BOSCH BDU310, BDU350, BDU365 Drive Units Instruction Manual

BOSCH BDU310, BDU350, BDU365 Drive Units

Safety instructions

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

Save all safety warnings and instructions for future ref-erence.
The term battery is used in these instructions to mean all original Bosch eBike rechargeable battery packs.

• Read and observe the safety warnings and directions contained in all the eBike system operating instructions and in the operating instructions of your eBike.

• Do not attempt to change – and especially increase –the power of your drive or the maximum speed that it supports. Doing this may put yourself and others at risk, and you may also breach statutory regulations.

• Do not make any modifications to your eBike system or fit any other products that might increase the performance of your eBike system. Doing so will generally reduce the service life of the system and risks damaging the drive unit and the bike. You also run the risk of losing the guarantee and warranty claims on the bicycle 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 ac-cidents that can be attributed to manipulation of the bi-cycle.

• Do not open the drive unit yourself. The drive unit must only be repaired by qualified personnel using only original spare parts. This will ensure that the safety of the drive unit is maintained. Unauthorised opening of the drive unit will render warranty claims null and void.

• All components fitted to the drive unit and all other components of the eBike drive (e.g. chainring, chain-ring receptacle, pedals) must only be replaced with identical components or components that have been specifically approved by the manufacturer for your eBike. This will protect the drive unit from overloading and becoming damaged.

• Remove the battery from the eBike before beginning work (e.g. inspection, repair, assembly, maintenance, work on the chain, etc.) on the eBike, transporting it with a car or aeroplane, or storing it. Unintentional activation of the eBike system poses a risk of injury.

• The eBike system can be activated by pushing the eBike backwards or by turning the pedals backwards.

• The push assistance function must only be used when pushing the eBike. There is a risk of injury if the wheels of the eBike are not in contact with the ground while using the push assistance.

• When the push assistance is activated, the pedals may turn at the same time. When the push assistance func-tion is activated, make sure that there is enough space between your legs and the turning pedals to avoid the risk of injury.

• When using the walk assistance, make sure that you can control the bike and that you can hold it securely at all times. Under certain circumstances, the walk assistance may stop (e.g. if the pedals hit an obstacle or if you accidentally let go of the button on the operating unit). The eBike may suddenly move back onto you or tip up. This presents a risk for the user particularly if there is an additional load on the bike. When using the walk assistance, do not bring the eBike into situations in which you cannot hold the eBike using your own strength.

• On sections of the drive, temperatures 60 °C may occur in extreme conditions, e.g. when carrying consistently high loads at low speed when riding up hills or transporting loads.

• After a ride, do not allow your unprotected hands or legs to come into contact with the housing of the drive unit. Under extreme conditions, such as continuously high torques at low travel speeds, or when riding up hills or carrying loads, the housing may reach a very high temperature.
  The temperature that the drive unit housing may reach is 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

• Use only original Bosch batteries that the manufacturer has approved for your eBike. Using other batteries can lead to injuries and pose a fire hazard. Bosch accepts no liability or warranty claims if other batteries are used.

• Observe all national regulations which set out the approved use of eBikes.

Privacy notice
When you connect the eBike to the Bosch DiagnosticTool, data about the Bosch drive unit (e.g. energy consumption, temperature, etc.) is transferred to Bosch eBike Systems (Robert Bosch GmbH) for the purposes of product improvement. You can find more information about this on the Bosch eBike website at www.bosch-ebike.com.

Product Description And Specifications

Intended use
The drive unit is intended exclusively for driving your eBike and must not be used for any other purpose. In addition to the functions shown here, changes to software relating to troubleshooting and functional modifications may be introduced at any time.

Product Features
Individual illustrations in these operating instructions may differ slightly from the actual conditions depending on the equipment of your eBike.

The numbering of the components shown refers to the illustrations on the graphics pages at the beginning of the manual.

1. Drive unit
2. Speed sensor
3. Speed sensor spoke magnet
4. Speed sensor (slim)a)
5. Magnetb)
   • different sensor type and installation position is possible
   • the different installation position is possible

Technical data

Drive unit|  | Active Line| Active Line Plus| Performance Line
---|---|---|---|---
Product code|  | BDU310| BDU350| BDU365
Continuous rated power| W| 250| 250| 250
Torque at drive, max.| Nm| 40| 50| 65
Rated voltage| V=| 36| 36| 36
Operating temperature| °C| –5 to +40| –5 to +40| –5 to +40
Storage temperature| °C| +10 to +40| +10 to +40| +10 to +40
Protection rating|  | IP54| IP54| IP54
Weight, approx.| kg| 2.9| 3.2| 3.2

The Bosch eBike system uses FreeRTOS (see http://www.freertos.org).

• Depends on legal regulations, not possible in all country-specific models via the eBike battery
• When changing the bulbs, ensure that they are compatible with the Bosch eBike system (ask your bicycle dealer) and are suitable for the specified voltage. Bulbs must only be replaced with bulbs of the same voltage.

Inserting a bulb incorrectly can cause it to blow.

Assembly

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

Checking the speed sensor (see Figure A)

Speed sensor (standard)
The speed sensor (2) and its spoke magnet (3) must be fitted such that the spoke magnet moves past the speed sensor at a distance of at least 5 mm and at most 17 mm with each rotation of the wheel.

Note:
If the distance between the speed sensor (2) and the spoke magnet (3) is too small or too large, or if the speed sensor (2) is not properly connected, the speedometer display will fail and the eBike drive unit will operate in emergency mode. Should this occur, loosen the screw of the spoke magnet (3) and fasten the spoke magnet to the spoke such that it runs past the marking on the speed sensor at the correct clearance. If the speed is still not being indicated on the speedometer display after doing this, please contact an authorised bicycle dealer. When changing a wheel, make sure that the sensor cable is routed so that it is not under tension and has no kinks.

Speed sensor (slim)
The speed sensor (slim) (4) and its magnet (5) must be mounted in such a manner that the magnet, after a turn of the wheel, moves past the speed sensor with a clearance of at least 2 mm, yet no more than 8 mm. If any structural changes are made, the correct distance between the magnet and the sensor must be complied with (see figure A).

Note:
Make sure you do not damage the sensor or the sensor holder when fitting or removing the rear wheel. When changing a wheel, make sure that the sensor cable is routed so that it is not under tension and has no kinks. The CenterLock magnet (5) can only be removed and reinserted up to five times.

Operation

Start-up

Requirements
The eBike system can only be activated when the following requirements are met:

• A sufficiently charged battery is inserted (see battery operating instructions).
• The onboard computer is properly inserted in the holder (see onboard computer operating instructions).
• The speed sensor is correctly connected (see “Checking the speed sensor (see figure A)”, page English – 2).

Switching the eBike system on/off
The following options are available for switching on the eBike system:

• If the onboard computer is already switched on when you insert it into the holder, the eBike system will be activated automatically.
• Once the onboard computer and the eBike battery are fitted, briefly press the on/off button on the onboard computer.
• With the onboard computer inserted, push the on/off button on the eBike battery (bicycle manufacturer-specific solutions are possible when there is no access to the battery on/off button; see the battery operating instructions).

The drive is activated as soon as you start pedalling (except if you are using the push-assistance function, Switching the push assistance on/off). The motor output depends on the settings of the assistance level on the onboard computer. As soon as you stop pedalling when in normal operation, or as soon as you have reached a speed of 25 km/h, the eBike drive switches off the assistance. The drive is automatically reactivated as soon you start pedalling again and the speed is below 25 km/h.

The following options are available for switching off the eBike system:

• Press the on/off button of the onboard computer.
• Switch off the eBike battery using its on/off button (bicycle manufacturer-specific solutions are possible when there is no access to the battery on/off button; see the bicycle manufacturer’s operating instructions).
• Remove the onboard computer from its holder.

If the eBike is not moved for approx. 10 min and no button is pressed on the on-board computer, the eBike system switches off 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.

Setting the assistance level
You can set the level at which the eBike drive assists you while pedalling on the onboard computer. The assistance level can be changed at any time, even while cycling.

Note:
In some models, the assistance level may be preset and cannot be changed. There may also be fewer assistance levels available than stated here.

The following assistance levels are available as a maximum:

• OFF: Motor assistance is switched off. The eBike can only be moved by pedalling, as with a normal bicycle. The walk assistance cannot be activated at this assistance level.
• ECO: Effective assistance with maximum efficiency, for a maximum range
• TOUR/TOUR+:
  • TOUR: Steady assistance, long range for touring
  • TOUR+: Dynamic assistance for natural, sporty cycling (only in conjunction with eMTB)
• SPORT/eMTB:
  • SPORT: Powerful assistance, for mountain biking and cycling in urban traffic
  • eMTB: Optimum assistance whatever the terrain, rapid acceleration when starting from a standstill, improved dynamics and top performance (eMTB only available in combination with the drive units BDU250P CX, BDU365, BDU450 CX and BDU480 CX. A software update may be required.)
• TURBO: Maximum assistance even at a high cadence, for sporty cycling

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

Performance Line (BDU365)
ECO| 40 %| 40 %| 55 %
TOUR| 100 %| 100 %| 120 %
SPORT/eMTB| 150 %| 180 %| 200 %/dynamicB)
TURBO| 250 %| 270 %| 300 %

• The assistance factor may vary in some models.
• The assistance level between TOUR and TURBO mode is dynamically progressive

Switching the push assistance on/off
The walk assistance makes it easier to push your eBike. The speed in this function depends on the selected gear and can reach a maximum of 6 km/h.

• The push assistance function must only be used when pushing the eBike. There is a risk of injury if the wheels of the eBike are not in contact with the ground while using the push assistance.

To activate the walk assistance, briefly press the WALK button on your on- board computer. Once it is activated, press the + button within 10 s and keep it held down. The eBike drive is now switched on.

Note: The push assistance cannot be activated at assistance level OFF.

The push assistance is switched off as soon as one of the following occurs:

• You release the + button;
• The wheels of the eBike are locked (e.g. by applying the brakes or hitting an obstacle);
• The speed exceeds 6 km/h.

The push assistance function is subject to local regulations; the way it works may therefore differ from the description above, or the function may even be deactivated completely.

Switching bicycle lights on/off
On the model where the bike lights are powered by the eBike system, the front light and taillight can be switched on and off at the same time via the on- board computer. Check that your bike lights are working correctly before every use.

Notes on cycling with the eBike system

When does the eBike drive work?
The eBike drive assists your cycling only when you are pedalling. If you do not pedal, the assistance will not work. The motor output always depends on the pedalling force you apply.

If you apply less force, you will receive less assistance than if you apply a lot of force. This applies irrespective of the assistance level. The eBike drive automatically switches off at speeds over 25 km/h. When the speed falls below 25 km/h, the drive automatically becomes 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 rotate when the push assistance is in use. You can also use the eBike as a normal bicycle without assistance at any time, either by switching off the eBike system or by setting the assistance level to OFF. The same applies when the battery is drained.

Interaction between the eBike system and gear-shifting
The gear-shifting should be used with an eBike drive in the same way as with a normal bicycle (observe the operating instructions of your eBike on this point). Irrespective of the type of gear-shifting, it is advisable to briefly stop pedalling when changing gear. This will facilitate the gear change and reduce wear on the powertrain. By selecting the correct gear, you can increase your speed and range while applying the same amount of force.

Gaining initial experience
We recommend that you gain initial experience with the eBike away from busy roads. Test the various assistance levels, beginning with the lowest level. As soon as you feel confident, you can ride your eBike in traffic like any other bicycle. Test the range of your eBike in different conditions before planning longer and more demanding trips.

Influences on range
The range is affected by a number of factors, such as:

• Assistance level
• Speed
• Gear shifting 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, rider and luggage

For this reason, it is not possible to predict the range accurately before and during a trip. However, as a general rule:

• 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 selected assistance level under otherwise constant conditions, the smaller the range will be.

Taking care of your 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). Extreme temperatures can cause the components (especially the battery) to become damaged. Have your eBike system checked by an expert at least once a year (including mechanical parts, up-to-date of system software).

Maintenance and servicing

Maintenance and cleaning
When changing the bulbs, ensure that they are compatible with the Bosch eBike system (ask your bicycle dealer) and are suitable for the specified voltage. Bulbs must only be replaced 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, and up-to-date of system software). Please have your eBike serviced and repaired by an authorised bicycle dealer.

After-sales service and advice on using products
If you have any questions about the eBike system and its components, contact an authorised bicycle dealer. For contact details of authorised bike dealerships, please visit www.bosch-ebike.com.

Disposal

• The drive unit, onboard computer incl. operating unit, battery, speed sensor, accessories and packaging should be disposed of in an environmentally correct manner.
• Check that your personal data has been deleted from the device.
• Do not dispose of eBikes and their components with household waste.

In accordance with Directive 2012/19/EU and Directive 2006/66/EC respectively, electronic devices that are no longer usable and defective/drained batteries must be collected separately and recycled in an environmentally friendly manner. Please return Bosch eBike components that are no longer usable free of charge to an authorised bicycle dealer or to a recycling facility.

Subject to change without notice.

Robert Bosch GmbH
72757 Reutlingen Germany
www.bosch-ebike.com.

References

• Bosch eBike Systems | Premium eBike systems & smart features - Bosch eBike Systems
• FreeRTOS - Market leading RTOS (Real Time Operating System) for embedded systems with Internet of Things extensions

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