BOSCH PowerPack 300 Rack Battery System Instruction Manual

PowerPack 300 / 400 / 500
PowerTube 400 / 500 / 625
BBS245/BBR245/BBS265/BBR265/ BBS275 / BBR275/
BBP280/BBP281/BBP282/BBP283/BBP290/BBP291
Original operating instructions

PowerPack 300 Rack Battery System

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**Safety instructions

**

Read all the safety and general instructions. Failure to observe the safety and general instructions may result in electric shock, fire and/or serious injury.
The contents of lithium-ion battery cells are flammable under certain conditions. You must therefore ensure that you have read and understood the rules of conduct set out in these operating instructions.
Save all safety warnings and instructions for future reference.
The term battery is used in these instructions to mean all original Bosch eBike rechargeable battery packs.
▶ Read and observe the safety warnings and directions contained in all the eBike system operating instructions and in the operating instructions of your eBike.
▶ Remove the battery from the eBike before beginning work (e.g. inspection, repair, assembly, maintenance, work on the chain, etc.) on the eBike, transporting it with a car or aeroplane, or storing it. Unintentional activation of the eBike system poses a risk of injury.
▶ Do not open the battery. There is a risk of short-circuiting. Opening the battery voids any and all warranty claims.
▶ Protect the battery against heat (e.g. prolonged sun exposure), fire and from being submerged in water.
Do not store or operate the battery near hot or flammable objects. There is a risk of explosion.
▶ When the battery is not in use, keep it away from paper clips, coins, keys, nails, screws or oth r small metal objects that could make a connection from one terminal to another. A short circuit between the battery terminals may cause burns or a fire. Short circuit damage which occurs in this instance voids any and all warranty claims against Bosch.
▶ Avoid mechanical loads and exposure to high temperatures. These can damage the battery cells and cause the flammable contents to leak out.
▶ Do not place the charger or the battery near flammable materials. Ensure the battery is completely dry and placed on a fireproof surface before charging. There is a risk of fire due to the heat generated during charging.
▶ The eBike battery must not be left unattended while charging.
▶ If used incorrectly, liquid may leak from the battery. Contact with this liquid should be avoided. If contact occurs, rinse off with water. If the liquid comes into contact with your eyes, seek additional medical attention. Liquid leaking from the battery may cause irritation or scalding.
▶ Batteries must not be subjected to mechanical shock. There is a risk of the battery being damaged.
▶ The battery may give off fumes if it becomes damaged or is used incorrectly. Ensure the area is well ventilated and seek medical attention should you experience any adverse effects. The fumes may irritate the respiratory system.
▶ Only charge the battery using original Bosch chargers.
When using chargers that are not made by Bosch, the risk of fire cannot be excluded.
▶ Use the battery only in conjunction with eBikes that have original Bosch eBike drive systems. This is the only way in which you can protect the battery against dangerous overload.
▶Use only original Bosch batteries that the manufacturer has approved for your eBike. Using other batteries can lead to injuries and pose a fire hazard. Bosch accepts no liability or warranty claims if other batteries are used. u Do not use the rack-mounted battery as a handle. Lifting the eBike up by the battery can damage the battery.
▶ Keep the battery away from children.

The safety of both our customers and our products is important to us. Our eBike batteries are lithium-ion batteries which have been developed and manufactured in accordance with the latest technology. We comply with or exceed the requirements of all relevant safety standards. When charged, these lithium-ion batteries contain a high level of energy. If a fault occurs (which may not be detectable from the outside), in very rare cases and under unfavourable conditions, lithiumion batteries can catch fire.

Privacy notice
When you connect the eBike to the Bosch DiagnosticTool, data about the eBike batteries (e.g. temperature, cell voltage, etc.) is transferred to Bosch eBike Systems (Robert Bosch GmbH) for the purposes of product improvement. You can find more information about this on the Bosch eBike website at www.bosch- ebike.com.

Product description and specifications

Intended Use
The Bosch eBike rechargeable batteries are intended exclusively for the power supply of your Bosch eBike drive unit and must not be used for any other purpose.
Product features
The numbering of the components shown refers to the illustrations on the graphics pages at the beginning of the manual.
All representations of bicycle parts, apart from the batteries and their holders, are schematic and may differ from those on your own eBike.
In addition to the functions shown here, changes to software relating to troubleshooting and functional modifications may be introduced at any time.

(1) Rack-mounted battery holder
(2) Rack-mounted battery
(3) Operation/state of charge indicator
(4) On/off button
(5) Key for the battery lock
(6) Battery lock
(7) Upper standard battery holder
(8) Standard battery| (9) Lower standard battery holder
(10) Cover (supplied only on eBikes with two battery packs)
(11) Charger
(12) Socket for charging connector
(13) Charging socket cover
(14) PowerTube battery safety restraint
(15) PowerTube battery
(16) PowerTube battery safety hook
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Technical data

BBR275 C)
Rated voltage| V=| 36| 36| 36
Nominal capacity| Ah| 8.2| 11| 13.4
Energy| Wh| 300| 400| 500
Operating temperature| °C| −5 to +40| −5 to +40| −5 to +40
Storage temperature| °C| +10 to +40| +10 to +40| +10 to +40
Permitted charging temperature range| °C| 0 to +40| 0 to +40| 0 to +40
Weight, approx.| kg| 2.5 A) /2.6 C)| 2.5 A)/2.6 C)| 2.6 A) /2.7 C)
Protection rating| | IP 54| IP 54| IP 54

A) Standard battery
B) Cannot be used in combination with other batteries in systems with two batteries
C) Rack-mounted battery

BBP291 vertical
Rated voltage| V=| 36| 36| 36
Nominal capacity| Ah| 11| 13.4| 16.7
Energy| Wh| 400| 500| 625
Operating temperature| °C| –5 to +40| –5 to +40| –5 to +40
Storage temperature| °C| +10 to +40| +10 to +40| +10 to +40
Permitted charging temperature range| °C| 0 to +40| 0 to +40| 0 to +40
Weight, approx.| kg| 2.9| 2.9| 3.5
Protection rating| | IP 54| IP 54| IP 54

A) Cannot be used in combination with other batteries in systems with two batteries

Fitting

▶ Ensure the battery is placed on clean surfaces only.
Avoid getting dirt, e.g. sand or soil, in the charging socket and contacts in particular.
Testing the battery before using it for the first time
Test the battery before charging it for the first time or using it in your eBike.
To do this, press the on/off button (4) to switch the battery on. If none of the LEDs on the battery charge indicator (3) light up, the battery may be damaged. If at least one (but not all) of the LEDs on the battery charge indicator (3) lights up, the battery will need to be fully charged before using it for the first time.
▶ Do not charge or use batteries if they are damaged.
Contact an authorised bicycle dealer.

Charging the battery
▶ A Bosch eBike battery must only be charged using an original Bosch eBike charger.
Note: The battery is supplied partially charged. To ensure full battery capacity, fully charge the battery in the charger before using it for the first time.
To charge the battery, read and follow the instructions in the operating manual for the charger.
The battery can be charged at any state of charge. Interrupting the charging process does not damage the battery.
The battery has a temperature monitoring function which only allows it to be charged within a temperature range of 0 °C to 40 °C.

If the temperature of the battery is outside this charging range, three of the LEDs on the battery charge indicator (3) will flash. Disconnect the battery from the charger and let it acclimatise.
Do not reconnect the battery to the charger until it has reached the correct charging temperature.

Battery charge indicator
The five LEDs on the battery charge indicator (3) indicate the battery’s state of charge when the battery is switched on.
Each LED represents approximately 20% of the charging capacity. When the battery is fully charged, all five LEDs will be lit.
The battery’s state of charge when switched on is also shown on the display of the on-board computer. Read and follow the instructions in the operating manuals for the drive unit and on-board computer.
If the battery capacity is less than 10%, the last remaining LED will flash.
If the battery capacity is less than 5%, all the LEDs on the battery charge indicator (3) on the battery will go out. The display function of the on-board computer, however, will carry on working.
Once charging is complete, disconnect the battery from the charger and the charger from the mains.

Using two batteries for one eBike (optional)
The manufacturer can also equip an eBike with two batteries. In this case, one of the charging sockets will not be accessible or it will have been sealed with a sealing cap by the bicycle manufacturer. Only charge the batteries via the charging socket that is accessible.
▶ Never open charging sockets that have been sealed by the manufacturer. Charging batteries via a charging socket that used to be sealed may cause irreparable damage.
If you want to use an eBike that is designed for two batteries with only one battery, cover the contacts of the unused socket using the cover (10) provided. Otherwise there is a
risk that the exposed contacts will cause a short circuit (see figures A and B).

Charging process for two batteries
If two batteries are fitted to an eBike, both batteries can be charged using the uncovered connection. To begin with, both batteries are charged one after the other until they reach approx. 80–90 % capacity, then they are both fully charged at the same time (the LEDs flash on both batteries). When the bike is in operation, power is drawn from both batteries on an alternating basis. If you take the batteries out of the holders, you can charge each one individually.
Charging with one battery fitted
If only one battery is fitted, you can only charge the battery that has the accessible charging socket on the bike. You can only charge the battery with the sealed charging socket if you take the battery out of the holder.
Inserting and removing the battery
▶ Always switch off the battery and the eBike system when inserting the battery into the holder or removing it from the holder.
Inserting and removing the standard battery (see figure  A)
In order for the battery to be inserted, the key (5) must be inserted into the lock (6) and the lock must be open.
To insert the standard battery (8), place it onto the contacts on the lower holder (9) on the eBike (the battery can be titled towards the frame by up to 7°). Tilt it into the upper holder (7) as far as possible until you hear it click into place.
Check that the battery is secure in all directions. Always secure the battery by closing the lock (6) – otherwise the lock may open and the battery may fall out of the holder.
Always remove the key (5) from the lock (6) after closing it.
This prevents both the key from falling out and the battery from being removed by unauthorised third parties when the eBike is not in use.
To remove the standard battery (8), switch it off and open the lock using the key (5). Tilt the battery out of the upper holder (7) and pull it out of the lower holder (9).
Inserting and removing the rack-mounted battery (see figure B)
In order for the battery to be inserted, the key (5) must be inserted into the lock (6) and the lock must be open.
To insert the rack-mounted battery (2), slide it contactsfirst into the holder (1) on the rack until you hear it click into place.
Check that the battery is secure in all directions. Always secure the battery by closing the lock (6) – otherwise the lock may open and the battery may fall out of the holder. Always remove the key (5) from the lock (6) after closing it.
This prevents both the key from falling out and the battery from being removed by unauthorised third parties when the eBike is not in use.
To remove the rack-mounted battery (2), switch it off and open the lock using the key (5). Pull the battery out of the holder (1).
Removing the PowerTube battery (pivot) (see figure C)

1. To remove the PowerTube battery (15), open the lock (6) using the key (5). The battery will be unlocked and fall into the safety restraint (14).
2. Press on the safety restraint from above. The battery will be unlocked completely and fall into your hand. Pull the battery out of the frame.

Note: As a result of varying designs, the battery may need to be inserted and removed using a different method. Read the operating instructions of the eBike manufacturer.
Inserting the PowerTube battery (pivot) (see figure D)
In order for the battery to be inserted, the key (5) must be inserted into the lock (6) and the lock must be open.

1. To insert the PowerTube battery (15), place it so that its contacts are in the lower holder of the frame.
2. Push the battery upwards until it is held by the safety restraint (14).
3. Hold the lock open with the key and press the battery upwards until you hear it click into place. Check that the battery is secure in all directions.
4. Always secure the battery by closing the lock (6) – otherwise the lock may open and the battery may fall out of the holder.

Always remove the key (5) from the lock (6) after locking it. This prevents both the key from falling out and the battery from being removed by unauthorised third parties when the eBike is not in use.

Operation

Start-up
▶Use only original Bosch batteries that the manufacturer has approved for your eBike. Using other batteries can lead to injuries and pose a fire hazard. Bosch accepts no liability or warranty claims if other batteries are used.
Switching on/off
Switching on the battery is one way to switch on the eBike system. Read and follow the instructions in the operating manuals for the drive unit and on- board computer.
Before switching on the battery, i.e. the eBike system, make sure that the lock (6) is closed.
To switch on the battery, press the on/off button (4). Do not use any sharp or pointed objects to press the button. The LEDs on the indicator (3) will light up, indicating the battery’s state of charge at the same time.
Note: If the battery capacity is less than 5 %, none of the LEDs on the battery charge indicator (3) will light up.
Whether the eBike system is switched on is only visible on the on-board computer/control unit.
To switch off the battery, press the on/off button (4) again.
The LEDs on the indicator (3) will go out. This will also switch the eBike system off.
If no power is drawn from the eBike drive for about 10 minutes (e.g. because the eBike is not moving) and no button is pressed on the on-board computer or the control unit of the eBike, the eBike system will switch off automatically.
The battery is protected against deep discharge, overloading, overheating and short-circuiting by the “Electronic Cell Protection (ECP)”. In the event of danger, a protective circuit switches the battery off automatically.

If a fault is detected in the battery, two of the LEDs on the battery charge indicator (3) will flash. Contact an authorised bicycle dealer if this happens.
Recommendations for optimal handling of the battery
The service life of the battery can be extended if it is looked after well and especially if it is stored at the correct temperature.
As it ages, however, the capacity of the battery will diminish, even with good care.
A significantly reduced operating time after charging indicates that the battery has deteriorated. The battery should be replaced.
Recharging the battery before and during storage
When you are not going to use the battery for an extended period (longer than three months), store it at a state of charge of around 30 % to 60 % (when two to three of the LEDs on the battery charge indicator (3) are lit).
Check the state of charge after six months. If only one of the LEDs on the battery charge indicator (3) is lit, charge the battery back up to around 30 % to 60 %.
Note: If the battery is stored with no charge for an extended period of time, it may become damaged despite the low selfdischarge and the battery capacity could be significantly reduced.
Leaving the battery permanently connected to the charger is not recommended.
Storage conditions
If possible, store the battery in a dry, well-ventilated place.
Protect it against moisture and water. When the weather conditions are bad, it is advisable to remove the battery from the eBike and store it in a closed room until you use it next, for example.
Store the eBike batteries in the following locations:

• In a room with a smoke alarm
• Away from combustible or easily flammable objects
• Away from heat sources

To ensure an optimum service life, store the eBike batteries at temperatures between 10 °C and 20 °C. Never store them at temperatures below –10 °C or above 60 °C.
Make sure that the maximum storage temperature is not exceeded. Do not leave the battery in your car in the summer, for example, and store it away from direct sunlight.
Leaving the battery on the bicycle for storage is not recommended.
Action in the event of a fault
The Bosch eBike rechargeable battery must not be opened, including for repairs. There is a risk of the Bosch eBike rechargeable battery catching fire, e.g. as a result of a short
circuit. This risk continues to apply on any Bosch eBike rechargeable battery ever opened, even at a later point in time.
In the event of a fault, do not have your Bosch eBike rechargeable battery repaired; instead, have it replaced with an original Bosch eBike rechargeable battery by your specialist retailer.

Maintenance and servicing

Maintenance and cleaning
▶ The battery must not be submerged in water or cleaned using a jet of water.
Keep the battery clean and avoid contact with skincare products and insect repellant.Clean it carefully with a soft, damp cloth.
Clean and lightly grease the connector pins occasionally.
Please contact an authorised bicycle dealer if the battery is no longer working.
After-sales service and advice on using products
If you have any questions about the batteries, contact an authorised bicycle dealer.
▶Note down the key manufacturer and number on the key (5). Contact an authorised bicycle dealer if you lose the key. Give them the name of the key manufacturer and the number on the key.
For contact details of authorised bicycle dealers, please visit www.bosch- ebike.com.
Transport
▶ If you transport your eBike attached to the outside of your car, e.g. on a bike rack, remove the on-board computer and the eBike battery to avoid damaging them.
The batteries are subject to legislation on the transport of dangerous goods. Private users can transport undamaged batteries by road without having to comply with additional requirements.
When batteries are transported by commercial users or third parties (e.g. air transport or forwarding agency), special requirements on packaging and labelling (e.g. ADR regulations) must be met. When preparing items for shipping, a dangerous goods expert can be consulted as required.
Do not ship batteries if the housing is damaged or the rechargeable battery is not fully functional. Use only the original Bosch packaging for transport. Apply tape over exposed contacts and pack the battery such that it cannot move around inside the packaging. Inform your parcel service that the package contains dangerous goods. Please also observe any additional national regulations should these exist.
If you have any questions about transporting the batteries, contact an authorised bicycle dealer. You can also order suitable transport packaging from the dealer.

Disposal
Batteries, accessories and packaging should be recycled in an environmentally friendly manner.
Do not dispose of batteries along with household waste.
Apply tape over the contact surfaces of the battery terminals before disposing of batteries.
Do not touch severely damaged eBike batteries with your bare hands – electrolyte may escape and cause skin irritation. Store the defective battery in a safe location outdoors.
Cover the terminals if necessary and inform your dealer.
They will help you to dispose of it properly.
** In accordance with Directive 2012/19/EU and Directive 2006/66/EC respectively, electronic devices that are no longer usable and defective/drained batteries must be collected separately and recycled in an environmentally friendly manner.
Li-ion:
Please observe the information in the section on (see “Transport”, page English – 5).
Subject to change without notice.**

Robert Bosch GmbH
72757 Reutlingen
Germany
www.bosch-ebike.com

0 275 007 XPX (2022.03) T / 78 WEU

Documents / Resources

| BOSCH PowerPack 300 Rack Battery System [pdf] Instruction Manual
PowerPack 300, PowerPack 400, PowerPack 500, PowerTube 400, PowerTube 500, PowerTube 625, BBS245, BBR245, BBS265, BBR265, BBS275, BBR275, BBP280, BBP281, BBP282, BBP283, BBP290, BBP291, PowerPack 300 Rack Battery System, Rack Battery System, Battery System
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