If you change elements in the cassette for those not intended, you may see unwelcome effects on the shifting. Not only will the shift ramps in the sprockets not be in the same places, but Campagnolo slightly change some of the sprocket-to-sprocket distances in some cassettes, which can interfere with the programmed values in the shifting matrix.
When you set the system up and tell it the positions of the 2nd and 10th sprocket (in 11s), you are telling the system, because the top three sprockets in any Campag cassette have slightly different spacing according to whether the cassette starts on 11, 12 or 13 teeth, what the start sprocket tooth number is. The system then makes an assumption, based on that and the fact that Campagnolo know what sprocket combinations they make, starting on 11, 12 or 13T, what the intermediate sprocket pattern is, in terms of spacing.
So - if you change an individual sprocket, or one of the triplets, or use a third party cassette where the makers have not properly understood Campagnolo’s system, you can see poor or glitchy shifting. The effective sprocket-to-sprocket spacing is sometimes managed on the sprockets themselves - so the teeth on the individual sprockets are not necessarily machined at the same point on the width of the sprocket - which is why sprockets with the same number of teeth, used at differing points in the cassette, may sometimes have different part numbers.
If you stick to the manufactured combinations, you won’t have problems. If you go off-piste, you may.
Power Units are only very, very seldom removed from the bike under normal circumstances. Once in place there is not normally any need to take them off / replace them. The internal PUs can be fitted into the majority of aero seat posts or fittings are available to fit them below the seatpost, or using the seat tube or even the downtube bottle cage boss fittings (assuming that the spaces inside the frame itself allow for these options). The switch system allows for switching the system off for air travel, where airlines demand it (most IME don’t).
As one of Campagnolo’s lead techs, I’d be interested to know why you’ve had to remove / replace the PU with enough frequency to make the fully-sealed wiring loom a problem? The system was designed in very close co-operation with the pro teams and amateur riders that Campag sponsors, many of whom travel with the bikes all the time and individual riders often have them in and out of bike bags etc - and we’ve not had any feedback from those quarters that we have missed a trick …
If the seatpost is regularly removed for travel with a bike box, etc, we recommend fitting of the PU, if at all possible, inside the frame, not the seatpost.
Thanks very useful information.
The sprocket 12-25 with which I had a problem shifting with is a standard campagnolo sprocket. But, as I wrote already, I could have made a mistake. I do not remember whether I made a new zero-setting on the 2nd and 10th cog. Maybe I could try it again once…
To the point of battery demount: I run an external battery (the bento-box shaped one) which is I think not available anymore. I had to demount it twice:
Firstly because the original battery was out of order from the beginning and I had to replace it with a guarantee-battery which is ok now since 4 years.
Secondly, I had a huge problem checking in on a plane. At first they thought it was an e-bike. I finally could convince the airline that electronic shifting has nothing to do with e-bikes.
However, the lady showed me a set of rules which included that batteries are not allowed in checked-in luggage. I was lucky however and she let me through. This was to Lanzarote. From Lanzarote back I wanted to avoid the hassle and I demounted the battery which is a lot of work.
After some research I concluded that most airlines do not allow any batteries in checked-in luggage, you rather have to carry that in hand-luggage.. You better belief that my wife works at an airline. Batteries in hand-luggage may not exceed a certain Wh , mostly 100 or 150 Wh. The battery of Campagnolo has 10 Wh, which is marked on it, so that is ok.
Needless to say that when I fly to Hawaii this October (sorry for the backdoor brag) I will dismount my battery again, mount it in Hawaii, and dismount it there again for the flight back. A huge hassle.