BOSCH BCS220, BCS230, BCS250 Charger Instruction Manual
- June 10, 2024
- Bosch
Table of Contents
BOSCH BCS220, BCS230, BCS250 Charger
Product Information
The Bosch eBike Battery Charger is designed to charge all original Bosch eBike rechargeable battery packs. The charger is available in three models: BCS220 Standard Charger, BCS230 Compact Charger, and BCS250 Fast Charger. The BCS220 is made in PRC while the BCS250 is made in Vietnam. The input for all chargers is 230V 50Hz, while the output for BCS220 and BCS230 is 36V 4A, and for BCS250, it is 36V 6A. The chargers have IP40 protection and can operate in temperatures ranging from 0°C to 40°C.
Product Usage Instructions
Charging the eBike Battery
- Connect the charger to a power outlet with an input voltage of 230V and 50Hz frequency.
- Plug the charger into the eBike battery.
- Turn on the power outlet switch.
- The battery will start charging, and the charging status will be displayed on the battery and the eBike’s display screen. The charging time will depend on the charger model and battery type.
- Once fully charged, unplug the charger from the battery and power outlet.
Safety Instructions
- Do not expose the charger to rain or wet conditions as it may result in electric shock.
- Do not charge the eBike battery unattended.
- Read and observe all safety warnings and directions contained in the operating instructions of your eBike and eBike system. Failure to do so may result in electric shock, fire, and/or serious injury.
Troubleshooting
If the battery does not start charging or stops charging before reaching
full capacity, check the following:
- The battery may be defective. Contact customer service for assistance.
- The battery may be too hot or too cold to charge. Wait until the battery reaches an appropriate temperature range before charging.
Maintenance and Disposal
- Clean the charger regularly and keep it away from dust and debris.
- Contact customer service for maintenance and repair services.
- Dispose of the charger in accordance with local regulations for electronic waste disposal.
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.
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.
- Do not expose the charger to rain or wet conditions. If water enters a charger, there is a risk of electric shock.
- Charge only Bosch lithium-ion batteries that are ap-proved for use in eBikes. The battery voltage must match the battery charging voltage of the charger. Otherwise there is a danger of fire and explosion.
- Keep the charger clean. Dirt poses a risk of electric shock.
- Always check the charger, cable and plug before use. Stop using the charger if you discover any damage. Do not open the charger. Damaged chargers, cables and plugs increase the risk of electric shock.
- Do not operate the charger on an easily ignited sur-face (e.g. paper, textiles, etc.) or in a flammable environment. There is a risk of fire due to the charger heating up during operation.
- Take care if you touch the charger while it is charging. Wear protective gloves. The charger can get very hot, especially when the ambient temperature is high.
- 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 experi-ence any adverse effects. The fumes may irritate the respiratory system.
- The eBike battery must not be left unattended while charging.
- Supervise children during use, cleaning and maintenance. This will ensure that children do not play with the charger.
- Children or persons who, owing to their physical, sensory or mental limitations or to their lack of experience or knowledge, are not capable of safely operat-ing the charger may only use this charger under supervision or after having been instructed by a responsible person. Otherwise, there is a danger of operating errors and injuries.
- A sticker in English is adhered to the bottom of the charger (marked (4) in the diagram on the graphics page). This says: Use ONLY with BOSCH lithium-ion batteries.
Product description and specifications
Intended Use
In addition to the functions shown here, changes to software relating to
troubleshooting and functional modifications may be introduced at any time.
The Bosch eBike chargers are intended exclusively for charging Bosch eBike
batteries 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.
Individual illustrations in these operating instructions may differ slightly from the actual conditions depending on the equipment of your bike.
- Charger
- Device socket
- Device connector
- Charger safety instructions
- Charging connector
- Socket for charging connector
- Charging socket cover
- Rack-mounted battery
- Operation/state of charge indicator
- Battery on/off button
- Standard battery
Technical data
Charger| | Standard charger
(36–4/230)
| Compact charger (36–2/100-230)| Fast charger (36–6/230)
---|---|---|---|---
Product code| | BCS220| BCS230| BCS250
Rated voltage| V~| 207 to 264| 90 to 264| 207 to 264
Frequency| Hz| 47 to 63| 47 to 63| 47 to 63
Battery charging voltage| V=| 36| 36| 36
Charging current (max.)| A| 4| 2| 6A)
Charging time
| – PowerPack 300, approx. | hrs | 2.5 | 5 | 2 |
|---|---|---|---|---|
| – PowerPack 400, approx. | hrs | 3.5 | 6.5 | 2.5 |
| – PowerPack 500, approx. | hrs | 4.5 | 7.5 | 3 |
| Operating temperature | °C | 0 to +40 | 0 to +40 | 0 to +40 |
| Storage temperature | °C | +10 to +40 | +10 to +40 | +10 to +40 |
| Weight, approx. | kg | 0.8 | 0.6 | 1.0 |
| Protection rating | IP 40 | IP 40 | IP 40 |
The charging current is limited to 4 A for the PowerPack 300 and for Classic+ Line batteries. The specifications apply to a rated voltage [U] of 230 V. These specifications may vary at different voltages and in country-specific models.
Operation
Start-up
Connecting the charger to the mains (see Figure A)
- Pay attention to the mains voltage. The voltage of the power source must match the voltage specified on the rating plate of the charger. Chargers marked 230 V can also be operated at 220 V.
Plug the device connector (3) of the power cable into the device socket (2) on the charger. Connect the power cable (country-specific) to the mains.
Charging the removed battery (see Figure B)
Switch the battery off and remove it from its holder on the bike. When doing
so, read and observe the operating instructions of the battery.
- 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.
Plug the charging connector (5) of the charger into the socket (6) on the battery.
Charging the battery on the bike (see figures C and D)
Switch the battery off. Clean the cover of the charging socket (7). Avoid
getting dirt, e.g. sand or soil, in the char-ging socket and contacts in
particular. Lift the cover of the charging socket (7) and plug the charging
connector (5) into the charging socket (6).
- There is a risk of fire due to the charger heating up during charging. Ensure the battery on the bike is completely dry and placed on a fireproof surface before charging. If this is not possible, remove the battery from the holder and charge it in a more suitable location. When doing so, read and observe the operating instructions of the battery.
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 process
The charging process begins as soon as the charger is connected to the battery
or charging socket on the bike and to the mains.
- Note: The charging process is only possible when the temperature of the eBike battery is within the permitted charging temperature range.
- Note: The drive unit is deactivated during the charging process.
The battery can be charged with and without the onboard computer. When
charging without the onboard computer, the charging procedure can be observed
on the battery charge indicator.
When the onboard computer is connected, a charging notification appears on the
display.
The state of charge is displayed by the battery charge indicator (9) on the battery and by the bars on the onboard computer. The LEDs on the battery charge indicator (9) flash during the charging process. Each solid illuminated LED represents approximately 20 % of the charging capacity. The flashing LED indicates the next 20 % currently charging. Once the eBike battery is fully charged, the LEDs go out immediately and the onboard computer is switched off. The charging process is terminated. The state of charge can be displayed for 3 seconds by pressing the on/off button (10) on the eBike battery.
Disconnect the charger from the mains and the battery from the charger. When the battery is disconnected from the charger, the bat-tery is automatically switched off.
Note:
If you have charged the battery on the bike, carefully close the charging
socket (6) with the cover (7) after char-ging, so that no dirt or water can
get in.
If the charger is not disconnected from the battery after charging, after a few hours the charger will switch itself back on, check the state of charge of the battery and begin the charging procedure again if necessary.
Errors – causes and corrective measures
| Cause | Corrective measures |
|---|
Battery defective
| Two LEDs flash on the battery.
Contact an authorised bike dealership.
Battery too warm or too cold
| Three LEDs flash on the battery.
Disconnect the battery from the charger until the charging temperature range has been reached.
Do not reconnect the battery to the charger until it has reached the correct charging temperature.
The charger is not charging.
| No LEDs flashing (one or more LEDs will remain perman- ently lit depending on the state of charge of the eBike bat- tery).
Contact an authorised bike dealership.
Charging not possible (no indicator on battery)|
Connector not attached properly| Check all connections.
Battery contacts dirty| Carefully clean the battery contacts.
Plug socket, cable or charger defective| Check the mains voltage, have the
charger checked over by a bike dealership.
Battery defective| Contact an authorized bike dealership.
Maintenance and servicing
If the charger fails, please contact an authorized bike dealership.
After-sales service and advice on using products
If you have any questions about the eBike system and its components, contact
an authorized bicycle dealer. For contact details of authorized bike
dealerships, please visit www.bosch-ebike.com.
Disposal
Chargers, accessories, and packaging should be recycled in an environmentally friendly manner. Do not dispose of chargers along with household waste. Check that your personal data has been deleted from the device.
Only for EU countries:
According to the European Directive 2012/19/EU on Waste Electrical and
Electronic Equipment and its implementation into national law, chargers that
are no longer usable must be collected separately and disposed of in an
environmentally friendly manner.
Please return Bosch eBike components that are no longer usable free of charge
to an authorized bicycle dealer or to a recycling facility.
Subject to change without notice.
Robert Bosch GmbH
72757 Reutlingen Germany
www.bosch-ebike.com.