Bosch Active Line eBike System 2016 User manual

Bosch eBike Systems 2016
More flexibility.
More experience.
More riding pleasure.
Active Line

Active Line
The versatile
drive system
Custom, versatile, and modern: The Bosch Active Line
makes exercise a pleasure and the eBike into an
everyday companion as a matter of course. To the
movies, into the countryside, or to dining with
friends – with the Active Line, you simply get to your
destination faster and more relaxed. For the
on-board computer, you can choose between the
fully networked Nyon or Intuvia with its basic
functions. Bosch PowerPacks set the market
standard in terms of weight, energy density,
and range. Perfectly matched components are
thus combined to form a first-class system.
Nyon is now also available
for the Active Line.

Active LineActive Line 0504
The Bosch eBike system at a glance
On-board computer, Drive Unit, PowerPack – the components of the Active Line work together as members of a practiced, perfectly
coordinated team. The result: a symbiotic connection between the rider and eBike and a thrillingly natural riding sensation.
PowerPack
The powerful lithium-ion batteries
are available with an energy con-
tent of 300, 400, and now even
500 Wh. A frame or rack variant
can be chosen.
Drive Unit
Drive Unit Active Cruise gives you a
unique, natural, and relaxed riding
experience up to 25 km/h. It is available
in Platinum or Black. With optional
backpedal function.
Your mobility is our drive
Range
In every Bosch drive system, perfectly matched components work
together efficiently, allowing you to ride the maximum ranges with your
pedelec.
Service
We challenge ourselves to meet the highest standards of quality and relia-
bility. This applies to our drive system as well as our comprehensive ser-
vice infrastructure. For this we train Bosch eBike Experts throughout
Europe who are available at bike dealers to offer advice and support.
Design
Bosch eBike Systems sets trends. This applies not only in the technical
and ergonomic sense but also in terms of aesthetics.
In the world of Bosch eBike Systems, the focus is on people. In the development of each product, we keep in mind what will
really help you with eBiking. For individual needs, individual riding enjoyment, always the right drive – that is our claim.
Riding sensation
Harmonious or powerful? The main thing is that it needs to feel natural.
The Bosch riding sensation creates a unique eBike experience. Three
sensors measure pedaling power, cadence, and speed more than 1000
times per second. This enables organic interplay between the rider
and eBike.
Ergonomics
The comfortable and safe handling of your eBike is always at the center of
our product development. We keep user-friendliness and ergonomics in
mind in particular. This is because the interaction between the rider and
eBike only works optimally when components and controls optimally
match the movements of the rider.
Intuvia
Using this clever control cen-
ter, you control your pedelec
experience easily and intui-
tively. Intuvia informs you
clearly and reliably regarding
all relevant information about
your eBike system.
Nyon
The all-in-one eBike on-board computer
accompanies you from route planning
to evaluation of the fitness data and is
connected to the online portal and smart-
phone app. Nyon is the first fully net-
worked ecosystem of the industry.

Adapted torque during shifting.
This reduces the strain on the compo-
nents, cuts down on wear, and makes
shifting smooth so you barely feel the shift.
Active Line
06
Drive Unit Active supports your ride very harmoniously and provides a unique, natural riding experience. This drive
extends your range and gets you to your destination faster and more relaxed. An increase in movement which not
only keeps you fit but also is a lot of fun.
Drive Unit Active
The versatile drive
Pure riding enjoyment thanks to the three-sensor concept
Three sensors for pedaling power, cadence, and speed ensure an
optimum balance of forces with 1000 measurements per second.
You receive perfectly coordinated, harmonious riding support at
all times.
Quiet, sturdy, and durable
Due to direct processing of the sensor signals and the precise
motor control, Drive Unit Active is optimized for minimum sound
emissions and vibration. The secure chain run helps to keep the
chain from being derailed and prevents the components from
being subjected to undue strain. This reduces wear, maximizes
comfort, and increases service life. Drive Unit Active is available
in Platinum as well as Black versions.
Compact and lightweight
Bosch eBike drive systems set standards in matters of ergonomics
and weight. The compact gear arrangement allows for optimal inte-
gration of the Drive Unit into the frame, giving you more ground
clearance. The reduced volume makes the drive lightweight.
Sporty riding, gentle shifting
While you are shifting, the drive adapts its torque auto-
matically to the shifting process. This takes stress off
the components and makes eBiking extremely comfortable.
Backpedal
Drive Unit Active is available with backpedal function on
request.

With backpedal function on request
Optionally available with 300, 400,
or 500 Wh
Intuvia with gear recommendation
Active Line 09
Technical specifications
Drive Unit Active
Cruise 25 km/h Cruise 25 km/h
Gear system type Hub gear system Derailleur system
Power 250 watts 250 watts
Support level (%) TURBO: 225
SPORT: 150
TOUR: 100
ECO: 40
TURBO: 250
SPORT: 150
TOUR: 100
ECO: 40
Maximum possible drive torque
(Nm) (converted to a gear ratio of 1:1
crankset to chainring)
TURBO: 48
SPORT: 45
TOUR: 40
ECO: 35
TURBO: 50
SPORT: 45
TOUR: 40
ECO: 35
Maximum cadence (r/min) with drive
support
TURBO: 100
SPORT: 100
TOUR: 100
ECO: 90
TURBO: 100
SPORT: 100
TOUR: 100
ECO: 90
Start-up behavior harmonious harmonious
Max. support up to 25 km/h 25 km/h
Backpedal function optional no
Gear shift detection no yes
Weight < 4 kg < 4 kg

Active LineActive Line 1110
With the on-board computer Intuvia, you control your pedelec experience easily and intuitively. The display, which is easy to
read even in sunlight, informs you reliably about speed, support mode, battery charge level, and range.
Suitable for every riding situation
Five riding modes assist you depending on your wishes and riding situation:
Eco, Tour, Sport, Turbo, and Off. The spectrum ranges from smart support for
the greatest possible range in Eco mode to maximum, powerful support in the
highest cadences in Turbo mode.
Off-board mode
Even when removed from the eBike, Intuvia remains a useful basis information
source that makes it possible for you to view all your tour information.
Charging mobile devices
Using the integrated micro-USB interface, you can charge mobile devices such
as your smartphone while you are on the go.
Shift recommendation
Your system detects whether you are in the optimum efficiency range and
recommends a higher or lower gear – using simple arrow symbols. The result:
a more pleasant riding experience and the greatest possible range.
Intuvia
The clever control center
Riding modes
You have the choice. Five riding modes assist
you in individual mobility: Eco, Tour, Sport,
Turbo, and Off. The additional walk assistance
up to 6 km/h makes your life a little easier.
Service interval display
An optional feature from your
dealer: With the new service
interval indicator, you find out in
due time when your eBike is due
for service. Maintenance perfor-
med by your dealer increases
safety, maintains value, and
extends the service life of
your pedelec.
Direct, powerful support up to maximum
cadence for athletic riding.
Immediate, powerful support for athletic riding
off-road and in city traffic
Sport
Steady support for long tours
Tour
Effective support at maximum efficiency
for maximum range
Eco
No support, all on-board computer functions
are available
O ff
Turbo

Scan here for the Nyon tour
report from Switzerland.
Active Line
12
Everything you need for a fascinating eBike experience is in view and ready to be accessed.
Navigation, riding data, range, fitness, incoming text messages, and much more: Nyon supports
you from route planning to the tour to the evaluation of your activities with additional features and
custom options. Nyon marks the beginning of a new era: the first fully networked ecosystem of
the industry.
Usability
The all-in-one on-board computer is rugged and
adapted to the needs of eBikers. Control is intuitive
using the 5-way joystick on the device or – during
the ride – on the separate control unit.
Overview
Large display, characteristic screen design,
concise presentation. The transreflective
4.3-inch color display is readable in all
lighting conditions.
Nyon is now available for retrofitting on all eBikes
with Bosch drive starting with model year 2014.
More storage
To make more maps available on Nyon, the storage
capacity has been expanded to 8 GB.
The all-in-one on-board computer for
the eBike

Active Line
14
All of the most important information relevant to riding at
a glance. Speed, riding mode, cadence, range, and much
more: You decide for yourself what data is displayed on
your Ride screen. And the size and order of presentation
is according to your wishes.
Nyon turns your pedelec into your own personal trainer. The
on-board computer measures fitness-relevant data such as
cadence and pedaling power. And Nyon calculates how
effectively you are exercising based on your body data. If
you wear a chest strap, Nyon even takes your cardiovascular
values into account in this calculation. In this way you have
all the information for supporting you in maintaining and
improving your fitness and health over the long term.
Plan your route online, on your smartphone, or on the
on-board computer itself. With intuitively understandable,
distinctive symbols, Nyon takes you on the most scenic or
fastest eBike routes.
A pop-up informs you via Bluetooth regarding arrival of
a new SMS on your smartphone and the sender. In this
way you are always up to date – no matter where your eBike
adventure takes you.
Fitness
Ride
Smartphone function
Navigation
By connecting with the smartphone app eBike Connect and the online portal eBike-Connect.com, Nyon provides access to the
fascinating world of Bosch eBike Systems. It offers numerous features that provide useful insights from data and make eBiking
into a completely personalized experience. Welcome!
Intelligently networked
Welcome to the world of Bosch eBike Systems
Smartphone app eBike Connect
Through custom adjustments in the smartphone app eBike Connect, you make Nyon
into your personal eBike assistant. You configure the screen or refine the settings of
your riding modes just as you wish with our premium feature. Data is exchanged
via Bluetooth.
Online portal
The Bosch online portal eBike-Connect.com creates your own personal eBike information
profile for you. You plan and analyze customized tours in the portal, with an overview of
times, elevation gain and loss, distance, and your fitness. Or you import a GPX track and
transmit it to Nyon via the portal.
Your personal eBike assistant
Nyon features overview
GPX import
You define your own routes
and import them into the
eBike-Connect.com portal.
MTB Routing
With the route profile “eMTB”
Nyon takes you mainly on un-
paved paths and trails.
Multiple way points
Plan routes with up to ten
destinations.

Active Line 17 Active Line
16
eShift with NuVinci Optimized™ Harmony H|Sync™
The cadence-based, continuously variable automatic trans-
mission for the eBike. Whether at full acceleration downhill or
when ascending – the rider pedals constantly at the selected
frequency of between 30 and 100 revolutions per minute. The
continuously variable gearbox provides for this. Those who
want to pedal more quickly or slowly adjust the cadence at the
press of a button.
eShift with SRAM DD3 Pulse
The speed-dependent shifting solution combines a 3-speed hub
system with a manual derailleur system. The gear hub selects
the gear automatically according to your speed. Fine adjust-
ments are made manually on the derailleur system. Because the
hub automatically shifts back when the rider comes to a stop,
starting up is noticeably easier.
eShift
Solutions for integrated gear shifting
The integrated electronic gear shifting solution for those who like to focus on what is essential in
eBiking – riding enjoyment. The innovative concept provides greater riding comfort, more safety,
and – due to a gear ratio that is always optimal – even more range. eShift is available in three variants
optimized for different riding styles.
eShift with Shimano Di2
Fast, sporty, efficient: eShift with Shimano Di2
shifts your pedelec like a sports car. Touching
the Shimano shift paddle is sufficient for quick
and dynamic gear shifting. In manual mode the
gearshift recommendation helps you to always
make optimal use of the battery. With the
Auto-Downshift function, the gear system auto-
matically switches to the defined starting
gear – increasing safety and riding comfort.
7
7
2
2
eShift with NuVinci Optimized™ Harmony H|Sync™
Manual electronic gear shifting is now possible in
nine pre-set speeds.
eShift with SRAM DD3 Pulse
Those who do not want to use automatic shifting can shift
the 3-speed hub electronically on the Bosch control unit.
eShift with Shimano Di2
Now with Auto-Downshift function. When the rider comes
to a stop, the gear shifting system automatically shifts to the
defined starting gear.
Auto-Downshift when stopping
with Shimano Di2
Riding with speed
Stop: eShift automatically
shifts down
Starting up in low gear

Lithium-ion battery
40-cell packs with the highest energy
density (190 Wh/kg) and the lowest
weight and volume.
New: PowerPack 500
25 % more range with additional
weight of just 4% compared to
PowerPack 400.
Reduced charging time
In approx. 4.5 hours, you can com-
pletely charge the PowerPack 500,
and you can charge it up to half in
approx. 2 hours.
Active Line 19 Active Line
18
Select the battery that suits you. Bosch PowerPacks for the Active Line are available with 300, 400, and now
also 500 Wh as a frame or rack battery. Common to all is their high energy density, exceptional mileage,
long service life, low weight, and easy handling.
Best in class: There’s nothing lighter
Bosch PowerPacks are the batteries with the best balance of
performance, size, and weight. How do you benefit? You get
a powerhouse that is so light that its weight is practically
negligible during riding.
Simply ingenious: The handling
Thanks to the ergonomically well-conceived handle and optimal
mount, the batteries can be easily inserted and removed. The
only thing easier is charging the PowerPacks directly on the
eBike.
High mileage and long life
The integrated Battery Management System (BMS) reliably
protects the battery from overcharging, undervoltage, over-
heating, and short circuit. A long service life with high mileage
is guaranteed.
PowerPacks
Your reliable energy source
Easy to store, optimally charged – anytime and
anywhere
Lithium-ion batteries have neither memory nor self-dis-
charge effects. This means the PowerPacks can also be
partially recharged at any time – without affecting the
service life.
PowerPack 400
Mounting type Frame battery Rack battery
Voltage 36 V 36 V
Capacity 11.0 Ah 11.0 Ah
Energy content 400 Wh 400 Wh
Weight 2.5 kg 2.6 kg
Size 325 × 92 × 90 mm 372 × 122 × 80 mm
PowerPack 500
Mounting type Frame battery Rack battery
Voltage 36 V 36 V
Capacity 13.4 Ah 13.4 Ah
Energy content 500 Wh 500 Wh
Weight 2.6 kg 2.7 kg
Size 325 × 92 × 90 mm 372 × 122 × 80 mm
PowerPack 300
Mounting type Frame battery Rack battery
Voltage 36 V 36 V
Capacity 8.2 Ah 8.2 Ah
Energy content 300 Wh 300 Wh
Weight 2.0 kg 2.4 kg
Size 325 × 92 × 82 mm 372 × 122 × 80 mm

Range of the
PowerPacks
Eco
Ideal conditions**
Flat terrain, approx. 15 km/h average speed, no headwind,
approx. 20°C ambient temperature, high-quality bike compo-
nents, tire tread and pressure with minimal rolling resistance,
experienced eBike rider (always shifts gears correctly), additional
weight (excluding bike weight) < 70 kg.
Favorable conditions**
Slightly hilly terrain, approx. 20 km/h average speed, slight headwind,
approx. 10 °C to 20 °C ambient temperature, medium-quality bike com-
ponents, tire tread and pressure with average rolling resistance, favorable
cadence, eBike rider shifts correctly most of the time, additional weight
(excluding bike weight) 70 kg to 80 kg.
Difficult conditions**
Terrain with long and steep inclines at 25 km/h average speed, possibly
strong headwind, < 10 °C ambient temperature, bicycle components with
relatively low efficiency, tire tread and pressure with increased rolling
resistance, unfavorable gear selection / cadence, additional weight (ex-
cluding bike weight) > 85 kg.
* Average of combined use of all four modes.
** The calculated ranges are typical values which can be reduced if any of the conditions
listed below worsen. The actual range of the eBikes is the responsibility of the eBike
manufacturer.
Turbo
Mix*
Eco
Tour
Sport
Cruise with PowerPack 300
0 20 40 60 80 100 120 140 160 180 200 220 240 km
180 200 220 240 km
Turbo
Mix*
Tour
Sport
Cruise with PowerPack 400
0 20 40 60 80 100 120 140 160
Turbo
Mix*
Eco
Tour
Sport
Cruise with PowerPack 500
0 20 40 60 80 100 120 140 160 180 200 220 240 km
Click here for the range
calculator:
www.bosch-ebike.com
You can find out everything worth
knowing about the PowerPack in
the eBike battery guide.

Active Line
22
Charger
Faster charging made easy
Bosch Chargers are compact, lightweight, and rugged. And
above all, really fast. To allow you to enjoy your eBike expe-
rience without interruption, you do not necessarily need
230 volts: While traveling you can charge your eBike with the
Travel Charger on the cigarette lighter of a car or motorhome.
Functional, rugged, and silent
An ergonomically shaped plug facilitates handling, and the very
compact dimensions make the unit easy to stow in your luggage.
The closed housing makes the Charger rugged and resistant to dirt.
When traveling: The Travel Charger
With the Travel Charger, you can charge your eBike on the
move – using the cigarette lighter or the 12 V power socket
of your car or motorhome. Clever: The device weighing barely
500 g has integrated discharge protection for the car battery.
Type Standard Charger
Charging current 4 A
Voltage range 230 V
Size 190 ×86 ×54 mm
Cable lengths AC input: approx. 1.5 m, DC output: approx. 1.0 m
Plug Country-specific power plug
Weight Approx. 800 grams
Compatibility Compatible with Active Line and Performance Line,
compatible with Classic+ Line via adapter plug
(optional part)
Charging time 300 Wh 50 % in approx. 1 h, 100 % in approx. 2.5 h
400 Wh 50 % in approx. 1.5 h, 100 % in approx. 3.5 h
500 Wh 50 % in approx. 2 h, 100 % in approx. 4.5 h
Doesn’t waste any time: The Bosch eBike Charger
An empty PowerPack 300 is fully charged within 2.5 hours, while a PowerPack
400 requires 3.5 hours for this. The new PowerPack 500 is fully charged
within 4.5 hours. Approx. 1 hour is required to charge the PowerPack 300 up
to half, 1.5 hours for the PowerPack 400. It takes approx. 2 hours to charge
the PowerPack 500 to 50%.
Compact and lightweight
The Bosch eBike Charger is only about as big as a water bottle and very
lightweight, at just under 800 grams.
Type Travel Charger
Charging current 2 A
Voltage range 12 V
Size 190 ×86 ×54 mm
Cable lengths DC input: approx. 1.0 m, DC output: approx. 1.0 m
Plug 12 V cigarette lighter + 12 V on-board power socket
(via adapter cap)
Weight Approx. 500 grams
Compatibility Compatible with Active Line and Performance Line,
compatible with Classic+ Line via adapter plug
(optional part)
Charging time 300 Wh 50 % in approx. 2.1 h, 100 % in approx. 5 h
400 Wh 50 % in approx. 2.8 h, 100 % in approx. 6.5 h
500 Wh 50 % in approx. 3.5 h, 100 % in approx. 7.5 h
Performance Line
More drive.
More passion.
More character.

Robert Bosch GmbH
Bosch eBike Systems
Postfach 1342
72703 Reutlingen
Germany
www.bosch-ebike.com
www.facebook.com/boschebikesystems
August 2015 / EN Subject to change