BOSCH BBP3620 PowerMore 250 Range Extender Smart System Instruction Manual

BBP3620 Power More 250 Range
Extender Smart System
Instruction Manual

BBP3620 Power More 250 Range Extender Smart System

Power More 250
BBP3620

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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 ebike battery is used in these instructions to mean all original Bosch ebike rechargeable battery packs from the system generation the smart system. The terms drive and drive unit used in these operating instructions refer to the  reginal Bosch drive units from the system generation the smart system.
The term charger is used in these instructions to mean all original Bosch chargers from the system generation the smart system.

• 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 eBike battery from the eBike before beginning work (e.g. inspection, repair, assembly, maintenance, work on the chain, etc.) on the eBike, transporting it by car or aero plane, or storing it. There is a risk of injury if the eBike is accidentally activated.

• Do not open the eBike battery. There is a risk of short-circuiting. Opening the eBike battery voids any and all warranty claims.

• Protect the eBike battery against heat (e.g. prolonged sun exposure), fire and from being submerged in water. Do not store or operate the eBike battery near hot or flammable objects. There is a risk of explosion.

• When the eBike battery is not in use, keep it away from paper clips, coins, keys, nails, screws or other small metal objects that could make a connection from one terminal to another. A short circuit between the 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 eBike battery near flammable materials. Ensure the eBike 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. u If used incorrectly, the eBike battery may leak fluid; avoid contact. If contact occurs, rinse off with water. If the fluid comes into contact with your eyes, seek medical attention. Fluid ejected from the battery may cause skin irritation or burns.

• eBike batteries must not be subjected to mechanical shock. There is a risk of the eBike battery being damaged.

• The eBike 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 eBike battery using an original Bosch charger from the system generation the smart system. When using chargers made by other manufacturers, the risk of fire cannot be excluded.

• Use the eBike battery only in conjunction with eBikes from the system generation the smart system. This is the only way in which you can protect the eBike battery against dangerous overload.

• Use only original Bosch eBike batteries from the system generation the smart system, which the manufacturer has approved for your eBike. Using other eBike batteries can lead to injuries and pose a fire hazard.
  Bosch accepts no liability or warranty claims if other eBike batteries are used.

• When not in use, disconnect the cable from the Power More battery and from the charging socket on the eBike battery and store the cable away securely.
  Failure to do so poses a serious risk of injury.

• Keep the eBike 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, 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 unfavorable conditions, lithium-ion batteries can catch fire.

Privacy notice
When you connect the eBike to the Bosch Diagnostic Tool 3 or replace eBike components, technical information about your eBike (e.g. manufacturer, model, bike ID, configuration data) and the eBike usage (e.g. total riding time, energy  consumption, temperature) is transferred to Bosch eBike Systems (Robert Bosch GmbH) for the purposes of processing your inquiry, servicing and product improvement. You can find further information about data processing at www.bosch-ebike.com/privacy-full.

Product description and specifications

Intended Use
The Bosch eBike batteries of the smart system generation of systems are intended exclusively for the power supply of your drive unit of the smart system generation of systems and must not be used for any other purpose.
Only the manufacturer-approved cable may be used to connect the eBike battery.
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 eBike 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) Power More battery
(2) Status/battery charge indicator
(3) Power More battery connection socket
(4) Power More battery cable connector
(5) On/off button
(6) Power More battery cable
(7) eBike charging socket cable connector
(8) eBike charging socket
(9) Power More battery holder
(10) Release button for Power More battery holder
(11) Guide rail for Power More battery holder
(12) Guide grooves for Power More battery
(13) Release buttons for Power More battery cable connector
(14) Release mechanism for eBike charging socket cable connector

Technical data

Fitting

• Ensure the eBike battery is placed on clean surfaces only. Avoid getting dirt, e.g. sand or soil, in the charging socket and contacts.
• The Power More battery is only permitted for installation on eBikes that the manufacturer has designed specifically for such batteries. Check whether your  eBike is compatible for use with the Power More battery.
  Follow the operating instructions of the eBike manufacturer. If you have any questions or need further information, contact an authorised bike dealership.
  The eBike battery may only be used in the battery holder on the eBike.
  Note: An eBike may also be fitted with two eBike batteries.
  Follow the operating instructions of the eBike manufacturer.
  If you have any questions or need further information, contact an authorised bike dealership.
  Note: During installation, pay particular attention to the markings on the battery holder and on the Power More battery.
  Note: The Power More battery is only permitted for installation on the guide rails provided. The guide rails are only permitted for use with the Power More battery and the compatible bottle holder. Observe the specifications of the eBike manufacturer.
  Note: When laying the cable, follow the specifications of the eBike manufacturer. If you have any questions or need further information, contact an authorised bike dealership.

Testing the eBike Battery Before Using it for the First Time
Test the eBike battery before charging it for the first time or using it in your eBike.
To do this, press the on/off button (5) to switch the eBike battery on. If none of the LEDs on the battery charge indicator (2) lights up, the eBike battery may be damaged.
If at least one (but not all) of the LEDs on the battery charge indicator (2) lights up, the eBike battery will need to be fully charged before using it for the first time.

• Do not charge or use eBike batteries if they are damaged. Contact an authorised bicycle dealer.

Charging the eBike Battery

• A Bosch eBike battery of the smart system generation of systems must only be charged using an original Bosch charger from the smart system generation of systems.
  Note: The eBike battery is supplied partially charged. To ensure full capacity of the eBike battery, fully charge the battery in the charger before using it for the first time.

To charge the eBike battery, read and follow the instructions in the operating manual for the charger.
The eBike battery can be charged at any state of charge. Interrupting the charging process does not damage the eBike battery.
The eBike battery has a temperature monitoring function that only allows it to be charged within a temperature range of 0°C to 40 °C.

If the temperature of the eBike battery is outside this charging range, three of the LEDs on the battery charge indicator (2) will flash. Disconnect the eBike battery from the charger and let it reach the correct temperature range.
Do not reconnect the eBike battery to the charger until it has reached the correct charging temperature.
Battery charge indicator outside of the eBike
Note: The Power More battery charge indicator (2) switches back off as soon as the eBike battery is switched on.
The five LEDs on the battery charge indicator (2) show the battery’s state of charge when the eBike battery is switched on.
Each LED represents approximately 20 % of the charging capacity. When the eBike battery is fully charged, all five LEDs will be lit. The eBike 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 eBike battery’s capacity is less than 10 %, the last remaining LED will flash.
Once charging is complete, disconnect the eBike battery from the charger and the charger from the mains.
Laying the Cable on the Power More Battery Holder (see figure A)
Note: When laying the cable (6), make sure that the cable (6) is fed under the release button (10). This prevents the release button (10) from being pressed accidentally and causing the Power More battery to be released.

Inserting and Removing the Power More Battery

• When inserting the battery into the holder or removing it from the holder, always switch off the eBike battery and the eBike beforehand.
• Once you have inserted the eBike battery, check that it is correctly positioned and secure in all directions.
• Only leave the Power More battery with the cable connected to the eBike.
• Once the Power More battery is installed, the connection socket of the battery must not face upwards.

Inserting the Power More Battery (see figure B)
To insert the battery (1), place its guide grooves (12) onto the guide rails (11). Ensure that the battery is aligned correctly and that the battery is positioned in both guide rails. Slide the battery (1) into the holder (9) until it audibly clicks into place.
Insert the cable connector (4) into the connection socket (3). Ensure that the cable connector (4) is aligned correctly.
Insert the cable connector (7) into the eBike charging socket (8). Ensure that the cable connector (7) is aligned correctly. Secure the cable (6) in place as directed by the eBike manufacturer (e.g. with cable clips).
Removing the Power More Battery (see figure C)
Firstly, disconnect the cable (6) by opening the cable lock as directed by the eBike manufacturer.
Pull the release mechanism (14) towards you ❶ and remove the cable connector  (7) from the eBike charging socket ❷.
Press the release buttons (13) and remove the cable connector (4) from the connection socket. To remove the battery (1), press the release button (10) and pull the battery (1) sideways out of the holder  (9).
Note: As a result of varying designs, the Power More battery may need to be inserted and removed using a different method. Read the eBike manufacturer’s operating instructions for how to do this.

Operation

Start-up

• Use only original Bosch eBike batteries from the system generation the smart system, which the manufacturer has approved for your eBike. Using other eBike batteries can lead to injuries and pose a fire hazard.
  Bosch accepts no liability or warranty claims if other eBike batteries are used.
  Note: The drive performance may be reduced when using solely the Power More battery.

Switching on/off
Switching on the eBike battery is one way to switch on the eBike. To do this, read and follow the instructions in the operating manuals for the drive unit and operating unit.
Once the Power More battery is connected to the eBike via the Power More cable, the eBike can be switched on/off via the on/off button (5). Do not use any sharp or pointed objects to press the button.
To switch off the eBike battery, press the on/off button (5) again. This will also switch the eBike off.
If no power is drawn from the 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 operating unit of the eBike, the eBike will switch off automatically.
The eBike battery is protected against deep discharge, overloading, overheating and short-circuiting by the “Battery Management System (BMS)”. In the event of danger, a protective circuit switches the eBike battery off automatically.
If a fault is detected in the eBike battery, two of the LEDs on the battery charge indicator (2) will flash. Contact an authorised bicycle dealer if this happens.

Recommendations for Optimal Handling of the Bike Battery
The service life of the eBike 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 eBike battery will diminish, even with good care.
A significantly reduced operating time after charging indicates that the eBike battery has deteriorated. The eBike battery should be replaced.
Recharging the eBike Battery Before and During Storage
When you are not going to use the eBike 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 (2) are lit). Check the  state of charge after six months. If only one of the LEDs on the battery charge indicator (2) is lit, charge the eBike battery back up to around 30 % to 60 %.
Note: If the eBike battery is stored with no charge for an extended period of time, it may become damaged despite the low self-discharge and the battery capacity could be significantly reduced.
Leaving the eBike battery permanently connected to the charger is not recommended.
Storage conditions
If possible, store the eBike 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 eBike battery from the eBike and store it in a closed room, for  example, until you use it next.
Do not store the eBike battery in the following locations:
– in areas without smoke alarms
– near combustible or easily flammable objects
– near heat sources
– in locked vehicles (especially in the summer)
– in direct sunlight
To ensure an optimum service life, store the eBike batteries at room temperature.
Never store them at temperatures below − 10 °C or above 60 °C.
Make sure that the maximum storage temperature is not exceeded.
Leaving the eBike battery on the eBike for storage is not recommended.
Action in the event of a fault
The eBike battery must not be opened, not even for repairs.
There is a risk of the eBike battery catching fire, e.g. as a result of a short circuit. This risk continues to apply for any Bosch eBike battery that has ever been opened, even at a later point in time.
In the event of a fault, do not have your eBike battery repaired; instead, have your bicycle retailer replace it with an original Bosch eBike battery of the smart system generation of systems.

Maintenance and servicing

Maintenance and cleaning

• The eBike battery must not be submerged in water or cleaned using a jet of water.
  Keep the eBike battery clean and avoid contact with skincare products, sun cream and insect repellant. Clean it carefully with a soft, damp cloth.
  Clean and lightly grease the connector pins occasionally. Use medical or technical Vaseline for this purpose.
  Please contact an authorised bicycle dealer if the eBike battery is no longer working.

After-sales service and advice on using products
If you have any questions about the eBike batteries, contact an authorised bicycle dealer.
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 (exception: built-in eBike battery) to avoid damaging them.
  The eBike batteries are subject to legislation on the transport of dangerous goods. Private users can transport undamaged eBike 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 eBike  battery is not fully functional. Use only the original Bosch  eBike battery packaging when transporting the eBike battery. Apply tape over exposed contacts and pack the eBike 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 eBike batteries, contact an authorised bicycle dealer. You can also order suitable transport packaging from the dealer.

Disposal and substances in products
You can find information about substances in products at the following link: www.bosch-ebike.com/en/material-compliance.
eBike batteries, accessories and packaging should be recycled in an environmentally friendly manner.
Do not dispose of eBike batteries along with household waste.
Apply tape over the contact surfaces of the battery terminals before disposing of eBike batteries.
Old or defective eBike batteries can be handed in free of charge at any specialist retailer that sorts these for environmentally friendly recycling. Store defective eBike batteries in a safe location outdoors and inform your specialist retailer.  Do not touch severely damaged eBike batteries with your bare hands – electrolyte may escape and cause skin irritation.
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 “Transport” (see “Transport”, page English – 4).
Please return eBike batteries that are no longer usable to an authorised bicycle dealer.

Subject to change without notice.
http://www.bosch-ebike.com/qr/disposal

Robert Bosch GmbH
72757 Reutlingen
Germany
www.bosch-ebike.com
0 275 007 3RE (2023.02) T / 81 WEU

Documents / Resources

| BOSCH BBP3620 PowerMore 250 Range Extender Smart System [pdf] Instruction Manual
BBP3620 PowerMore 250 Range Extender Smart System, BBP3620, PowerMore 250 Range Extender Smart System, 250 Range Extender Smart System, Range Extender Smart System, Extender Smart System, Smart System
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References

• Material Compliance - Bosch eBike Systems
• General. Data protection - Bosch eBike Systems - Bosch eBike Systems

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