BOSCH BDU310 Drive Units Instruction Manual

BOSCH BDU310 Drive Units Instruction Manual

Safety instructions

Read all the safety information and instructions. Failure to observe the safety in- formation and follow instructions 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 bike rechargeable battery packs.

• 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 bike system or fit any other products that might increase the performance of your bike 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 accidents that can be attributed to manipulation of the bicycle.

• 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. Unauthorized 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 aero plane, or storing it. Unintentional activation of the eBike system poses a risk of injury.

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

• The push assistance function must only be used when pushing the bike. 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 function is activated, make sure that there is enough space between your legs and the turning pedals to avoid the risk of injury.
  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 transport- ing 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 bike. 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 ap- proved use of eBikes.

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

Privacy notice

When you connect the eBike to the Bosch Diagnostic Tool, data about the eBike drive unit (e.g. energy consumption, temperature, etc.) is transferred to Bosch eBike Systems (Robert Bosch GmbH) for the purpose 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. Speeds Ensor (slim)^)
5. Magnet)
   A) different sensor type and installation position is possible
   B) 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| P54| IP:54| P54
Weight, approx.| kg| 2.9| 3.2| 3.2

The Bosch e Bike system uses Free RTOS (see http://www.freertos.org).

Bicycle lights

Voltage approx.| V=| 12
Maximum power| |
Front light| W| 17.4
Tail light| W| 0.6

A) Depends on legal regulations, not possible in all country-specific models via the elflike battery
B) When changing the bulbs, ensure that they are compatible with the Bosch e Bike 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)

Speeds Ensor (standard)
The speed sensor (2) and its spoke magnet (3) must be fit- ted 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 dis- play will fail and the eBike drive unit will operate in emer- gency 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 clear- ance. If the speed is still not being indicated on the speedo- meter display after doing this, please contact an authorized bicycle dealer.

Speeds Ensor (slim)
The speeds Ensor (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.

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 on-board computer is properly inserted in the holder (see on-board 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 on-board computer is already switched on when you insert it into the holder, the eBike system will be activated automatically.
• Once the on-board computer and the eBike battery are fitted, briefly press the on/off button on the on-board computer.
• With the on-board 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 on-board 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 on-board computer.
• Switch off the eBike battery using its on/off button (bi- cycle manufacturer-specific solutions are possible when there is no access to the battery on/off button; see the bi- cycle manufacturer operating instructions).
• Remove the on-board 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.

shift (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 on-board 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 just be moved by pedalling, as with a normal bicycle. The push assistance cannot be activated at this assistance level.

• ECO: Effective assistance with maximum efficiency, for maximum range

• TOUR: Steady assistance, long range for touring

• 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 dy- namics 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 high pedalling speeds, for sport cycling

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

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

Switching the push assistance on/off
The push assistance aids you when pushing your eBike. The speed in this function depends on the selected gear and can reach a maximum of 6 km/h. The lower the selected gear, the lower the speed of the push assistance function (at full power).

• 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 push assistance, briefly press the WALK button on your on- board computer. After activation, press the button within 3 s and keep it pressed. The eBike drive is 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 bike system

When does the bike drive work?
The eBike drive assists your cycling only when you are pedaling. If you do not pedal, the assistance will not work. The motor output always depends on the pedaling 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 as- sistance 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 ped- alling. The pedals may rotate when the push assistance is in use.

You can also use the eBike as a normal bicycle without as- sistance 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 pedaling 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 bike 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 behavior
• 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-datedness of system software).

Please have your eBike serviced and repaired by an authorized bicycle dealer.

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 re- placed with bulbs of the same voltage.

Do not immerse any components, including the drive unit, in water or clean them with pressurized water.
Have your eBike system checked by an expert at least once a year (including mechanical parts, up-to-datedness 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 authorized bicycle dealer. For contact details of authorized bike dealerships, please visit www.bosch-ebike.com.

Disposal

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

Do not dispose of eBikes and their components with house- hold 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 to an authorized bicycle dealer.
Subject to change without notice.

Documents / Resources

| BOSCH BDU310 Drive Units [pdf] Instruction Manual
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