Your eBike Battery Guide

Structure of a Lithium-ion Battery

A typical lithium-ion battery consists of a cathode (often made of nickel, manganese, aluminum, and cobalt-containing mixed oxides), an anode (made from graphite), and a separator film. The separator prevents direct contact between the electrodes, safeguarding against short circuits. An electrolyte, a conductive solution, facilitates the transport of lithium ions between the cathode and anode.

Properties of lithium-ion batteries

• Benefits: Rechargeable, high energy density in a compact space, lighter than other rechargeable batteries, quickly ready for use even after long storage periods.
• Risks: Sensitive to overheating and short circuits. Potential danger of gas leaks and fire if damaged or incorrectly handled.

Interesting facts

• Capacity (charge and energy): Capacity is measured in ampere-hours (Ah), indicating how much power can be drawn and for how long. Energy storage is measured in watt hours (Wh), representing the battery's working capacity and its relevance to achievable range.
• Easy charging: Lithium-ion batteries can be charged quickly regardless of their charge level, and charging interruptions do not harm the battery. They do not suffer from the "memory effect" seen in older battery systems.
• Extremely low self-discharge: Batteries retain their charge well, even after long storage periods like over winter, and can be used without recharging.
• Service life: Batteries are wearing parts that age over time due to internal chemical reactions (calendar aging). This aging process accelerates with exposure to high temperatures or extreme charge states. Cyclical aging is caused by charging and discharging; more intensive use leads to faster aging.

Bosch eBike batteries

Bosch offers powerful eBike batteries designed for various needs:

• Frame battery (PowerPack): Easy to access and remove, offering balanced weight distribution due to its low center of gravity.
• Rack battery: Positioned higher on the eBike, allowing for convenient removal and charging while standing.
• Integrated battery (PowerTube): Integrates seamlessly into the frame for an elegant eBike design.
• DualBattery: Combining two Bosch batteries significantly increases energy capacity and range.
• Range extender: A compact, bottle-sized battery provides additional range as a portable energy reserve.

For more information on suitable batteries for any requirement, visit bosch-ebike.com/batteries.

Battery safety

Bosch eBike Systems sets high standards in battery safety, exceeding strict legal requirements with rigorous testing throughout the value chain.

Examples of safety measures:

• Battery Management System (BMS)
• Mechanical isolation of battery cells
• Electrical isolation of battery cells
• Thermal isolation of battery cells
• Protection against water ingress
• Automation in production

Potential dangers are counteracted to minimize risks. ❗ Warning: This battery housing must not be opened. It is reserved for qualified and trained personnel. Opening the battery compromises its certified condition and entails safety risks.

How Bosch technology makes batteries safer

• Battery Management System (BMS): Continuously monitors battery condition, detects faults, and protects against overheating, overload, and deep discharge, extending battery life.
• Mechanical isolation of battery cells: Individual cells are encased in flame-retardant plastic.
• Electrical isolation of battery cells: An integrated fuse provides electrical interruption in case of increased current flow from a cell.
• Thermal isolation of battery cells: Encased cells and separators reduce overheating risks and potential thermal chain reactions. Gas evolution is managed through a controlled escape point.
• Protection against water ingress: The sealing concept protects against water and consequential damage.
• Automation in production: High automation levels reduce assembly errors.

Basic rules for greater safety

1. Do not open the battery. This is reserved for qualified personnel.
2. Protect the battery from heat, sunlight, and fire.
3. Do not immerse the battery in water, transport it on a car's rear bike rack in the rain, or clean it with direct water jets or high-pressure cleaners.
4. Keep batteries away from small metal objects (keys, nails, screws) to prevent short circuits.
5. Do not damage the battery, for example, through hard shocks or sharp objects.

Charging

Chargers: Always use original Bosch chargers for Bosch eBike batteries. This ensures compatibility, protects the battery from damage, and prevents risks like overheating or short circuits.

Charging facilities

• Charging on the eBike: Connect the charging cable; the drive unit automatically locks, and charging begins.
• Charge separately: If the battery is removable, ensure it clicks securely into the mount when reinserting.
• Charging on the go: Bosch chargers are compact and light, making them easy to carry for charging during rides.

Tips for optimal charging

• Before charging: Check the battery for visible damage and allow it to cool down.
• Charge level: Only charge fully if necessary.
• After charging: Disconnect the battery and charger from the power supply.
• Usage: Avoid emptying the battery completely while riding.
• Location: Do not charge in escape routes, on flammable surfaces, or near combustible materials. Do not leave the battery unattended while charging.

More information:

• Use only original Bosch chargers.
• Ensure the environment is dry and has smoke detectors.
• Charge the battery at ambient temperatures between 0 and 40 °C.
• Avoid direct sunlight.

Storing

Where should the battery be stored?

• Store the battery in a dry place protected from the weather, ideally in a well-ventilated room with a smoke detector, away from heat sources or flammable materials.
• Storing in a basement or garage is preferable to living spaces due to cooler temperatures.
• Remove the battery from the eBike if it will not be used or stored for an extended period.

How should the battery be stored?

• Ideally, store the battery at temperatures between 0 and 20 °C in a dry environment, or between 10 and 20 °C in a humid environment with dew formation.
• Avoid excessive heating and direct sunlight.
• Cold temperatures are harmless but may temporarily reduce power output.
• An ideal charge level for storage is between 30 and 60%, corresponding to 2 to 3 indicator lights on the battery display.

Care

Cleaning & care:

• If possible, remove the battery before cleaning your eBike.
• Use a damp cloth to clean the battery surface.
• Occasionally clean and lightly grease the plug poles.
• Avoid cleaning the battery with direct water jets or high-pressure cleaners to protect the electronics.

Winter use:

• If storing the battery in a garage, move it to a heated area to warm up before riding on cold days.
• For longer journeys in cold conditions, consider using thermal protective covers.

Regular inspection of your eBike by a specialist dealer is important for checking your battery's condition using Bosch eBike Systems tools. ✔️

Transporting

Lithium-ion batteries store significant energy, requiring precautions during transport.

• By car: If transporting the eBike outside the car (e.g., on a luggage rack), remove the on-board computer and battery if possible, and store them safely inside the car to prevent damage.
• By train: eBikes can usually be taken on trains with bicycle compartments, often requiring a ticket and reservation. The battery must remain installed and not be charged during the journey. Check transport conditions with the service provider.
• On commuter services and long-distance buses: Check regulations with the transport authority. Some services may allow eBikes at off-peak times with a bicycle ticket. Contact coach providers in advance.
• Flights: Air transportation organizations like IATA prohibit battery transport on passenger planes. Consider renting a Bosch eBike battery at your destination.

Safety on the go: It is best to transport the battery with a charge level of 30% and charge it fully upon arrival at your destination.

Digression: Hazardous goods

Lithium-ion batteries are classified as hazardous goods due to their flammability under certain conditions. Following care, charging, and storage tips minimizes risks. Further precautions apply to shipping.

Regulations for the transport of hazardous goods: Special legislation (e.g., ADR in Europe) governs the international transport of hazardous goods by road. These regulations apply to commercial transport. For private individuals transporting batteries themselves, these regulations generally do not apply. However, if the battery is handed over to a third party (e.g., for shipping), hazardous goods legislation applies in full.

Note: Due to these laws, parcel services typically do not accept eBike batteries from private individuals for shipping. Simplified conditions may apply only to batteries under 100 Wh.

Interesting fact: Transport certifications may expire if repairs or interventions are performed by unauthorized parties.

Exchange instead of repair

Batteries, including eBike batteries, are wearing parts that lose capacity over time. For safety, do not repair or refresh faulty or old batteries; instead, have them recycled appropriately.

Risks attached to repairing or refreshing Bosch eBike batteries:

• Batteries are sealed to protect cells from water and dirt. Improper opening and reassembly can lead to loss of tightness, increased friction, weakened insulation, cell displacement, compromised electrical/mechanical connections, and other risks.
• Incorrect repairs may compromise the Battery Management System's function, potentially leading to fire due to short circuits.
• Improper repairs can also affect warranty claims and compliance with legal requirements, such as transport regulations.

Recycling

Your eBike battery should not be disposed of in household waste, as improper disposal can mix it with flammable materials, potentially destroying the battery and causing dangerous short circuits.

How to recycle: Hand in your old or defective eBike battery to a specialist dealer.

Recycling of an eBike battery: Proper recycling conserves resources by returning valuable raw materials to the materials cycle.

Percentage of raw materials in an eBike battery pack:

• 38% Carbon, nickel, cobalt, manganese, lithium
• 36% Iron, copper, aluminium
• 23% Separators, electrolytes, residues
• 2% Electronic components, cables

Of which recycled: 88% (overall), with 97% of iron/copper/aluminum, 100% of separators/electrolytes/residues, and 0% of electronic components/cables being recycled.

Nearly 71% of raw materials in a used eBike battery can be recovered and used for new products.

Incorrect use (second use): Bosch batteries are designed and certified specifically for eBikes. Reliable operation in other applications cannot be guaranteed.

Range

How far can I ride with my eBike battery?

Range is a key question for eBikers, but it depends on many factors. Bosch's range assistant tool helps estimate typical range under various parameters. The graphic below illustrates how range changes, for example, between Turbo and Eco modes.

Use the range assistant for more reliable planning: calculate your eBike battery's likely support kilometers for your next ride at bosch-ebike.com/range.

What should I do if water gets into the battery mount?

The mount is designed to allow water to drain and contacts to dry. Keep the mount and plug area clean. The contacts have a protective coating against corrosion and wear. Terminal greases or technical Vaseline can be used to maintain contacts if needed.

How do I deal with a defective battery?

Heavily damaged batteries should not be touched with bare hands due to potential electrolyte leakage, which can cause skin irritation. Store damaged batteries safely outdoors, protected from rain and direct sunlight, with contacts taped, before disposing of them via a dealer.

Are chargers from other manufacturers safe to use?

Bosch original chargers are specifically designed for the Bosch eBike system, featuring the correct software for efficient charging and battery management. Using incompatible chargers may reduce the lifespan of Bosch eBike batteries or cause other damage or malfunctions.

Can I use replacement batteries from other manufacturers?

Bosch recommends using only original spare parts. Bosch eBike components are precisely matched and certified as a complete system, ensuring reliability and efficiency.

I have found a used battery for the Bosch eBike system online. Can I use this?

When purchasing used batteries, always ensure they are undamaged. Damaged or repaired batteries pose a high safety risk and can lead to dangerous malfunctions. Be aware that illegal or stolen goods may also be available online.

Bosch eBike battery check: If you buy a used battery, use the serial number to check if a service case has already been registered for it at bosch-ebike.com/accu-check.

You have any further questions? We have the answers!

Help Center: Find answers to frequently asked questions at bosch-ebike.com/help-center.

How-to videos: Our videos offer helpful tips about products and features at bosch-ebike.com/help-center/video.