I wanted to be able to charge my Bosch Powerpack 500 battery in my car when I'm on trips. Unfortunately the standard 4A Bosch charger pulls 170Watts which is more than my car's AC Inverter can support. I also tried to use my 300Watt Pure Sine Wave Inverter, but my cigarette lighter socket only supports 120W. So I decided to build my own 12V 2A Bosch Ebike battery charger. A side benefit is that I can adjust the maximum charge voltage. You can set it to 80% and get more cycles out of your battery.
Designing the Connector was relatively easy. You can use standard spade connectors from the hardware store. The hard part was figuring out how to put the Bosch battery into charge mode. It turns out to be pretty simple (It always is after you figure it out ;-). You just have to supply 5VDC on the third pin. I was able to find DC Boost converters on Amazon. The first one I chose did not even closely meet their specs. I had to down grade the charge current to 1.3A and the temp was still 112F. I ended up going with a more substantial (and more expensive) boost converter.
Items used:
150W boost converter that did not meet specs ( https://www.amazon.com/gp/product/B076TTBKFG/ref=as_li_ss_tl?ie=UTF8&psc=1&linkCode=sl1&tag=simple3d0e-20&linkId=2fe55fb0de0bce586d4e33d01d2ff9d6&language=en_US )
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| boschconnector.stl | 4.2MB | |
| boschconnectorcover.stl | 4.5MB |
