BOSCH AKKU PowerTube, PowerPack Instruction Manual
- June 3, 2024
- Bosch
Table of Contents
PowerTube 500 | 625 | 750
PowerPack 545 | 725
BBP3750 | BBP3751 | BBP3760 | BBP3761 |
BBP3770 | BBP3771 | BBP3551 | BBP3570
Original operating instructions
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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 other 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.
-
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 3, 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) Key for the battery lock
(2) Battery lock
(3) PowerTube battery safety hook
(4) PowerTube battery (pivot)
(5) Socket for charging connector
(6) Operation/battery charge indicator
(7) On/off button
(8) PowerTube battery safety restraint
(9) Locking mechanism
(10) Pull strap
(11) Axial rail
(12) PowerTube battery (axial)
(13) Upper axial PowerTube holder
(14) Upper holder for PowerPack battery
(15) PowerPack battery
(16) Lower holder for PowerPack battery (socket without charging option)
(17) Lower holder for PowerPack battery (socket with charging option)
(18) Charger
(19) Charging socket cover
Technical data
Li-ion battery| | PowerTube 500| PowerTube 625| PowerTube
750
---|---|---|---|---
Product code| Horizontal| BBP3750| BBP3760| BBP3770
Product code| Vertical| BBP3751| BBP3761| BBP3771
Rated voltage| V=| 36| 36| 36
Nominal capacity| Ah| 13.| 17.| 20.
Energy| Wh| 500| 625| 750
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| 3.0| 3.6| 4.3
Protection rating| | IP54| IP54| IP54
Li-ion battery| | PowerPack 545| PowerPack 725
---|---|---|---
Product code| | BBP3551| BBP3570
Rated voltage| V=| 36| 36
Nominal capacity| Ah| 14.4| 19.2
Energy| Wh| 545| 725
Operating temperature| °C| -5 to +40| -5 to +40
Storage temperature| °C| +10 to +40| +10 to +40
Permitted charging temperature range| °C| 0 to +40| 0 to +40
Weight, approx.| kg| 3.0| 4.0
Protection rating| | IP54| IP54
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 (7) to switch the battery on. If none of
the LEDs on the battery charge indicator (6) light up, the battery may be
damaged.
If at least one (but not all) of the LEDs on the battery charge indicator (6)
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 (6) 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 (6) 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 (6) 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.
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.
Removing the PowerTube battery (pivot) (see figure A)
❶ To remove the PowerTube battery (4), open the lock (2) using the key (1).
The battery will be unlocked and fall into the safety restraint (8).
❷ 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 B)
In order for the battery to be inserted, the key (1) must be inserted into the
lock (2) and the lock must be open.
❶ To insert the PowerTube battery (4), place it so that its contacts are in
the lower holder of the frame.
❷ Push the battery upwards until it is held by the safety restraint (8).
❸ 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.
❹ Always secure the battery by closing the lock (2) – otherwise the lock may
open and the battery may fall out of the holder.
Always remove the key (1) from the lock (2) 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.
❶ To remove the PowerTube battery (12), open the lock (2) using the key (1),
remove the key (1) and fold the locking mechanism (9) to the side.
❷ Use the pull strap (10) to pull the battery (12) out of the frame and keep
hold of it so that it does not fall 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 (axial) (see figure D) In order for the
battery to be inserted, the locking mechanism (9) must be folded to the side.
At this point, the key (1)
must not be inserted in the battery lock (2).
❶ To insert the PowerTube battery, insert it into the frame with the socket
for the charging connector (5) facing upwards until the battery clicks into
place. Ensure that the battery is aligned correctly.
❷ Close the locking mechanism (9), insert the key (1) into the battery lock
(2) and secure the battery. Make sure that the safety hook (3) is hooked in at
the opening of the axial rail (11).
❸ Check that the battery is secure in all directions.
Always remove the key (1) from the lock (2) 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.
Inserting and Removing the PowerPack battery (see figure E)
In order to insert the battery, the key (1) must not be inserted in the lock
(2).
To insert the PowerPack battery (15), place it so that its contacts are in the
lower holder (16) on the eBike. Tilt it into the upper holder (14) as far as
possible until you hear it
click into place.
Check that the battery is secure in all directions. Do not ride with the key
(1) inserted. Make sure that the key is no longer inserted when you park the
eBike. To remove the PowerPack battery (15), switch it off and open the lock
(2) using the key (1).
Tilt the battery out of the upper holder (14) and pull it out of the lower
holder (16).
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 (2) is closed.
To switch on the battery, press the on/off button (7). Do not use any sharp or
pointed objects to press the button. The LEDs on the indicator (6) 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 (6) 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 (7)
again.
The LEDs on the indicator (6) 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 “Battery Management System (BMS)”. 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 (6) 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 (6) are lit). Check the state of charge
after six months. If only one of the LEDs on the battery charge indicator (6)
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 (1). 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 dditional
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). Please return 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 3PX (2022.05) T / 79 WEU
References
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