLR connector to maintain the current rating but it does require a solder connection.
Have you tried confirming that the BMS cuts off if you charge with more than 4.5 amps? Justin reported this in the comments on another video.
Thanks! Another thing that should probably be done is to have some sort of "fuse" that shuts off if someone accidentally outputs a voltage higher than 42V. Any ideas of a good part? I'll check the Bosch BMS charge current cut-off.
@@chrisnafis7000 I've read discussions on Endless Sphere about adding "HVC" (high voltage cut-off) protection in special cases like when someone is running a battery pack without a BMS. It was never clear to me if there's a commercially available component specifically for this purpose or if you would need to scratch-build your own circuit with a voltage detector and some kind of switch.
I'm not sure it's needed here? Anyone using your approach should be instructed to only connect a 42.0V charger/solar charge controller. I believe the BMS inside the battery pack likely has over-voltage protection with monitoring for each cell group as part of the cell balancing function which should provide this protection.
I just checked charging with my Bosch Powerpack 500 battery. I can charge at 6.5A. When I went to 7A, the BMS cut out.
@@SerendipitySue Interesting. I found this page which shows their 2A, 4A and 6A chargers and charge times for different batteries. At the bottom, it says "Charging current is limited to 4 A for the PowerPack 300 and Classic + Line batteries." so that must have been what Justin had on hand for testing. It looks like all others can take up to 6A. I would set up my Satiator with both 4A and 6A charger profiles and use the 4A one to prolong battery life and the 6A only when I'm in a big hurry. Thanks for testing. www.bosch-ebike.com/en/products/charger/
Very nice design, well done
Hi will the charger show the batteries amp hour capacity? Thank you
Were you able to charge your Bosch battery with 8A?
Grin now sells the adapter, too. It also comes with the plug to connect it to the PC.
The 230V Bosch charger is available as 6A charger but they never made one for the 120V 🙄
The Bosch battery BMS (battery management system) does not allow charging much over 5A. It shuts down the charging.
@@SerendipitySue do you have the current software version on the battery that allows 6A charging?
If your battery is older and it's software has never been updated, it won't support the 6A.
Can you please explain how to enabler wire works? For charging and discharge on say a grin tech controller. And do you know the max amp draw the bms provides?
Thank you
I figured out the bosch charger experimentally. You can up the charge current to 5.5A I think before the BMS turns off. It's been a while since I tested it. 4A works fine.
Will this work on the most recent 2024 bosch battery ?
don't know, I don't have one
@SerendipitySue, Could you please post a wiring diagram? I didn't understand the wiring in your project. I'd appreciate it very much if you could. Thank you
The GRIN plug has a GND and +42V out. The BOSCH has a GND and +42V in. The Step-down transformer has a GND and +42V in and 5V out.
Hook all the GNDs together. Hook the GRIN +42V out to the BOSCH +42V in AND the Step-down transformer IN. The connect the 5V output of the step-down transformer to the GRIN 5V input.
@@SerendipitySue thank you. I understand now. Thank you again!
@@SerendipitySue I am trying to understand what is going on electrically between the Cycle satiator and the Bosch battery. From what I understand (and correct me where I am wrong), the bosche battery requires an initial voltage of 5v through its charging leads (+ and -) to click a relay inside it which then allows it to get the full voltage and amperage pumped into it? And your design gives that initial 5v, but then it switches to the 36v (or whatever profile you have set for the battery) to engage and charge the battery? Or does the bosch battery have a second circuit that you plug the 5v + and - into which must always be providing a 5v current while charging the battery? or?
Would you consider selling one of these Bosch to Grin kits? I don't have a 3-d printer.
Thanks
sorry, I'm not in a position to make/sell things. I put my designs out for free
If I was to charge at 8a, how fast would this charge a standard 625wh battery?
The Bosch battery BMS will turn off if you try to charge too high
Hello i need your help plz. I lost my charger bosch ebike.i made one at home (40V 3.5A) with 2 pin (+.-) but not charge it. What can i do plz
The Bosch battery needs 5V applied to a 3rd pin inorder to charge. Check out my other video: ruclips.net/video/d2r3jbL78iQ/видео.html
I want to create a "smart" charger out of an stock bosch charger for my gen4 bosch e-bike system. I'm going to use a Arduino to switch the power to the charger on and off using a solid-state relay. I want to be able to automatically charge by battery to a set level, like 70% to preserve the battery when I don't need all the capacity.
I can create a simple timer, but than you need to calculate how much the battery needs to be charge to reached the desired level. To make it more user friendly, I would like the Arduino to be able to measure the battery voltage, and than calculate the time it needs. I have the same 3 pin charger, and I believe you can't measure the battery without the 5v active?
So I think I need a seperate 5v power supply to measure, than turn of the 5v power supply, and than activate the charger?
No resistor needed on the 5v? And does someone knows if it's oke just to cut off the charging line, in order to measure the voltage, and connect it again to resume charging?
And are there any pin-out guides?
The 5V just enables charging. It hardly draws any power. I used a Grin charge controller. It is programmable ( ruclips.net/video/YejPGydMOnw/видео.html )
@@SerendipitySue yea, I came across the grin charger. I would buy it if it was able to charge the dual battery both to a set level. Sadly, i tested the charge behavior of the Bosh dual tube battery system, and it charge one battery to 100% and only than switches to the other, no way to force this switch. Im forced to remove one from the bike, and charge both batteries on there own chargers. I bought 2x 2A bosch chargers, and I'm going to transform them into a smart dual battery charger using solidstate relays to swich the charger AC and its output voltage on and off and a voltage sensor to check the battery level.
non rien à faire j'ai regardé plusieurs fois la vidéo mais la barrière de la langue m'empêche de comprendre il faudrait un schéma
merci quand même 😉🇫🇷
5v присутствует на третьем выводе штекера зарядки, при всех режимах. BMS подключает батарею с достаточным остаточным напряжением к заряднику, и только после этого зарядник подаёт своё напряжение для заряда. BMS после достижения заряда отключает напряжение в самом зарядке.
Think I will just buy a Bosch charger 🙄used for $80 on eBay