BOSCH BAT 6120 Charger for 12 V Batteries Instruction Manual

BAT 6120
Charger for 12 V batteries

Original operating instructions

Notes on the documentation

1.1 Using the documentation
Before commissioning, connecting and using Bosch products, it is essential to go through the operating instructions – and the safety instructions, in particular with great care. By doing so, you can eliminate any uncertainties in handling Bosch products and associated safety risks upfront, which is in the interest of your own safety and will help avoid damage to the products. Should a Bosch product be passed on to another person, the operating instructions with information on its intended use must be handed over as well.

1.2 Symbols used in the documentation

| Warning of possible physical damage to the component or product or of environmental pollution.
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| Practical hints, recommendation or reference to other information.
| Warning of danger for the user during subsequent procedures.
| Single-step procedure.
| Optional step.
| Result of a procedure.
| Reference to a page.

1.3 Warnings in the documentation
1.3.1 Meaning of the signal words
Warnings warn of dangers to the user or people in the vicinity. The signal word in the warning indicates the likelihood of occurrence and the severity of the danger if it is disregarded.

Signal word| Likelihood of occurrence| Severity of danger if disregarded
---|---|---
DANGER| Immediate, imminent danger| Death or severe injury
WARNING| Possible impending danger| Death or severe injury
CAUTION| Possible dangerous situation| Minor injury

1.3.2 Structure of warnings specific to sections
Warnings specific to sections refer to several steps within a dangerous sequence of actions. Warnings specific to sections are placed before a dangerous sequence of actions.
Signal word
Warning sign
Type, source and consequences of the danger.
 Measures and instructions to prevent the danger.
1.3.3 Structure of embedded warnings
Embedded warnings refer to an individual dangerous step. Embedded warnings are placed before a dangerous step. The remedies are embedded in the sequence of actions.
SIGNAL WORD – type and source of danger. Possible consequence if disregarded.

Safety

2.1 Safety instructions
Voltage must be supplied to BAT 6120 via a grounded mains voltage system.
The power supply cable and battery cable B+/B– must be in perfect condition.
Only use the battery cable B+/B– supplied by Bosch.
Do not extend or shorten the battery cable B+/B–.
When using an extension cable, make sure that the total current of all devices connected to this extension cable does not exceed the permissible current for the extension cable and the upstream fuse in the fuse box.
Only charge batteries in well ventilated areas.
Avoid naked flames and spark formation when charging batteries.
Do not attempt to charge non-rechargeable batteries.
Do not charge lithium iron phosphate batteries (LFP = LiFePO4) without the battery management system (BMS).
Switch off all electrical equipment in the vehicle whilst charging (also applies to charging of exhausted batteries).
 Do not short-circuit battery terminals.

Battery hazard
Risk of chemical burns – Electrolyte leaking from batteries and accumulators may cause eye and skin burns.
Make sure that any leaking liquid (electrolyte) does not come into contact with skin or eyes.
If electrolyte contacts the relevant areas, immediately rinse with water and then consult a medical professional.
Do not short-circuit batteries and accumulators.
Risk of fire, explosion – Batteries and accumulators can cause burns and injury if overcharged (gassed) or short-circuited.
No open flames or sources of sparks.
Do not smoke.
Ensure that there is sufficient ventilation and extraction in enclosed rooms.
 Do not short-circuit batteries and accumulators.

2.2 Target group
The product may only be used by trained and instructed personnel. Apprentices or personnel undergoing training or instruction may use the product only under the continual supervision of an experienced person.
Children must be supervised to ensure that they do not play with the product.

Work on electrical systems or equipment must only be performed by qualified electricians or trained personnel under the guidance and supervision of an electrician.
2.3 Other applicable documents
General safety instructions Bosch Automotive Aftermarket

| https://help.boschdiagnostics.com/generalsafetynotes
---|---
| BAT 6120 Help Center
https://help.boschdiagnostics.com/BAT6120

2.4 Intended use
BAT 6120 is a battery charger in the workshop area used to charge 12 V vehicle batteries or to supply vehicles with current, e.g. during repair.
2.5 Foreseeable misuse
Misuse ( ) with corresponding intended use ( ):
 Use outside the allowed ambient conditions.
Use the BAT 6120 only under the allowed ambient conditions.
Battery terminals are connected or disconnected incorrectly.
When connecting or disconnecting, BAT 6120 must be switched off.
Connecting: Connect the red battery terminal to the positive terminal (+) first. Next, connect the black battery terminal to the negative terminal (–).
Disconnecting: Disconnect the black battery terminal first. Next, disconnect the red battery terminal.

2.6 Prerequisites

• Place the BAT 6120 on a solid subsurface or hook on‐ to the wall mounting.
• The installation location must have an adequate loadbearing capacity. Pay attention to the weight of the BAT 6120 and the weight of the battery to be charged.
• Note and maintain a safe distance of 0.5 m between the BAT 6120 and battery.
• Protect the BAT 6120 against damp and moisture.
• Do not cover up the BAT 6120.
• On installing the BAT 6120 maintain a lateral clearance of at least 15 cm for ventilation.

2.7 Protective clothing and equipment

• Safety goggles
• Protective gloves

2.8 Warranty and liability
No modifications may be carried out on our products.
Our products may only be used with genuine accessories and genuine spare parts. Otherwise, all warranty claims will be rendered null and void.

Product description

3.1 Scope of delivery

Power supply cable 3 m for:
0 687 000 149
0 687 000 044
0 687 000 111
0 687 000 081| 1 684 461 201
1 684 461 202
1 684 461 203
1 684 461 204
Battery cable B+/B– (3 m; 25 mm2)| 1 684 437 008
Retaining bracket (1 x) with screw for battery cable B+/B–| –
Retaining bracket (4 x) for wall mounting| –
Operating instructions for:
0 687 000 149
0 687 000 044, 0 687 000 111, 0 687 000 081| 1 689 989 524
1 689 989 525

3.2 Symbols on the product
All warning signs must be in legible condition.

| Dispose of used electrical and electronic devices, including cables, accessories and batteries, separately from household waste.
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| Before working with the BAT 6120, the operating instructions must be read and understood.
| Only use the BAT 6120 indoors and protect against damp and moisture.
| Do not use the BAT 6120 outdoors and protect against damp and moisture.
| BAT 6120 is suitable for use in countries with a tropical climate.
| 1. Switch off the battery charger.
2. Connect or disconnect the battery terminals.
| Danger due to flammable gases and acidic liquid.

3.3 Functional description
The powerful battery charger BAT 6120 can be used to charge the following batteries:

• UNI, WET, AGM, EFB, GEL/VRLA: 12 V lead-acid batteries.
• LFP: 12 V lithium iron phosphate (LFP = LiFePO4) batteries with battery management system (BMS).

The batteries can be charged either in the vehicle while installed or when removed. The BAT 6120 can also be used to supply voltage to the vehicle electrical system when replacing batteries or programming control units. Other applications include supplying power to the vehicle electrical system when troubleshooting the vehicle or supplying power to the vehicle electrical system for vehicles in showrooms. The BAT 6120 is intended for use by automotive workshops, car dealership showrooms, technical supervisory authorities, petrol stations and battery retailers.

3.3.1 BAT 6120 overview
Front view

1 On/Off switch
2 Handle| 3 LCD display
4 Selection buttons
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Rear view

1 Battery cable connection B+/B–
2 USB port| 3 Slide switch for mains voltage (230 V or 115 V)
4 Power supply cable connection
---|---

3.3.2 Selection keys
Menu/mode activation or next menu stage.
Abort process or previous menu stage.
Menu/mode selection or change parameters (enlarge).
Menu/mode selection or change parameters (reduce).

3.3.3 Display
Blue: Normal operation.
Yellow: Restricted operation, e.g. with warning message Load too high! Voltage reduced.
Green: E.g. at the end of charging phases.
Red: A fault has occurred. The mode was canceled.

Initial commissioning

4.1 Checking the voltage setting
Before switching on, make sure that the mains voltage matches with the voltage set on the BAT 6120.
If the voltage is not the same, adjust the voltage with a flat-head screwdriver.
– 230 V: Move the slide switch for mains voltage to the left.
– 115 V: Move the slide switch for mains voltage to the right.

4.2 Connect and secure battery cable B +/B–.
The retaining bracket must be mounted to prevent unintentional disconnection of the battery cable B+/B– during operation and to protect the BAT 6120 connection.

Retaining bracket assembly

1. Remove the screws (2 x) below the battery cable connection B+/B–.
2. Mount the retaining bracket using the 2 screws.
   

Mounting the battery cable B+/B–

1. Insert the plug of the battery cable B+/B– as far as it will go into the battery cable connection B+/B–.
2. Attach the plug of the battery cable B+/B– to the retaining bracket using a screw.

4.3 Securing the BAT 6120 to the wall (optional)
For further information, see “BAT 6120 Help Center”.

4.4 Initial switching on
A language must be selected during initial commissioning.
The selected language can be changed subsequently in the settings.

1. Connect the power supply cable to the mains voltage system.

2. Switch on the BAT 6120 with the on/off switch.
   The “LANGUAGE” menu is displayed.

3. Select the language with or .

4. Save the changes with .
   The “POWER SUPPLY” mode is displayed.

Resetting the language selection
If you selected a language that you do not understand, you can reset the language.

1. Switch off the BAT 6120.

2. Hold down and switch on the BAT 6120 again.
   The “LANGUAGE” menu is displayed.

3. Release .

4. Select the language with or .

5. Save the changes with .
   The “POWER SUPPLY” mode is displayed.

4.5 Selecting the power limit
The output of BAT 6120 can be selected.

1. Select “SETTINGS >> MAX. POWER”.

2. Press .
   The “MAX. POWER” menu with the currently selected power limit is displayed.

3. Press .

4. Select the region-specific or individual power limit with or .
   The desired power limit can be selected individu‐ ally with “1200W…1750W”.

5. Save the changes and return to the “SETTINGS” menu with .

Operation

5.1 Connecting BAT 6120 to the battery

1. Connect the BAT 6120 to the mains voltage system via the power supply cable.

2. Connect the red battery terminal to the positive terminal (+) of the battery.

3. Connect the black battery terminal to the negative terminal (–) of the battery.
   When charging vehicle batteries in the installed condition, the black battery terminal (‒) can also be connected to the body away from the battery and gasoline line.

4. Switch on the BAT 6120 with the on/off switch.
   The display lights up.

5.2 Disconnecting BAT 6120 from the battery

1. Interrupt the power supply with .
2. Confirm the message Abort charging? with .
3. Optional: Switch off the BAT 6120 with the on/off switch.
4. Disconnect the black battery terminal.
5. Disconnect the red battery terminal.

5.3 Main menu
After switching on, BAT 6120 is in the main menu. In the main menu, the desired mode is selected and settings are made.
For further information, see “BAT 6120 Help Center”.

“POWER SUPPLY” mode
Mode for power supply of vehicles when working on the vehicles, e.g. control unit programming or troubleshooting.
“CHARGE BATTERY” mode
Mode for charging different types of batteries (UNI, WET, AGM, EFB, GEL/VRLA, LFP). Depending on the selected battery type, different charging characteristics and charging parameters are stored.
“SHOWROOM” mode
Mode for permanent power supply of vehicles, e.g. in showrooms.
“BATT.REPLACEMENT” mode
Mode for power supply of vehicles and consumers when replacing the battery.
“SETTINGS” menu
Individual settings can be made (e.g. rotating the display, changing the language). The “BAT 6120 Help Center” can be accessed via the QR code.

5.4 Opening the Help Center
For further information, see BAT 6120 Help Center.
Select “SETTINGS >> Help Center”.

The BAT 6120 Help Center can also be accessed via the QR code or the following URL: https://help.boschdiagnostics.com/BAT6120

Maintenance

6.1 Cleaning
Coarse workshop rags and abrasive cleaning agents may damage the BAT 6120 .
 Use only neutral cleaning agents and soft cloths to clean the BAT 6120.

6.2 Spare parts
For further information, see “BAT 6120 Help Center”.

6.3 Replacing the protective film
The protective film on the display and selection keys can be replaced in case of damage.
For further information, see “BAT 6120 Help Center”.

6.4 BAT 6120 update
If a firmware update is available, it can be transferred to the BAT 6120 using the “Battery Charger” software installed on a computer.
For further information, see “BAT 6120 Help Center”.

Decommissioning

7.1 Changing location
If the BAT 6120 is passed on, all the documentation included in the scope of delivery must be handed over together with the unit.
The BAT 6120 is only ever to be transported in the original or equivalent packaging.
 Heed the notes on initial commissioning.

7.2 Temporary shutdown
Disconnect the electricity.

7.3 Disposal and scrapping

The BAT 6120, its accessories and packaging should be recycled in an environmentally friendly manner.

1. Disconnect the BAT 6120 from the mains voltage system and remove the power supply cable.
2. Dismantle the BAT 6120, sort the components by materials, and dispose of them in accordance with applicable regulations.
3. Proper disposal prevents environmental pollution and health hazards.
   The BAT 6120 is subject to the European directive 2012/19/EU (WEEE).

Technical data

8.1 BAT 6120 specifications

Mains voltage
0 687 000 149
0 687 000 044
0 687 000 111
0 687 000 081| 220 – 240 VAC
220 – 240 VAC
120 – 127 VAC
100 – 127 VAC
Mains frequency| 50 Hz /  60 Hz
Rated battery voltage| 12 V
Maximum power output
0 687 000 149
0 687 000 044
0 687 000 111
0 687 000 081| 1750 W
1750 W
1750 W
1250 W
“POWER SUPPLY” mode
Supply voltage
Factory setting
Max. Output current
0 687 000 149
0 687 000 044
0 687 000 111
0 687 000 081| 12 V – 14.2 V
13.5 V120 A
120 A
120 A
100 A
“CHARGE BATTERY” mode
Charging voltage| 14 V – 15.5 V
“SHOWROOM” mode
Supply voltage
Max. Output current
Factory setting| 12.8 V – 13.8 V
20 A – 50 A
13.5 V; 40 A
“BATT.REPLACEMENT” mode
Supply voltage
Max. Output current
Factory setting| 12 V – 13.2 V
10 A – 30 A
12.6 V; 20 A
Function temperature range| -5 °C – 45 °C /
23 °F – 113 °F
Storage temperature range| -25 °C – 60 °C /
-13 °F – 140 °F
Degree of protection| IP 20D
Degree of protection| I
Dimensions (W x H x D)| 329 x 116 x 433 mm /12.6 x 4.6 x 17.1 “
Weight (without accessories)| 8.5 kg / 18.7 lb
Weight with power supply cable and bat‐
tery cable B+/B–| 11.5 kg / 25.4 lb
Battery cable B+/B– length| 3 m / 9.8 ft
Battery cable B+/B– cross-section| 25 mm2

Robert Bosch GmbH
Franz-Oechsle-Str. 4
73207 Plochingen
Deutschland
www.bosch.com
bosch.prueftechnik@bosch.com
1 689 989 524 | 2023-11-08

| www.boschaftermarket.com
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| www.downloads.bosch-automotive.com

References

• help.boschdiagnostics.com/BAT6120
• tics.com/BAT6120
• Invented for life | Bosch Global
• help.boschdiagnostics.com/
• help.boschdiagnostics.com/BAT6120
• help.boschdiagnostics.com/generalsafetynotes

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