BOSCH BBS245 300 PowerPack User Guide

PowerTube 400 | 500 | 625
Power Pack 300 | 400 | 500
BBS245 | BBR245 | BBS265 | BBR265 | BBS275 | BBR275 |
BBP280 | BBP281 | BBP282 | BBP283 | BBP290 | BBP291

Original operating instructions

BBS245 300 Power Pack

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.

• 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 aeroplane, 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 shortcircuiting. 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.

• 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 original Bosch chargers. When using chargers that are not made by Bosch, the risk of fire cannot be excluded.

• Use the eBike battery only in conjunction with eBikes that have original Bosch eBike drive systems. This is the only way in which you can protect the eBike battery against dangerous overload.

• Use only original Bosch eBike batteries that 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.

• Do not use the rack-mounted battery as a handle. Lifting the eBike up by the battery can damage the battery.

• 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 unfavourable conditions, lithium-ion batteries can catch fire.

Privacy notice
When you connect the eBike to the Bosch Diagnostic Tool 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 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 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. Rack-mounted battery holder
2. Rack-mounted battery
3. Status/battery 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 eBike 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

Technical data

Li-ion battery| | Power Pack 300| Power Pack 400| Power Pack 500
---|---|---|---|---
Product code| | BBS245 A) B)
BBR245 B) C)| BBS265 A)
BBR265 C)| BBS275 A)
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| 2.5A) /2.6C)| 2.5A) /2.6C)| 2.5A) /2.7C)
Protection rating| | IP55| IP55| IP55

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

Li-ion battery| | PowerTube 400| PowerTube 500| PowerTube 625
---|---|---|---|---
Product code| | BBP282
horizontal A)
BBP283 vertical A)| BBP280 horizontal
BBP281 vertical| BBP290 horizontal
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| | IP55| IP55| IP55

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

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.

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 (4) to switch the eBike battery on. If none of the LEDs on the battery charge indicator (3) lights up, the eBike battery may be damaged.

If at least one (but not all) of the LEDs on the battery charge indicator (3) 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 must only be charged using an original Bosch eBike charger.

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 (3) 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
The five LEDs on the battery charge indicator (3) indicate 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.
If the eBike battery capacity is less than 5%, all the LEDs on the battery charge indicator (3) on the eBike battery will go out. The display function of the on-board computer, however, will carry on working.
Once charging is complete, disconnect the eBike battery from the charger and the charger from the mains.

Using Two eBike Batteries for One eBike (optional)
The manufacturer can also equip an eBike with two eBike 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 eBike 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 eBike batteries with only one e-Bike 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 eBike Batteries
If two eBike batteries are fitted to an eBike, both eBike batteries can be charged using the uncovered connection.
To begin with, both eBike 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 eBike batteries).
When the eBike is in operation, power is drawn from both eBike batteries on an alternating basis.
If you take the eBike batteries out of the holders, you can charge each one individually.

Charging With One eBike Battery Fitted

If only one eBike battery is fitted, you can only charge the eBike battery that has the accessible charging socket on the bike. You can only charge the eBike battery with the sealed charging socket if you take the eBike battery out of the holder.

Inserting and Removing the eBike 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.

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°). Twist it into the upper holder (7) as far as possible until you hear it click into place.
Always secure the eBike battery by closing the lock (6) – otherwise the lock may open and the eBike 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 eBike 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 eBike 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 contacts first into the holder (1) on the rack until you hear it click into place.
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 eBike 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 battery lock (6) using the key (5). The battery will be unlocked and fall into the safety restraint (14).
   Note: When removing the eBike battery, hold it firmly in your hand.

2. Hold the battery firmly and press on the safety restraint (14) from above. The battery will be unlocked completely and fall into your hand. Then 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 battery lock (6) and the battery 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. Twist the battery upwards until it is held by the safety restraint (14).
3. Hold the battery lock open with the key and press the battery upwards until you hear it click into place.
4. Always secure the battery by closing the battery lock (6) – otherwise the battery lock may open and the battery may fall out of the holder.

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

Operation

Start-up

• Use only original Bosch eBike batteries that 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.

Switching on/off
Switching on the eBike battery is one way to switch on the eBike. Read and follow the instructions in the operating manuals for the drive unit and on- board computer.
Before switching on the eBike battery, i.e. the eBike, make sure that the battery lock (6) is locked.
To switch on the eBike 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 eBike battery capacity is less than 5%, none of the LEDs on the battery charge indicator (3) will light up.
Whether the eBike is switched on can only be determined from the on-board computer/control unit.
To switch off the eBike battery, press the on/off button (4) again. The LEDs on the indicator (3) will go out. 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 “Electronic Cell Protection (ECP)”. 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 (3) will flash. Contact an authorised bicycle dealer if this happens.

Recommendations for Optimal Handling of the eBike 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 (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 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 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 battery repaired; instead, have it replaced with an original Bosch eBike battery by your bicycle retailer.

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 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 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 – 5).
Please return eBike batteries that are no longer usable to an authorised bicycle dealer.

Subject to change without notice.

Robert Bosch GmbH
72757 Reutlingen
Germany
www.bosch-ebike.com
0 275 007 XPX (2023.05) T / 84 WEU

Documents / Resources

| BOSCH BBS245 300 PowerPack [pdf] User Guide
BBS245, BBR245, BBS265, BBR265, BBS275, BBR275, BBP280, BBP281, BBP282, BBP283, BBP290, BBP291, BBS245, 300 PowerPack, PowerPack
---|---

References

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

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