PowerPack 500 Active Line - Rechargeable Battery BOSCH - Free user manual and instructions

USER MANUAL PowerPack 500 Active Line BOSCH

Active Line/Performance Line Active Line/Performance Line

Two grayscale 3D renderings of a handheld electronic device with attached cables (no text or symbols visible)

Robert Bosch GmbH

Bosch eBike Systems

72703 Reutlingen

GERMANY

www.bosch-ebike.com

0 275 007 XPX (2016.04) T/57 WEU

PowerPack 300|400|500

0 275 007 509|0 275 007 510|0 275 007 511|0 275 007 512

0 275 007 513|0 275 007 514|0 275 007 522

0 275 007 529|0 275 007 530|0 275 007 531|0 275 007 532

BOSCH

Technical diagram of a handheld device with numbered parts and labeled indicators for electrical contact or testing.

A 6 5 7 8 10 9 7°

B 1 6 5 10 2

Sicherheitshinweise

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.

Save all safety warnings and instructions for future reference.

The term “battery pack” used in these operating instructions refers both to standard battery packs (battery packs with holder on the bike frame) and to rack-type battery packs (battery packs with holder in the rear rack/carrier), except when explicitly referring to the design type.

Remove the battery pack 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 plane, or storing it. Unintentional activation of the eBike system poses a risk of injury.
▶ Do not open the battery pack. Danger of short-circuiting. Opening the battery pack voids any and all warranty claims.

Protect the battery against heat (e.g. prolonged sun exposure) and 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.

▶ Keep the battery pack not being used away from paper clips, coins, keys, nails, screws or other small metal objects, that can make a connection from one terminal to another. Shorting the battery-pack terminals together may cause burns or a fire. For short-circuiting damage caused in this manner, any and all warranty claims through Bosch shall be invalid.

▶ Do not place the charger or battery pack near to flammable materials. Charge battery packs only when dry and in a fireproof area. There is a risk of fire due to the heat generated during charging.

▶ The eBike battery must not be left unattended while charging.

▶ Under abusive conditions, liquid may be ejected from the battery pack. Avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery pack may cause skin irritations or burns.

▶ Battery packs must not be subjected to mechanical impacts. There is a risk that the battery pack will be damaged causing vapours to escape. The vapours can irritate the respiratory system. Provide for fresh air and seek medical attention in case of complaints.

The battery may give off fumes if it becomes damaged or is used incorrectly. Provide a fresh air supply and seek medical advice in the event of pain or discomfort. These fumes may irritate the respiratory tract.

▶ Charge the battery pack only with original Bosch battery chargers. When using non-original Bosch chargers, the danger of fire cannot be excluded.

▶ Use the battery pack only together with eBikes that have an original Bosch eBike drive system. This is the only way to protect the battery pack against dangerous overload.

▶ Use only original Bosch battery packs approved for your eBike by the manufacturer. Using other battery packs can lead to injuries and pose a fire hazard. When using other battery packs, Bosch shall not assume any liability and warranty.

▶ Do not use the rack-type battery pack as a handle. Lifting the eBike up by the battery pack can cause damage to the battery pack.

▶ Read and observe the safety warnings and instructions in all operating instructions of the eBike system and in the operating instructions of your eBike.

▶ Keep the battery pack out of reach of children.

Product Description and Specifications

Product Features

The numbering of the product features refers to the illustrations on the graphics pages.

All representations of bike components, with exception of the battery packs and their holders, are schematic and can deviate from your eBike.

1 Holder of the rack-type battery pack
2 Rack-type battery pack
3 Operation and charge-control indicator
4 On/Off button
5 Key of the battery pack lock
6 Battery-pack lock
7 Upper holder of the standard battery pack
8 Standard battery pack
9 Bottom holder of the standard battery pack

10 Cover lid (Supplied only on eBikes with 2 battery packs)

11 Battery charger

12 Socket for charge connector

13 Charge socket cover

Technical Data

Lithium-ion battery pack	PowerPack 300	PowerPack 400	PowerPack 500
Article number
- Standard battery pack 0 275 007 509	0 275 007 511	0 275 007 510	0 275 007 529
		0 275 007 512	0 275 007 530
- Rack-type battery pack	0 275 007 513	0 275 007 514	0 275 007 531
		0 275 007 522	0 275 007 532
Rated voltage	V= 36 36 36
Rated capacity	Ah 8.2 11 13.4
Energy	Wh 300 400 500
Operating temperature	°C	-10...+40	-10...+40
Storage temperature	°C	-10...+60	-10...+60
Allowable charging temperature range	°C	0...+40	0...+40
Weight, approx.	kg	2.0/2.4	2.5/2.6
Degree of protection	IP 54 (dust and splash water protected)	IP 54 (dust and splash water protected)	IP 54 (dust and splash water protected)

Assembly

▶ Place down the battery pack only on clean surfaces. In particular, avoid soiling the charge socket and the contacts, e.g. by means of sand or soil.

Checking the Battery Pack Before Using for the First Time

Check the battery pack before charging it or using it with your eBike for the first time.

For this, press the On/Off button 4 to switch on the battery pack. When no LED of the charge-control indicator 3 lights up, the battery pack may be damaged.

When at least one, but not all LEDs of the charge-control indicator 3 is lit, then fully charge the battery pack before using for the first time.

▶ Do not attempt to charge or use a damaged battery pack. Please refer to an authorised Bosch eBike dealer.

Charging the Battery Pack

▶ Use only the Bosch charger provided with your eBike or an identical original Bosch charger. Only this charger is matched to the lithium-ion battery pack used in your eBike.

Note: The battery pack is supplied partially charged. To ensure full battery pack capacity, completely charge the battery pack in the charger before using for the first time.

For charging the battery pack, read and observe the operating instructions of the charger.

The battery pack can be recharged at any time on its own or on the bike without shortening the lifespan. Interrupting the charging process does not damage the battery pack.

The battery pack is equipped with a temperature control indicator, which enables charging only within a temperature range between 0 °C and 40 °C.

When the battery pack is not within the charging-temperature range, three LEDs of the charge-control indicator 3

flash. Disconnect the battery pack from the charger until its temperature has adjusted.

Do not connect the battery pack to the charger until it has reached the allowable charging temperature.

Charge-control Indicator

When the battery pack is switched on, the five green LEDs of the charge-control indicator 3 indicate the charge condition of the battery pack.

In this, each LED indicates approx. 20 % capacity. When the battery pack is completely charged, all five LEDs light up.

The charge level of the switched on battery pack is also shown on the display of the on-board computer. When doing so, read and observe the operating instructions of the drive unit and on-board computer.

If the capacity of the battery pack is below 5%, all LEDs of the charge-control indicator 3 on the battery pack go out. However there is another display function of the on-board computer.

Using Two Battery Packs for One eBike (optional)

An eBike can also be equipped with two battery packs by the manufacturer. In this case, one of the charge sockets is not accessible or is sealed by the bicycle manufacturer with a sealing cap. Charge the battery packs only at the accessible charge socket.

▶ Never open charge sockets that have been sealed by the manufacturer. Charging at a previously sealed charge socket can lead to irreparable damage.

If you have an eBike that is designed for two battery packs and you want to use it with only battery pack, cover off the contacts of the unused socket using the cover lid 10 provided because otherwise the open contacts pose a risk of short-circuiting (see figures A and B).

Charging with Two Battery Packs Inserted

If two battery packs are mounted on one eBike, both battery packs can be charged using the unsealed connection. The charging process will charge both battery packs alternately, automatically switching between both battery packs numerous times. The charging times add up.

Both battery packs are also discharged alternately during operation.

If you take the battery packs out of the holders, you can charge each battery pack individually.

Charging with One Battery Pack Inserted

If only one battery pack is inserted, then you can charge only the battery pack that has the accessible charge socket on the bike. You can charge the battery pack with the sealed charge socket only when you take the battery pack out of the holder.

Inserting and removing the battery pack (see figures A–B)

▶ Always switch off the battery pack and the eBike system when you insert the battery pack into the holder or when you take it out of the holder.

In order for the battery pack to be inserted, the key 5 must be inserted into the lock 6 and the lock must be unlocked.

To insert the standard battery pack 8, place it with the contacts on the lower holder 9 on the eBike (the battery pack can be inclined up to 7° to the frame). Tilt it into the upper holder 7 until it engages.

To insert the rack-type battery pack 2, slide it with the contacts facing ahead until it engages in the holder 1 of the rear rack/carrier.

Check if the battery pack is tightly seated. Always lock the battery pack with lock 6, as otherwise the lock can open and the battery pack could fall out of the holder.

After locking, always remove the key 5 from the lock 6. This prevents the key from falling out and the battery pack from being removed from unauthorised persons when the eBike is parked.

To remove the standard battery pack 8, switch it off and unlock the lock with the key 5. Tilt the battery pack out of the upper holder 7 and pull it out of the lower holder 9.

To remove the rack-type battery pack 2, switch it off and unlock the lock with the key 5. Pull the battery pack out of the holder 1.

Operation

Initial Operation

▶ Use only original Bosch battery packs approved for your eBike by the manufacturer. Using other battery packs can lead to injuries and pose a fire hazard. When using other battery packs, Bosch shall not assume any liability and warranty.

Switching On and Off

Switching on the battery pack is one of the ways of switching on the eBike system. When doing so, read and observe the operating instructions of the drive unit and on-board computer.

Before switching on the battery pack or the eBike system, check that the lock 6 is locked.

To switch on the battery pack, press the On/Off button 4. The LEDs of indicator 3 light up and at the same time indicate the charge condition.

Note: If the capacity of the battery pack is below 5 %, no LED on the charge-control indicator 3 lights up. It is only visible on the on-board computer, if the eBike system is switched on.

To switch off the battery pack, press the On/Off button 4 again. The LEDs of indicator 3 go out. This also switches off the eBike system.

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 operating unit of the eBike, the eBike system and therefore also the battery pack will shut down automatically to save energy.

The battery pack is protected against deep discharging, overcharging, overheating and short-circuiting through the “Electronic Cell Protection (ECP)”. In case of hazardous situations, a protective circuit automatically switches off the battery pack.

When a defect of the battery pack is detected, two LEDs of the charge-control indicator 3 flash. In this case, please refer to an authorised Bosch eBike dealer.

Notes for Optimum Handling of the Battery Pack

The battery-pack life can be prolonged when being properly maintained and especially when being operated and stored at the right temperatures.

With increasing age, however, the battery-pack capacity will diminish, even when properly maintained.

A significantly reduced operating period after charging indicates that the battery pack is worn out and must be replaced. You can replace the battery pack yourself.

Recharging the Battery Pack prior to and during Storage

When not using the battery pack for a longer period, charge it to approx. 60% (3 to 4 LEDs lit on the charge-control indicator 3).

Check the charge condition after 6 months. When only one LED of the charge-control indicator 3 lights up, recharge the battery pack again approx. 60%.

Note: When the battery pack is stored discharged (empty) for longer periods, it can become damaged despite the low self-discharging feature and the battery-pack capacity may be strongly reduced.

It is not recommended to have the battery pack connected permanently to the charger.

Storage Conditions

Store the battery pack in a dry, well-ventilated location. Protect the battery pack against moisture and water. Under unfavourable weather conditions, it is recommended e.g. to remove the battery pack from the eBike and store it in an enclosed location until being used again.

The battery pack can be stored at temperatures between -10^ and +60^ . For a long battery-pack life, however, storing the battery pack at a room temperature of approx. 20^ is of advantage.

Take care that the maximal storage temperature is not exceeded. As an example, do not leave the battery pack in a vehicle in summer and store it out of direct sunlight.

It is recommended to not store the battery pack on the bike.

Maintenance and Service

Maintenance and Cleaning

Keep the battery clean. Clean it carefully with a soft, damp cloth.

The battery must not be submerged in water or cleaned using a jet of water.

When the battery pack is no longer operative, please refer to an authorised Bosch eBike dealer.

After-sales Service and Application Service

In case of questions concerning the battery packs, please refer to an authorised bicycle dealer.

▶ Note down the manufacturer and the number of the key

1. In case of loss of the keys, please refer to an authorised bicycle dealer. Please provide the name of the manufacturer and the number of the key.

For contact data of authorised Bosch eBike dealers, please refer to www.bosch-ebike.com

Transport

▶ If you carry your eBike outside of your car, e.g. on a luggage rack, remove the eBike battery pack in order to avoid damaging it.

The battery packs are subject to the Dangerous Goods Legislation requirements. Private users can transport undamaged battery packs by road without further requirements.

When being transported by commercial users or third parties (e.g. air transport or forwarding agency), special requirements on packaging and labelling must be observed (e.g. ADR regulations). If necessary, an expert for hazardous materials can be consulted when preparing the item for shipping.

Dispatch battery packs only when the housing is undamaged. Tape or mask off open contacts and pack up the battery pack in such a manner that it cannot move around in the packaging.

Inform your parcel service that the package contains dangerous goods. Please also observe the possibility of more detailed national regulations.

In case of questions concerning transport of the battery packs, please refer to an authorised Bosch eBike dealer. The Bosch eBike dealers can also provide suitable transport packaging.

Disposal

Battery packs, accessories and packaging should be sorted for environmental-friendly recycling.

Do not dispose of the battery packs into household waste!

Tape or mask off the contact surfaces of the battery pack's terminals with adhesive tape before disposing of battery packs.

Only for EC countries:

According to the European Guideline 2012/19/EU, electrical devices/tools that are no longer usable, and according to the European Guideline 2006/66/EC, defective or used battery packs/batteries, must be collected separately and disposed of in an environmentally correct manner.

Please return battery packs that are no longer usable to an authorised bicycle dealer.

Li-Ion Li

Li-ion:

Please observe the instructions in section "Transport", page English-4.

Subject to change without notice.

* Bosch eBike Systems

72703 Reutlingen

GERMANY

Claus Fleischer

Senior Vice President

Gunter Flinspach

Vice President

Bosch eBike Systems, 72703 Reutlingen, GERMANY