Bosch Active Plus User Manual

Bosch

Active Plus

EN: User manual

SV: Bruksanvisning

457_Kaften_v6.indd 3 03-07-17 11:40

English

Original instructions

Active Line Plus 25 km/u

1 270 020 XBI | (11.4.16) Bosch eBike Systems

2 |

TURBO

SPORT

TOUR

ECO

OFF

MPH

KM/H

Reichweite

AMM

PMWH

MIN

MPH

RESET

TURB

TOUR

KM/

ichweite

TURBO SPORT

TOUR

ECO

OFF

MPH KM/H

Reichweite

AMM PMWH MIN MPH KM/H

7 8

b c

6 5

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ECO

MPH

KM/H

Reichweite

RESET

KM/H

chw

ite

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Safety Notes

Read all safety warnings and all instructions. Failure to follow the warnings and in-

structions 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, irrespective of model, 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).

f Do not use the on-board computer as a handle. Lifting

the eBike up by the on-board computer can cause irreparable damage to the on-board computer.

f Make sure to not be distracted by the display of the

on-board computer. If you do not focus exclusively on

the traffic, you risk being involved in an accident. If you want to make entries in your on-board computer other than switching the assistance level, stop and enter the appropriate data.

f Read and observe the safety warnings and instructions

in all operating instructions of the eBike system and in the operating instructions of your eBike.

Product Description and Specifications

Intended Use

The Intuvia on-board computer is designed to control Bosch eBike systems and display riding data.

Product Features

The numbering of the components shown refers to the illustrations on the graphic pages at the beginning of the manual. Individual illustrations in these operating instructions may differ slightly from the actual circumstances depending on the equipment of your eBike.

1 Display-function button “i” 2 Bike lights button 3 On-board computer 4 Holder for on-board computer 5 On/Off button for on-board computer 6 “RESET” button 7 USB port 8 Protective cap of USB port

9 Operating unit 10 Display-function button “i” on the operating unit 11 Decrease assistance level/scroll down button “– ” 12 Increase assistance level/scroll up button “+” 13 Push-assistance button “WALK”

14 Lock latch for on-board computer 15 Locking screw for on-board computer

USB charging cable (Micro A – Micro B) *

* not illustrated; available as accessory

Display elements of on-board computer

a Drive unit assistance indicator b Assistance-level indicator c Light indicator d Text indication e Value indication

f Speed indication g Shift recommendation: higher gear h Shift recommendation: lower gear

i Battery charge-control indicator

Technical Data

Assembly

Inserting and removing the battery pack

For inserting and removing the eBike battery pack in/from the eBike, please read and observe the battery pack operating instructions.

Inserting and removing the on-board computer (see figure A)

To insert the on-board computer 3, slide it from the front into the holder 4.

To remove the on-board computer 3, press the lock latch 14 and slide the on-board computer toward the front out of the holder 4.

On-board computer Intuvia

Article number

1 270 020 906/909

Max. charging current, USB connection

mA 500

Charging voltage, USB connection

V 5

USB charging cable

1 270 016 360

Operating temperature

°C –5 ...+ 40

Storage temperature

°C –10 ...+ 50

Charging temperature

°C 0... +40

Internal lithium-ion battery

mAh

3.7

240

Protection type

IP 54 (dust and splash

water protected)

Weight, approx.

kg 0.15

1) Not included in standard scope of delivery

2) When USB cover is closed Bosch eBike system uses FreeRTOS (see www.freertos.org)

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f Remove the on-board computer when you park the

eBike.

It is possible to secure the on-board computer against removal in the holder. To do so, remove the holder 4 from the handlebar. Put the on-board computer in the holder. Screw the locking screw 15 (thread M3, 8 mm long) from below into the thread provided in the holder. Mount the holder back onto the handlebar.

Operation

Initial Operation

Requirements

The eBike system can only be activated when the following requirements are met: – A sufficiently charged battery pack is inserted (see battery

pack operating instructions).

– The on-board computer is properly inserted in the holder

(see “Inserting and removing the on-board computer”, page English– 1).

– The speed sensor is connected properly (see drive unit

operating instructions).

Switching the eBike System On/Off

Options for switching on the eBike system: – If the on-board computer is already switched on when you

insert it into the holder, then the eBike system will be switched on automatically.

– When the on-board computer and the eBike battery pack

are inserted, briefly press the On/Off button 5 of the onboard computer.

– When the on-board computer is inserted, press the On/Off

button of the eBike battery pack (see battery pack operating instructions).

The drive is activated as soon as you step on the pedals (except for in the push assistance function or in assistance level “OFF”). The motor output depends on the settings of the assistance level on the on-board computer. As soon as the system is activated, “Active Line/Performance Line” will appear briefly on the display.

As soon as you stop pedaling when in normal operation, or as soon as you have reached a speed of 25/45 km/h, the assistance from the eBike drive is switched off. The drive is automatically re-activated as soon you start pedaling again and the speed is below 25/45 km/h.

Options for switching off the eBike system: – Press the On/Off button 5 of the on-board computer. – Switch the eBike battery pack off by its On/Off button (see

battery pack operating instructions).

– Remove the on-board computer out of its holder. If the eBike is not moved and no button is pressed on the on-

board computer for 10 minutes, the eBike system will shut down automatically in order to save energy.

eShift (optional)

eShift is the integration of automatic gear shifting systems into the eBike system. To support the rider in the best way possible, the function indications and the basic settings menu have been adapted for the “eShift” function.

eShift with NuVinci H|Sync

The optimum gear for the respective speed is automatically set according to a pre-defined desired cadence. In manual mode you can choose between multiple gears.

In the “ NuVinci Cadence” mode you can use the “ –” or “+” button on the operating unit to increase or decrease the desired cadence. If you hold down the “ –” or “+” button, the cadence will increase or decrease in steps of five. The desired cadence is shown on the display.

In the “ NuVinci Gear” mode you can use the “ –” or “+” button on the operating unit to switch back and forth between several defined transmission ratios. The engaged transmission ratio (gear) is shown on the display.

eShift with SRAM DD3 Pulse

The gear hub of the SRAM DD3 Pulse works on a speed-dependent basis. Regardless of which gear is engaged on the derailleur gears, one of the three gears of the gear hub will automatically be engaged “ Gear: Auto”.

The engaged gear will be shown briefly on the display whenever the gear of the gear hub is shifted.

If the eBike is brought to a standstill from a speed of more than 10 km/h, the system can automatically switch back to a set “Start gear”. The “Start gear” can be set in the basic set- tings menu (see “Displaying/Adapting Basic Settings”, page English –5).

In the “ Gear” mode you can use the “ –” or “+” button on the operating unit to switch back and forth between several defined transmission ratios. The engaged transmission ratio (gear) is shown on the display.

In the “ Gear” manual mode, the system can also automatically switch back to a set “Start gear”.

The drive unit recognises the gear shift and briefly reduces the motor assistance level as a result of it, which means the gear can also be shifted at any time under load or on a hill.

eShift with Shimano Di2

For Shimano eShift you use the Shimano control lever to shift gears.

The engaged gear will be shown briefly on the display whenever the gear of the gear hub is shifted.

The drive unit recognises the gear shift and briefly reduces the motor assistance level as a result of it, which means the gear can also be shifted at any time under load or on a hill.

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Displays and configurations of the on-board computer

Energy supply of the on-board computer

If the on-board computer is in the holder 4, a sufficiently charged battery pack is inserted in the eBike and the eBike system is turned on, then the on-board computer is powered by the battery pack of the eBike.

If the on-board computer is removed from the holder 4, the energy is supplied via an internal battery pack. If the internal battery pack is weak when the on-board computer is switched on, “Attach to bike” will appear in text indication d for 3 s. The on-board computer will then turn off again.

To charge the internal battery pack, put the on-board computer back in the holder 4 (when a battery pack is inserted in the eBike). Switch the eBike battery pack on by its On/Off button (see battery pack operating instructions).

You can also charge the on-board computer via the USB port. Open the protective cap 8. Connect the USB port 7 of the onboard computer via a suitable USB cable to a standard USB charger or the USB port of a computer (5 V charging voltage, max. 500 mA charging current). “USB connected” will appear in text indication d of the on-board computer.

Switching on/shutting down the on-board computer

To switch on the on-board computer, briefly press the On/Off button 5. The on-board computer can also be switched on when it is not inserted in the holder (if the internal battery pack is sufficiently charged).

To switch off the on-board computer, press the On/Off button 5.

If the on-board computer is not inserted in the holder, it automatically switches off after 1 minute to save energy if no button is pressed.

f If you do not use your eBike for several weeks, remove

the on-board computer from its holder. Store the on-

board computer in a dry environment at room temperature. Regularly recharge the on-board computer’s battery pack.

Battery Charge-control Indicator

The battery charge-control indicator i displays the charge level of the eBike battery pack, not that of the on-board computer’s internal battery pack. The charge level of the eBike battery pack can also be checked on the LEDs of the battery pack itself.

If the on-board computer is removed from the holder 4, the last displayed battery charge level is saved.

If an eBike is operated with two battery packs, the battery charge-control indicator i displays the level of both battery packs.

If an eBike has two battery packs inserted into it and both battery packs are charged on the bike, the charging progress of both battery packs will be indicated on the display (the left-hand battery pack is being charged in the illustration). You can tell by the flashing indicator on the battery pack which of the two battery packs is being charged.

Setting the Assistance Level

On the operating unit 9 you can set how much the eBike drive assists you while pedalling. The assistance level can be changed at any time, even while cycling.

Note: For individual versions, it is possible that the assistance level is pre-set and cannot be changed. It is also possible that less assistance levels are available for selection than listed here.

The following assistance levels (max.) are available: – “OFF”: The motor assistance is switched off, and the eBike

can be moved as a normal bicycle only by pedalling. The push assistance cannot be activated in this assistance level.

– “ECO”: Effective assistance at maximum efficiency for

maximum cruising range

– “TOUR”: Uniform assistance, for touring with long cruising

range

– “SPORT”: Powerful assistance for sportive riding off road

as well as for urban traffic

– “TURBO”: Maximum assistance, supporting highest ca-

dence for sportive riding

To increase the assistance level, press the “+” 12 button on the operating unit until the desired assistance level appears in the display b. To decrease the assistance level, press the button “– ” 11.

The requested motor output is displayed in indicator a. The maximum motor output depends on the selected assistance level.

When the on-board computer is removed from the holder 4, the last indicated assistance level is stored; the motor-output indicator a remains empty.

On indicator i, each bar of the battery pack symbol is equivalent to a capacity of approx. 20 %:

The eBike battery pack is fully charged.

The eBike battery pack should be recharged.

The LEDs of the charge-control indicator on the battery pack extinguish. The capacity for assisting the drive has been used up, and assistance is gently switched off. The remaining capacity is made available for the lighting and the on-board computer. The indicator flashes. The capacity of the eBike battery pack is enough for about 2 hours of lighting. This does not account for other consumers (e.g. automatic gearbox, charging external devices at the USB port).

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Interaction of the eBike System with the Bicycle Gears

The bicycle gears should be used as with a normal bicycle, even with eBike motor assistance (please observe the operating instructions of your eBike).

Independent of the type of gearing, it is recommended to briefly interrupt the pedaling while changing gears. This makes changing gears easier and reduces the wear of the drive train.

By selecting the right gear, you can increase the speed and range with the same pedaling effort.

For this reason, follow the shift recommendations provided by indications g and h on your display. If indication g is displayed, you should shift to a higher gear with lower cadence. If indication h is displayed, you should select a lower gear with higher cadence.

Switching bike lights on/off

In the model in which the lighting is powered by the eBike system, the front and rear lights can be switched on and off at the same time via the on-board computer with button 2. When the lighting is switched on “Lights on” appears and when the lighting is switched off “Lights off” appears for approx. 1 s in text indication d. The lighting symbol c is displayed when the light is on.

Switching the bike light on and off has no effect on the back lighting of the display.

Switching the Push-assistance mode On/Off

The push-assistance feature makes it easier to push the eBike. The speed in this function depends on the set gear and cannot exceed 6 km/h (max.). The lower the set gear, the lower the speed in the push-assistance function (at full output).

f The push-assistance function may only be used when

pushing the eBike. Danger of injury when the wheels of

the eBike do not have ground contact while using the pushassistance function.

To activate the push-assistance function, briefly press button “WALK” on your on-board computer. After activation, press button “+” within 3 s and keep it pressed. The eBike drive is switched on.

Note: The push assistance cannot be activated in the “OFF” assistance level.

The push assistance is switched off as soon as one of the following occurs: – you release button “+” 12, – the wheels of the eBike are blocked (e.g. by actuating the

brakes or impacting against an obstacle),

– the speed exceeds 6 km/h. Note: On some systems the push-assistance function can be

started directly by pressing the “WALK” button.

Displays and configurations of the on-board computer

Speed and Distance Indication

The speed indication f always displays the current speed. The following functions are available in the function indica-

tion (combination of text indication d and value indication e): – “Clock”: Current time – “Max. speed”: Maximum speed achieved since the last

reset – “Avg. speed”: Average speed achieved since the last reset – “Trip time”: Trip time since the last reset – “Range”: Estimated range of the available battery-pack

charge (for constant conditions such as assistance level,

route profile, etc.) – “Odometer”: Display of the total distance travelled with

the eBike (cannot be reset) – “ NuVinci Cadence/Gear”: This menu item is displayed

only in conjunction with a Nu Vinci H|Sync automatic trans-

mission.

If you press the “i” button for longer than 1 s, you will

access the NuVinci menu item from any menu item in the

information menu.

To switch from the “ NuVinci Cadence” mode to the

“ NuVinci Gear” mode, press the “i” button for 1 s.

To switch from the “ NuVinci Gear” mode to the

“ NuVinci Cadence” mode, all you have to do is briefly

press the “i” button.

The default setting is “ NuVinci Cadence”.

– “Gear”: This menu item appears only in conjunction with a

Shimano Di2 gear hub. The currently engaged gear of the

transmission is shown on the display. The newly engaged

gear will be shown briefly on the display whenever the gear

is shifted. – “ Gear: Auto”: This menu item appears only in conjunc-

tion with an SRAM automatic transmission.

By pressing the “i” button for more than 1 s, you can

switch back and forth between the “ Gear: Auto” auto-

matic mode and the “ Gear” manual mode.

Range Odometer NuVinci Cadence

(1 s)

NuVinci Gear

Range Odometer Gear: Auto

(1 s)

Gear

(1 s)

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If you are in first gear in manual mode, you can also press the “– ” 11 button to go to the “ Gear: Auto” mode. By pressing the “– ” 11 button again, you can switch back to the manual mode. It is also possible to access the manual mode by pressing the “+” 12 button.

– “Trip distance”: Distance covered since the last reset To switch between display functions, press button “i” 1 on

the on-board computer or button “i” 10 on the operating unit repeatedly until the required function is displayed.

To reset “Trip distance”, “Trip time” and “Avg. speed”, switch to any of the three functions and then press and hold the “RESET” button 6 until the indication is set to zero. This also resets the values of the other two functions.

To reset the “Max. speed”, switch to this function and then press and hold the “RESET” button 6 until the indication is set to zero.

To reset “Range”, switch to this function and then press the “RESET” 6 button until the display is reset to the value of the factory setting.

If the on-board computer is removed from the holder 4, all val- ues of the features are saved and can still be displayed.

Displaying/Adapting Basic Settings

The basic settings can be displayed and changed regardless of whether the on-board computer is inserted in the holder 4 or not. Some settings are visible and changeable only when the operating computer is inserted. Some menu items may be missing depending on the equipment of your eBike.

To access the basic settings menu, press and hold the “RESET” button 6 and the “i” button 1 until “Configuration” is displayed in text indication d.

To switch between the basic settings, press button “i” 1 on the on-board computer repeatedly until the required basic setting is displayed. If the on-board computer is inserted in the holder 4, you can also press button “i” 10 on the operating unit.

To change the basi c settings, press the On/Off button 5 next to indication “– ” to reduce or scroll down, or the lighting button 2 next to indication “+” to increase or scroll up. If the on-board computer is inserted in the holder 4, it is also possible to change using buttons “ –” 11 and “+” 12 on the operating unit. To exit the function and save a changed setting, press the “RESET” button 6 for 3 s.

The following basic settings are available: – “– Clock +”: The current time can be set here. Pressing

and holding the setting buttons fast-forwards the setting speed.

– “– Wheel circum. +”: You can change this value pre-set by

the manufacturer by ± 5 %. This menu item is displayed only when the on-board computer is in the holder.

– “– English +”: You can change the language of the text indi-

cations. You can choose between German, English, French, Spanish, Italian, Portuguese, Swedish, Dutch and Danish.

– “– Unit km/mi +”: The speed and distance can be dis-

played either in kilometres or miles. – “– Time format +”: The time can be displayed either in the

12 hour or 24 hour format. – “– Shift recom. on/off +”: You can switch the indication

of a shift recommendation on and off. – “Power-on hours”: Indicates the total travel duration with

the eBike (not changeable). – “Gear calibration” (only NuVinci H|Sync): Here you can

calibrate the continuously variable transmission. Confirm

the calibration by pressing the “Bike lights” button. Then

follow the instructions.

In the event of an error, it can also be necessary to perform

calibration when riding. In this case, you also confirm the

calibration by pressing the “Bike lights” button and then

follow the instructions on the display.

This menu item is displayed only when the on-board com-

puter is in the holder. – “– Startgear +”: The starting gear can be set here. The au-

tomatic shift-back function is switched off in the “––” posi-

tion. This menu item is displayed only in connection with

SRAM DD3 Pulse and Shimano Di2. This menu item is dis-

played only when the on-board computer is in the holder. – “Gear adjustment”: This menu item can be used to per-

form fine adjustment of the Shimano Di2. The pre-defined

adjustment range can be found in the operating instruc-

tions provided by the transmission manufacturer. Perform

fine adjustment as soon as you hear unusual sounds com-

ing from the transmission. This will prevent premature

wear of the transmission and also avoid any impairments in

gear shifting behaviour which could cause you to fall in ad-

verse situations. This menu item is displayed only in con-

junction with Shimano Di2. This menu item is displayed

only when the on-board computer is in the holder. – “Displ. vx.x.x.x”: This is the software version of the display. – “DU vx.x.x.x”: This is the software version of the drive

unit. This menu item is displayed only when the on-board

computer is in the holder. – “DU # xxxxxxxxx”: This is the serial number of the drive

unit. This menu item is displayed only when the on-board

computer is in the holder. – “ Service MM/YYYY”: This menu item is displayed

when the bike manufacturer has set a fixed service ap-

pointment. – “ Serv. xx km/mi”: This menu item is displayed when

the bike manufacturer has set a fixed service appointment

after a certain mileage has been reached. – “Bat. vx.x.x.x”: This is the software version of the battery

pack. This menu item is displayed only when the on-board

computer is in the holder. – “1. Bat. vx.x.x.x”: When using 2 battery packs this is the

software version of one of the battery packs. This menu

item is displayed only when the on-board computer is in

the holder.

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– “2. Bat. vx.x.x.x”: When using 2 battery packs this is the

software version of the other battery pack. This menu item is displayed only when the on-board computer is in the holder.

– “Gear vx.x.x.x”: This is the software version of the automat-

ic transmission. This menu item is displayed only when the

on-board computer is in the holder. This menu item is dis-

played only in conjunction with an automatic transmission.

Error Code Indication

The components of the eBike system are continuously and automatically monitored. When an error is detected, the respective error code is indicated in text indication d.

Press any button on the on-board computer 3 or on the operating unit 9 to return to the standard indication.

Depending on the type of error, the drive unit is automatically shut off, if required. Continued travel without assistance from the drive unit is possible at any time. However, have the eBike checked before attempting new trips.

f Have all repairs performed only by an authorised bike

dealer.

Code Cause Corrective Measure

410 One or more buttons of the on-board

computer are blocked.

Check if any buttons are blocked, e. g. from dirt or debris. Clean the buttons, if required.

414 Connection problem of the operating

unit

Have connections and contacts checked.

418

One or more buttons of the operating unit are blocked.

Check if any buttons are blocked, e. g. from dirt or debris. Clean the buttons, if required.

419

Configuration error Restart the system. If the problem persists, contact your Bosch eBike

dealer. 422 Connection problem of the drive unit Have connections and contacts checked. 423 Connection problem of the eBike

battery pack

Have connections and contacts checked.

424 Communication error among the

components

Have connections and contacts checked.

426

Internal time-out error Restart the system. If the problem persists, contact your Bosch eBike

dealer. In this error status, it is not possible to display or adjust the wheel

circumference in the basic settings menu. 430

Internal battery pack of the on-board computer is empty.

Charge the on-board computer (in the holder or via the USB port).

431

Software version error Restart the system. If the problem persists, contact your Bosch eBike

dealer. 440

Internal error of the drive unit Restart the system. If the problem persists, contact your Bosch eBike

dealer. 450 Internal software error Restart the system. If the problem persists, contact your Bosch eBike

dealer. 460 Error at USB connection Remove the cable from the USB connection of the on-board computer.

If the problem persists, contact your Bosch eBike dealer. 490

Internal error of the on-board computer

Have the on-board computer checked.

500

Internal error of the drive unit Restart the system. If the problem persists, contact your Bosch eBike

dealer. 502

Bike lighting error Check the light and the associated wiring. Restart the system. If the prob-

lem persists, contact your Bosch eBike dealer. 503

Error of the speed sensor Restart the system. If the problem persists, contact your Bosch eBike

dealer. 510

Internal sensor error Restart the system. If the problem persists, contact your Bosch eBike

dealer. 511

Internal error of the drive unit Restart the system. If the problem persists, contact your Bosch eBike

dealer.

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530

Battery pack error Switch off the eBike, remove the eBike battery pack and reinsert the

eBike battery pack. Restart the system. If the problem persists, contact

your Bosch eBike dealer. 531 Configuration error Restart the system. If the problem persists, contact your Bosch eBike

dealer. 540

Temperature error The eBike is outside of the permissible temperature range. Switch off the

eBike system and allow the drive unit to either cool down or heat up to the

permissible temperature. Restart the system. If the problem persists,

contact your Bosch eBike dealer. 550

An improper load was detected. Remove load. Restart the system. If the problem persists, contact your

Bosch eBike dealer. 580 Software version error Restart the system. If the problem persists, contact your Bosch eBike

dealer. 591 Authentication error Switch off the eBike system. Remove the battery pack and reinsert it. Re-

start the system. If the problem persists, contact your Bosch eBike dealer. 592

Incompatible component Insert a compatible displa y. If the problem persists, contact your Bosch

eBike dealer. 593

Configuration error Restart the system. If the problem persists, contact your Bosch eBike

dealer. 595, 596 Communication error Check the wiring to the transmission and restart the system. If the prob-

lem persists, contact your Bosch eBike dealer. 602

Internal battery pack error while charging

Unplug the charger from the battery pack. Restart the eBike system. Plug

the charger into the battery pack. If the problem persists, contact your

Bosch eBike dealer. 602

Internal battery pack error Restart the system. If the problem persists, contact your Bosch eBike

dealer. 603

Internal battery pack error Restart the system. If the problem persists, contact your Bosch eBike

dealer. 605

Battery pack temperature error The eBike is outside of the permissible temperature range. Switch off the

eBike system and allow the drive unit to either cool down or heat up to the

permissible temperature. Restart the system. If the problem persists,

contact your Bosch eBike dealer. 605

Battery pack temperature error while charging

Unplug the charger from the battery pack. Allow the battery pack to cool.

If the problem persists, contact your Bosch eBike dealer. 606

External battery pack error Check the wiring. Restart the system. If the problem persists, contact

your Bosch eBike dealer. 610 Battery pack voltage error Restart the system. If the problem persists, contact your Bosch eBike

dealer. 620

Charging error Replace the charger. Contact your Bosch eBike dealer.

640

Internal battery pack error Restart the system. If the problem persists, contact your Bosch eBike

dealer. 655

Multiple battery pack errors Switch off the eBike system. Remove the battery pack and reinsert it. Re-

start the system. If the problem persists, contact your Bosch eBike dealer. 656

Software version error Contact your Bosch eBike dealer so that he can perform a software update.

7xx

Transmission error Please observe the operating instructions provided by t he transmission

manufacturer. No display

Internal error of the on-board computer

Restart your eBike system by switching it off and back on.

Code Cause Corrective Measure

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Power Supply of External Devices via USB Connection

With the USB connection, it is possible to operate and charge most devices whose power supply is possible via USB (e. g., various mobile phones).

Prerequisite for charging is that the on-board computer and a sufficiently charged battery pack are inserted in the eBike.

Open the protective cap 8 of the USB port on the on-board computer. Connect the USB connection of the external device to the USB port 7 on the on-board computer using the USB charging cable Micro A – Micro B (available from your Bosch eBike dealer).

Once the consumer has been disconnected, the USB connection must be sealed again carefully with the protective cap 8.

f A USB connection is not a waterproof plug-in connec-

tion. When riding in the rain, an external device must not be connected and the USB connection must be completely sealed with the protective cap 8.

Maintenance and Service

Maintenance and Cleaning

Do not immerse any components, including the drive unit, in water or clean them with pressurised water.

Clean your on-board computer using a soft cloth dampened only with water. Do not use any detergents.

Have your eBike system checked by an expert at least once a year (including mechanical parts, up-to-dateness of system software).

The bicycle manufacturer or dealer may also base the service date on the distance travelled and/or a period of time. In this case, the on-board computer will show you every time it is switched on that the service date is due in the text indication d by displaying “ Service” for 4 s.

For service or repairs on the eBike, please refer to an authorised bicycle dealer.

After-sales Service and Application Service

In case of questions concerning the eBike system and its components, please refer to an authorised Bosch eBike dealer.

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

Transport

f 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. (If

the on-board computer cannot be fitted onto a bracket, it is not possible to remove it from the bicycle. In this case, the on-board computer may remain on the bicycle.)

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 forward ing 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.

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

The drive unit, on-board computer including operating unit, battery pack, speed sensor, accessories and packaging should be disposed of in an environmentally correct manner.

Do not dispose of eBikes and their components into household waste!

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.

The integrated battery pack in the on-board computer may only be removed for disposal. Opening the housing shell can destroy the on-board computer.

Please return battery packs and on-board computers that are no longer usable to an authorised bicycle dealer.

Li-ion:

Please observe the instructions in section “Transport”, page English –8.

Subject to change without notice.

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Safety Notes

Read all safety warnings and all instructions. Failure to follow the warnings and in-

structions may result in electric shock, fire and/or serious injury.

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.

f Do not open the drive unit yourself. The drive unit must

be repaired only by qualified experts and only with original spare parts. This will ensure that the safety of the

drive unit is maintained. Unauthorised opening of the drive unit will void warranty claims.

f All components mounted to the drive unit and all other

components of the eBike drive (e.g., the chainwheel, chainwheel seat, pedals) may be replaced only with identical components or components specifically approved for your eBike by the bicycle manufacturer.

This protects the drive unit against overload and damage.

f Remove the battery pack from the eBike before begin-

ning 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.

f The eBike system can switch itself on when the eBike is

pushed backwards.

f The push-assistance function may only be used when

pushing the eBike. Danger of injury when the wheels of

the eBike do not have ground contact while using the pushassistance function.

f When the push-assistance function is activated, the

pedals turn at the same time. When the push-assistance

function is activated, make sure that there is enough space between your legs and the turning pedals. There is a risk of injury.

f 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.

f After a ride, do not allow your unprotected hands or

legs to come into contact with the aluminium housing of the drive unit. Under extreme conditions, such as con-

tinuously high torques at low travel speeds, or when riding up hills or carrying loads, very high temperatures may be reached on the aluminium housing.

The temperatures that may be reached at the drive unit housing are influenced by the following factors:

– Ambient temperature – Ride profile (route/gradient) –Ride duration –Assistance modes – User behaviour (personal effort) – Total weight (rider, eBike, luggage) – Motor cover on the drive unit – Heat dissipation properties of the bicycle frame – Type of drive unit and type of gear-shifting

f Do not make any modifications to your eBike system or

fit any other products which would be suitable for increasing the performance of your eBike system. This

normally reduces the lifetime of the system and risks damage to the drive unit and the bike. There is also a risk of losing the guarantee and warranty claims on the bike you have purchased. By handling the system improperly you are also endangering your safety and that of other road users, thus running the risk of high personal liability costs and possibly even criminal prosecution in the event of accidents attributable to manipulation.

f Please observe all national regulations on registering

and using eBikes.

f Read and observe the safety warnings and instructions

in all operating instructions of the eBike system and in the operating instructions of your eBike.

Product Description and Specifications

Intended Use

The drive unit is intended only for driving your eBike and must not be used for other purposes.

In addition to the functions shown here, changes to software relating to troubleshooting and functional enhancements may be introduced at any time.

Product Features

1 Drive unit Active Line Plus 2 Speed sensor 3 Spoke magnet of the speed sensor

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Technical Data

Drive Unit Active Line Plus

Article number Rated continuous output Torque at drive, max. Rated voltage Operating temperature Storage temperature Degree of protection

W250

Nm 50

V36

°C –5...+40 °C –10...+50

0 275 007 047

IP 54 (dust and splash

water protected)

Weight, approx.

Bosch eBike system uses FreeRTOS (see www.freertos.org)

Bike lights

Voltage, approx.

kg 3.3

V12

Maximum output –Front light –Taillight

1) Not possible via the eBike battery pack in all country-specific versions, depending on the statutory regulations

2) When changing the bulbs, ensure that th e bulbs are compatible with the Bosch eBike system (ask your bicycle dealer) and that the specified voltage matches. Bulbs must be replaced only with bulbs of the same voltage.

f Incorrectly inserted bulbs can be destroyed!

W W

17.4

0.6

Assembly

Inserting and removing the battery pack

For inserting and removing the eBike battery pack in/ from the eBike, please read and observe the battery pack operating instructions.

Checking the Speed Sensor (see figure A)

The speed sensor 2 and its spoke magnet 3 must be mounted in such a manner that the spoke magnet, after a turn of the wheel, moves past the speed sensor with a clearance of at least 5 mm, yet no more than 17 mm.

Note: If the distance between speed sensor 2 and spoke magnet 3 is too small or too large, or if the speed sensor 2 is not properly connected, the speed indication will fail, and the eBike drive unit will operate in emergency mode. In this case, loosen the screw of the spoke magnet 3 and fasten the spoke magnet to the spoke in such a manner that it runs past the mark of the speed sensor at the correct clearance. If the speed is still not being indicated in the speed indication after this, please contact an authorised bicycle dealer.

Operation

Initial Operation

Requirements

The eBike system can only be activated when the following requirements are met: – A sufficiently charged battery pack is inserted (see battery

pack operating instructions).

– The on-board computer is properly inserted in the holder

(see on-board computer operating instructions).

– The speed sensor is connected properly (see “Checking

the Speed Sensor”, page English –2).

Switching the eBike System On/Off

Options for switching on the eBike system: – If the on-board computer is already switched on when you

insert it into the holder, then the eBike system will be switched on automatically.

– With the on-board computer and the eBike battery pack

inserted, briefly press the On/Off button of the on-board computer (see on-board computer operating instructions).

– With the on-board computer inserted, push the On/Off

button on the eBike battery (bicycle manufacturer solutions are possible whereby there is no access to the battery On/Off button; see the battery operating instructions).

The drive is activated as soon as you step on the pedals (except when in the push aid feature, see “Switching the Push-assistance mode On/Off”, page English– 3). The motor output depends on the settings of the assistance level on the on-board computer.

As soo n as you stop pedaling wh en in normal operation, or as soon as you have reached a speed of 25 km/h, the assistance from the eBike drive is switched off. The drive is automatically re-activated as soon you start pedaling again and the speed is below 25 km/h.

Options for switching off the eBike system: – Press the On/Off button of the on-board computer. – Switch off the eBike battery using its On/Off button

(bicycle manufacturer-specific solutions are possible whereby there is no access to the battery On/Off button; see the bicycle manufacturer operating instructions).

– Remove the on-board computer out of its holder. If the eBike is not moved and no button is pressed on the

on-board computer for 10 minutes, the eBike system will shut down automatically in order to save energy.

eShift (optional)

eShift is the integration of electronic gear shifting systems into the eBike system. The eShift components are electrically connected to the drive unit by the manufacturer. The separate operating instructions describe how to operate the electronic gear-shifting systems.

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Setting the Assistance Level

On the on-board computer you can set how much the eBike drive assists you while pedalling. The assistance level can be changed at any time, even while cycling.

Note: For individual versions, it is possible that the assistance level is pre-set and cannot be changed. It is also possible that less assistance levels are available for selection than listed here.

The following assistance levels (max.) are available: – “OFF”: The motor assistance is switched off, and the eBike

can be moved as a normal bicycle only by pedalling. The push assistance cannot be activated in this assistance level.

– “ECO”: Effective assistance at maximum efficiency for

maximum cruising range

– “TOUR”: Uniform assistance, for touring with long cruising

range

– “SPORT”: Powerful assistance for sportive riding off road

as well as for urban traffic

– “TURBO”: Maximum assistance, supporting highest

cadence for sportive riding

The motor output requested appears on the display of the onboard computer. The maximum motor output depends on the selected assistance level.

Assistance Level Assistance Factor *

“ECO” “TOUR” “SPORT” “TURBO”

* The assistance factor may vary on the individual versions.

40 % 100 % 180 % 270 %

Switching the Push-assistance mode On/Off

f The push-assistance function may only be used when

pushing the eBike. Danger of injury when the wheels of

the eBike do not have ground contact while using the pushassistance function.

Note: The push assistance cannot be activated in the “OFF” assistance level.

The push assistance is switched off as soon as one of the following occurs: – You release the “+” button; – The wheels of the eBike are prevented from turning (e.g.

by braking or being hit by your leg);

– The speed exceeds 6 km/h. Note: On some systems the push-assistance function can be

started directly by pressing the “WALK” button. Depending on the statutory specifications in some countries,

the push-assistance function may vary by region.

Switching bike lights on/off

In the version which has the bike lights powered by the eBike system, the front and rear lights can be switched on and off at the same time via the on-board computer.

Notes on Riding with the eBike System

When does the eBike Drive Unit Operate?

The eBike drive unit assists you when riding, as long as you step into the pedals. Without pedaling, there is no assistance. The motor output always depends on the amount of your pedaling power.

When applying less pedaling power, the assistance or support will be lower than when applying a lot of pedaling power. This applies independent of the assistance Level.

The eBike drive automatically switches off at speeds in excess of 25 km/h. When the speed falls below 25 km/h, the drive is automatically available again.

An exception applies to the push-assistance function, in which the eBike can be pushed at low speed without pedalling. The pedals may also rotate when the push assistance is used.

The eBike can also be ridden as a normal bicycle without assistance at any time, by either switching off the eBike system or setting the assistance level to “OFF”. The same applies when the battery pack is empty.

Interaction of the eBike System with the Bicycle Gears

The bicycle gears should be used as with a normal bicycle, even with eBike motor assistance (please observe the operating instructions of your eBike).

Independent of the type of gearing, it is recommended to briefly interrupt the pedaling while changing gears. This makes changing gears easier and reduces the wear of the drive train.

By selecting the right gear, you can increase the speed and range with the same pedaling effort.

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Gathering First Experience

It is recommended to gather first experience with the eBike away from roads with heavy traffic.

Test the various assistance levels. Start with the lowest assistance level. As soon as you feel confident, you can ride your eBike in traffic like any other bike.

Test the operating range of your eBike under different conditions before planning longer and more challenging rides.

Influences on the Operating Range

The range is affected by a number of factors, such as: – Assistance level –Speed –Gear changing behaviour – Tyre type and tyre pressure – Age and condition of the battery – Route profile (gradients) and conditions (road surface) – Headwind and ambient temperature – Weight of eBike, driver and luggage.

For this reason, it is not possible to precisely predict the range before and during a trip. General rules: –With the same assistance level on the eBike drive: The less

energy you need to exert in order to reach a certain speed (e.g. by changing gears optimally), the less energy the eBike drive will consume and the higher the range per battery charge will be.

–The higher the assistance level under otherwise same

conditions, the lower the range.

Careful Handling of the eBike

Please observe the operating and storage temperatures of the eBike components. Protect the drive unit, on-board computer and battery against extreme temperatures (e.g. from intense sunlight without adequate ventilation). The components (especially the battery pack) can become damaged through extreme temperatures.

After-sales Service and Application Service

In case of questions concerning the eBike system and its components, please refer to an authorised Bosch eBike dealer.

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

Disposal

The drive unit, on-board computer including operating unit, battery pack, speed sensor, accessories and packaging should be disposed of in an environmentally correct manner.

Do not dispose of eBikes and their components into household waste!

Only for EC countries:

Subject to change without notice.

Maintenance and Service

Maintenance and Cleaning

When changing the bulbs, ensure that the bulbs are compatible with the Bosch eBike system (ask your bicycle dealer) and that the specified voltage matches. Bulbs must be replaced only with bulbs of the same voltage.

Do not immerse any components, including the drive unit, in water or clean them with pressurised water.

Have your eBike system checked by an expert at least once a year (including mechanical parts, up-to-dateness of system software).

For service or repairs on the eBike, please refer to an authorised bicycle dealer.

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+ 42 hidden pages

Bosch Active Plus User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual