Bosch C40-Li Charger: Operating Instructions

This document provides operating instructions for the Bosch C40-Li charger.

Device Description

The Bosch C40-Li charger is designed for charging various types of batteries. Key components include:

1. Charger: The main unit.
2. Mounting hook: For securing the charger.
3. Mains cable with mains connection: Connects the charger to the power supply.
4. Charging cable with cable plug (red and black): Connects to the battery. Includes a plug (4a).
5. Charging cables with ring eyelets (red and black): Alternative connection to the battery, includes a fuse (5b).
6. (+) Terminal clamp (red): Positive connection to the battery.
7. (-) Terminal clamp (black): Negative connection to the battery.
8. Standby indicator: Shows the charger's status.
9. Mode Select Button: Used to cycle through charging modes.
10. Reverse polarity protection: Protects against incorrect connection.

The charger features a battery capacity indicator (LEDs 8-11) and mode indicators (LEDs 9-13).

Technical Data

Specification	Value
Input voltage	230 VAC / 50 Hz
Starting current	< 50 A
Rated input current	Max. 0.8 A (rms value)
Power input	90 watts
Nominal output voltage	DC 6 V / 12 V
Charging voltage	7.2 V / 14.4 V (± 0.25 V), 14.2 V / 14.7 V (± 0.25 V), 16.5 V (± 0.5 V)
Charging current	5 A (± 10%), 1 A (± 10%), 1.5 A (± 0.3 A), 0.5 A (± 0.4 A)
Rated output current	1 A & 5 A
Reverse flow	< 5 mA (no AC input)
Degree of protection	IP65 (dustproof, waterproof)
Battery type	12 V LiFePO4 and 6 V & 12 V Lead-Acid type (WET, EFB, GEL, AGM, open and VRLA)
Battery capacity	6 V: 1.2 Ah – 14 Ah, 12 V: 1.2 Ah – 120 Ah
Fuse (internal)	3.15 A
Fuse (fuse holder)	10 A
Noise level	< 50 dB(A)
Temperature	0 °C to + 40 °C
Dimensions	169 x 81 x 54 mm (L x W x H)

Note: Reverse flow is the current the charger consumes from the battery when no mains power is connected.

Safety

Before using the charger, read all instructions carefully.

CAUTION: If the supply cord is damaged, it must be replaced by the manufacturer or its service agent to avoid a hazard. Disconnect the supply before making or breaking connections to the battery. Connect the positive (+) red terminal first, then the negative (-) black terminal to the vehicle body, away from battery and fuel lines. Connect the charger to the mains supply last. When disconnecting, remove the mains connection first, then the chassis connection, and finally the battery connection.
WARNING: The AC power plug must not be exposed to water. Prevent water from flowing towards the mains supply to avoid electric shock.
WARNING: Explosion hazard and fire hazard due to explosive gases. Prevent flames or sparks and ensure adequate ventilation during charging.
Battery Compatibility: Suitable for 12 V 1.2 Ah - 120Ah LiFePO4 and Lead-Acid types (WET, EFB, GEL, AGM, open and VRLA), or 6 V 1.2 Ah - 14 Ah Lead-Acid types.
WARNING: Do not attempt to charge a non-rechargeable battery. Keep children and others away from the charger.

The appliance can be used by children aged 8 and above and persons with reduced capabilities if supervised. Children should not play with the appliance. Cleaning and maintenance should be done without supervision. For indoor use only. The device is dustproof, waterproof, and Class II Construction (double insulated).

Environment friendly disposal: Dispose of used power tools separately and correctly according to local regulations. Packaging is made of ecological materials.

Operation

3.1 Before commissioning

Read the battery operating instructions before connecting the charger.
Observe the vehicle manufacturer's recommendations if the battery is still connected to the vehicle.
Clean the battery terminals, avoiding contact with eyes or mouth.
Ensure adequate ventilation, as hydrogen gas may escape from the battery during charging.

3.2 Connecting

Connect the (+) port (red) of the charger to the (+) port on the battery.
Connect the (-) port (black) of the charger to the (-) port of the battery or vehicle body (away from fuel lines).
Ensure connections are firm.
Connect the power plug to the mains.

3.3 Disconnecting

Put the charger into standby mode using the mode selector button.
Unplug the power cord.
Disconnect the (-) port (black) from the battery.
Disconnect the (+) port (red) from the battery.

3.4 Overheating protection

If the unit overheats, output power and current are automatically reduced to prevent damage.

3.5 Standby and reverse polarity protection

Mode	Indicator	Function
Illumination	Stand by	Lights up when turned on and fully charged. Flashes while charging.
Standby	Stand by	Lights up when powered on and in case of faults.
Reverse polarity	[Reverse polarity symbol]	Lights up when terminal blocks have been swapped.

4 Mode Selection

Select the desired mode using the mode button. The corresponding LED will light up. If no other operation occurs, the charger will automatically enter charging mode in 5 seconds.

Mode	Output	Indicator	Operation	Battery types supported
Mode 1 Car Mode	14.4 V 5 A	12V	Press the button once to select Mode 1. LED 12 lights up.	12 V WET, EFB and most GEL batteries. Capacity of > 14 Ah in normal state.
Mode 2 Motorcycle Mode	14.2 V 1 A	[Motorcycle symbol]	Press the button 2 times to select Mode 2. LED 11 lights up.	12 V LiFePO4 Batteries. Capacity of ≤ 14 Ah in normal condition.
Mode 3 LiFePO4 Mode	14.2 V 5 A	LiFePO	Press the button 3 times to select Mode 3. LED 10 lights up.	12 V LiFePO4 Batteries. Capacity of > 14 Ah in normal condition.
Mode 4 Cold/AGM Mode	14.7 V 5 A	AGM	Press the button 4 times to select mode 4. LED 9 lights up.	Cold state (0 - 4 °C) of 12 V WET, EFB and most GEL batteries. And for many 12 V AGM batteries in normal condition. Capacity of > 14 Ah.
Mode 5 Regeneration mode¹	16.5 V 1.5 A	[Regeneration symbol]	Press the button 5 times to select Mode 5. LED 8 and LED 12 will light up.	Suitable for the regeneration of 12 V batteries after short-term extreme discharge. Capacity of > 14 Ah.
Mode 6 6V Mode	7.2 V 1 A	6V	Press the button once to select Mode 6. LED 7 lights up.	6 V WET, AGM, EFB and most GEL batteries. Capacity of ≤ 14 Ah in normal condition.
Mode 7 Push Mode	0.5 A	6V [Push symbol]	Press and hold the mode button for 5 seconds, LED 13 flash alternatively. When flashing to 6 V LED, press the MODE button again to select 6 V push mode.	6 V batteries. 25% LED flash at battery voltage between 0.5 V and 3.75 V.
Mode 8 Push Mode	0.5 A	12V [Push symbol]	Press and hold the mode button for 5 seconds, LED13 on, 6 V & 12 V LED flash alternatively. When flashing to 12 V LED, press the MODE button again to select 12 V push mode.	12 V batteries. 25% LED flash at battery voltage between 0.5V and 3.75 V.

Note: For regeneration mode, ensure all connections between the battery and the electrical system are disconnected.

4.1 Pulse charging

This is an automatic charging function. If the battery voltage in mode 1 & 4 is between 7.5 V (± 0.5 V) and 10.5 V (± 0.5 V), the charger automatically switches to pulse.

4.2 Trickle loading phase

The charger has an automatic trickle charging phase with max. 300 mA at full charge.

4.3 Maintenance phase

When the battery is fully charged, the 100% LED lights up, and the charger enters a maintenance phase to keep the battery capacity full.

4.4 Memory function

If the charger is unplugged during charging, it saves the previously selected mode. Upon reconnection, if the battery type is the same, the device automatically starts in the last mode. If the battery type is different (e.g., switching from cold/AGM to normal lead-acid), manually reselect the mode to avoid overcharging.

Note: Mode 5 (regeneration) and modes 7 & 8 (push mode) do not have a memory function.

4.5 Battery detection

When connected to a 7.3 V - 10.5 V battery, the charger's 6 V and 12 V LEDs flash alternatively as it attempts to detect the battery voltage. After 1-3 minutes, it will detect the battery type (6 V or 12 V) and switch to the appropriate mode.

4.6 Override Mode

If the charger detects a 6 V battery but the user is certain it is a 12 V battery, the mode button can be pressed and held for 5 seconds to switch to any 12 V charging mode.

CAUTION: Use this override mode only if you are sure the battery is 12 V. Incorrect use with a 6 V battery can lead to overcharging and other dangers.

4.7 Device protection function

The fuse (5b) on the charging cable protects the device and electrical system from short circuits.

5 Maintenance and care

Always unplug the mains connector before cleaning the charger. The device is maintenance-free.

Turn off the device.
Clean plastic surfaces with a dry cloth.
Do not use solvents or aggressive cleaning agents.
Repairs should only be carried out by qualified personnel using original spare parts.
For 24 V battery charging, use the C70 model.

EU Version Contact:
Robert Bosch GmbH
Auf der Breit 4
76227 Karlsruhe
Phone: +49 0391 832 29671
E-Mail: kundenberatung.kfztechnik@de.bosch.com

UK Version Contact:
Robert Bosch GmbH
Broadwater Park,
Uxbridge UB9 5HJ
Phone: 03448920115
E-Mail: contact@uk.bosch.com

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