Bosch PowerTube 750 Series Use and care manual

Battery Guide 2022
Bosch eBike Systems |EN
bosch-ebike.com
THE eBIKE
BATTERY GUIDE

e
L+
–
+
Costs
The cost of filling the
tank of a passenger car
is approximately $38.28;
the full charge of an
eBike battery costs only
6 cents*. Thus, 638
eBike battery charges
cost as much as filling
the tank once.
PowerPacks and PowerTubes are the energy sources for Bosch eBike
systems. Useful tips to determine and optimize range, efficiency and
service life are provided on the following pages, as well as pointers for
safety and handling.
Contents
* All totals rounded to nearest cent. U.S. estimated national average gasoline price: $3.19/Gal. U.S.
estimated average cost of energy: $0.11/kWh. Average sedan fuel tank size: 12 gallons. Thus, it only
costs 6 cents to charge a battery with 500 Wh. Sources: ADAC battery test; Federal Environment
Agency; Lithium-ion battery handbook; U.S. Dept. of Energy; EIA.gov
Areas of application
Lithium-ion batteries are
used in smartphones,
cordless screwdrivers and
electric cars, as well as
eBikes.
Service life
In its service life, an
eBike battery can take
you an equivalent
distance up to 1 1/2
times around
the world.
Recycling
Some dealers will accept
used eBike batteries
and recycle them free of
charge.
Depending on the
recycling process for a
specific region, more than
80% of
the precious raw
materials can be recovered
and recycled.
How it works
A lithium-ion battery generates
electromotive force by displacing
lithium ions. While the eBike is in
motion, the electrodes move from the
negative anode via the drive unit to
the positive cathode. The lithium
ions provide balance. The reverse
process takes place when the
battery is charged.
Engineering
A common eBike battery
contains 40-60 lithium-ion
cells. In terms of
cell volume, 130 eBikes
correspond to an average
of about one electric car.
Lithium-ion batteries
Everything you need to know about eBike batteries
4 – Bosch batteries and chargers
12
– Range
20
– Handling, care and transport
28
– Replace or repair?
30
– Recycling
32
– Safety
34
– Questions & Answers
35
– Test bench measurement R200
322

BOSCH
BATTERIES AND
CHARGERS
More energy for traveling
Bosch batteries provide the energy
source for eBikes. They combine impres-
sive range, a long service life and low
weight at approximately 5.5 to 9.7 lbs.
(2.5 to 4.4 kg.), with ergonomic design
and convenient handling. The high-qual-
ity lithium-ion batteries are equipped
with a Battery Management System
(BMS). It continuously monitors the bat-
tery, detects potential sources of error
and protects the cells as much as possi-
ble from overload.
Benefits
Reasons to choose Bosch eBike batteries
Efficient, durable, state-of-the-art technology: There are good reasons
why Bosch eBike batteries are some of the most popular on the market.
▶ No memory effect
Bosch batteries with lithium-ion cells
can be charged quickly and at any time
irrespective of their charge level. Inter-
ruptions of the charging process do not
harm the battery. Complete discharge
is not required.
▶ Low self-discharge
Even after long periods of storage, e.g.
during winter months, the battery can
be used without recharging. For longer
storage, a charge status of approxi-
mately 30-60% is recommended as is
charging after a longer period in storage.
▶ Long service life
Bosch batteries are designed for lots of
trips, miles and years of service. The
intelligent, electronic Bosch Battery
Management System (BMS) continu-
ously protects against excessive operat-
ing temperatures, overloading and deep
discharge. The BMS checks every cell,
extending the life of the battery.
▶ Rapid charging
Bosch chargers are available in a range of
different sizes and performance levels,
and enable rapid charging according to
your needs.
▶ Easy to remove
Bosch batteries can be removed with a
few simple hand movements. The battery
can therefore be charged and stored
away from the eBike. This simplifies use,
for example, when using in the winter.
As the battery delivers less power at
lower temperatures, in winter it should
be stored at room temperature until
shortly before a ride.
▶ Extremely efficient
Bosch batteries represent an economical
drive solution. It costs no more than
6cents to fully charge a PowerPack500
(based on a green electricity rate of
11cents per kWh).
▶ Competent service
Bosch batteries are well-protected and
require little maintenance. Should sup-
port be required, a competent service
team is available to provide assistance.
▶ Safety matters
Our complete eBike system is certified
to UL 2849 safety standard and meets
all rigorous requirements of this safety
standard for peace of mind.
544

* Only available with components of the smart system.
** DualBattery is not available in combination with PowerTube 400.
*** Advertised battery capacity is an approximation. Due to many different factors, the measured
capacity of the battery may vary slightly from the advertised battery capacity.
Bosch batteries
Powerful in every design
PowerPack Frame
Sporty and dynamic: When used as a
frame battery, the PowerPack 400 or 500
sits close to the center of gravity of the
bike to ensure optimal weight distribution.
PowerPack Rack
Comfortably convenient: On step-through
models, the rack battery frees up space
and allows the rider to mount and dis-
mount safely. Available in two variants:
400 or 500.
PowerTube
Stylishly elegant: There are two versions
of the PowerTube: horizontal or vertical.
Both are installed by the manufacturer
according to the eBike's specific design.
They are available in 400, 500 or 625
versions. There is a PowerTube with
750 Wh for the smart system.
DualBattery
Double the power: Combining two Bosch
eBike batteries provides energy content up
to 1,250 Wh.**
PowerTube 400
PowerTube 500
PowerTube 625
PowerTube 750*
2 x PowerPack
2 x PowerTube
PowerPack + PowerTube
PowerPack 400
PowerPack 500
PowerPack 400
PowerPack 500
Frame battery Rack battery
DualBatteryIntegrated battery
76

Compact Charger
Faithful companion: The Compact Charger is ideal
for all cyclists who are constantly on the move. It
weighs less than 600 g and is 40% smaller than the
Standard Charger—small enough to fit into many
saddlebags.
Standard Charger
All-rounder: The robust and functional Standard
Charger features a unique balance between per-
formance, size and weight. It is suitable for every
possible use.
4A Charger
Compact: As a small and lightweight charger, the
4A Charger is ideal when you are on the go. It charges
the PowerTube 750* in a short period of time.
Bosch chargers
Reliable power sources
Bosch chargers are handy, lightweight and robust. Wherever your journey
may take you: The 2A Compact Charger, the 4A Standard Charger, and
the 4A Charger for the smart system, supply Bosch eBikes with power
quickly and reliably. All Bosch chargers work
quietly and are suitable for
all battery types. They also feature a practical
velcro fastener for easily
stowing the cable.
* Only available with components of the smart system.
988

Charging times
As fast as you like
Charging times depend on the capacities of the batteries and the type of
charger. The graphics below show how quickly various batteries can be
charged with a particular charger.
* DualBattery is not available in combination with PowerTube 400.
** Only available with components of the smart system.
Bosch battery
PowerPack 400
PowerTube 400
PowerPack 500
PowerTube 500 PowerTube 625
Compact Charger
approx. 6.5 h
approx. 2.5 h
approx. 7.5 h
approx. 3.5 h
approx. 8.8 h
approx. 4.2 h
Standard Charger
approx. 3.5 h
approx. 1.5 h
approx. 4.5 h
approx. 2 h
approx. 4.9 h
approx. 2.1 h
50% charge 100% charge
Bosch battery
DualBattery 1250*PowerTube 750**
approx. 17.6 h
approx. 8.4 h
4ACharger (smart system)
approx. 6 h
approx. 2.3 h
approx. 9.8 h
approx. 4.2 h
1110

The range of Bosch batteries depends on numerous factors. Range is
influenced by the rider and the chosen support mode, as well as the
drive unit or battery installed in the eBike. Environmental factors such
as temperature, wind conditions and riding surface also play a key role
in how far you can get on a battery charge.
Our range calculator tool makes it possible to estimate typical range
under various parameters. This online tool will show important information
regarding battery range in a visual, easy-to-understand way.
The Bosch Range Calculator
Easier planning
This is a common question for many
riders. There is a vast number of factors
that have an effect on the range. Some-
times a single battery charge will take
you less than 12 miles (20 km), while at
other times it
will take you much farther
than 62 miles (100 km). Following a
few tips can help maximize the range
of the battery.
RANGE
What is the range of a single
battery charge?
Calculate the range for yourself:
bosch-ebike.com/range
131212

The range graphs show how far the product lines can
travel with different batteries under favorable condi-
tions (average value of all
support levels). The range will
be reduced
in difficult conditions.
Product line ranges
Extending your range
Favorable conditions* Difficult conditions*
Cadence 50–70 rpm 70–90 rpm
Total weight
(Overall weight
consisting of rider including
eBike and cargo)
231 lbs. (105 kg.)
330 lbs. (150 kg.) for Cargo
Line
253 lbs. (115 kg.)
375 lbs. (170 kg.) for Cargo
Line
Rider type/
rider performance
Average Average
Bosch eBike system Drive Unit, battery and
Intuvia
Drive Unit, battery and
Intuvia
Shifting system Derailleur system Derailleur system
Tire tread City bike tires MTB tires
Bicycle type City MTB
Terrain type Hilly Low mountain ranges
Surface Mainly gravel and paved
forest paths
Dirt tracks and
off-road trails
(e.g. trail biking)
Starting frequency Bike ride with occasional
standing starts
Bike ride with regular
standing starts
Wind conditions Slight wind Moderate wind
Rider
eBike
Environment
Range of the various Bosch batteries in mixed modes*
* Average of combined use of all modes and favorable conditions.
** These drive units are not available in Canada.
Bosch eBike Systems
Model year 2021
Estimated range
of Bosch batteries (mixed modes)*
Active Line Plus
Cargo Line
Performance Line
Performance Line Speed
Performance Line Sport
Performance Line CX
Active Line
* Average of combined use of all four modes and favorable conditions.
**The ranges are typical values of the new batteries, which may decrease if one of the conditions listed above deteriorates.
Favorable conditions**
Cadence Rider weight (overall
weight consisting of
rider incl. eBike and
luggage)
Rider type/
rider performance
Bosch
eBike system
Shifting
system
Tire tread Wheel type Terrain type Surface Starting up
frequency
Wind conditions
50–70 rpm 231 lbs
331 lbs Cargo Line
Average Drive unit,
battery and
Intuvia
Derailleur
system
Trekking tires Touring bike Hilly Mainly gravel
and paved
forest paths
Bike ride with
occasional standing
starts
Slight wind
Rider eBike Environment
Batteries
Batteries
Batteries
Batteries
Batteries
Batteries
Batteries
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
625
625
625
625
625
625
625
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
500
500
500
500
500
500
500
400
400
400
400
400
400
400
Cargo Line Speed
Batteries
625
1250
DualBattery
500 400
Bosch eBike Systems
Model year 2021
Estimated range
of Bosch batteries (mixed modes)*
Active Line Plus
Cargo Line
Performance Line
Performance Line Speed
Performance Line Sport
Performance Line CX
Active Line
* Average of combined use of all four modes and favorable conditions.
**The ranges are typical values of the new batteries, which may decrease if one of the conditions listed above deteriorates.
Favorable conditions**
Cadence Rider weight (overall
weight consisting of
rider incl. eBike and
luggage)
Rider type/
rider performance
Bosch
eBike system
Shifting
system
Tire tread Wheel type Terrain type Surface Starting up
frequency
Wind conditions
50–70 rpm 231 lbs
331 lbs Cargo Line
Average Drive unit,
battery and
Intuvia
Derailleur
system
Trekking tires Touring bike Hilly Mainly gravel
and paved
forest paths
Bike ride with
occasional standing
starts
Slight wind
Rider eBike Environment
Batteries
Batteries
Batteries
Batteries
Batteries
Batteries
Batteries
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
625
625
625
625
625
625
625
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
500
500
500
500
500
500
500
400
400
400
400
400
400
400
Cargo Line Speed
Batteries
625
1250
DualBattery
500 400
* These drive units are not available in Canada.
Active Line Plus Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Cargo Line Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500
400
Cargo Line Speed*
0
Battery Size (Wh)
2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500
400
Performance Line Cruise Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500
400
Performance Line Sport*
0
Battery Size (Wh)
2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Performance Line Speed* Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Performance Line CX
0
(80 km) (160 km)
Battery Size (Wh)
2010 4030 6050 8070 10090 120 miles110
625
1250
500
400
Active Line
Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Bosch eBike Systems
Model year 2021
Estimated range
of Bosch batteries (mixed modes)*
Active Line Plus
Cargo Line
Performance Line
Performance Line Speed
Performance Line Sport
Performance Line CX
Active Line
* Average of combined use of all four modes and favorable conditions.
**The ranges are typical values of the new batteries, which may decrease if one of the conditions listed above deteriorates.
Favorable conditions**
Cadence Rider weight (overall
weight consisting of
rider incl. eBike and
luggage)
Rider type/
rider performance
Bosch
eBike system
Shifting
system
Tire tread Wheel type Terrain type Surface Starting up
frequency
Wind conditions
50–70 rpm 231 lbs
331 lbs Cargo Line
Average Drive unit,
battery and
Intuvia
Derailleur
system
Trekking tires Touring bike Hilly Mainly gravel
and paved
forest paths
Bike ride with
occasional standing
starts
Slight wind
Rider eBike Environment
Batteries
Batteries
Batteries
Batteries
Batteries
Batteries
Batteries
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
625
625
625
625
625
625
625
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
500
500
500
500
500
500
500
400
400
400
400
400
400
400
Cargo Line Speed
Batteries
625
1250
DualBattery
500 400
Bosch eBike Systems
Model year 2021
Estimated range
of Bosch batteries (mixed modes)*
Active Line Plus
Cargo Line
Performance Line
Performance Line Speed
Performance Line Sport
Performance Line CX
Active Line
* Average of combined use of all four modes and favorable conditions.
**The ranges are typical values of the new batteries, which may decrease if one of the conditions listed above deteriorates.
Favorable conditions**
Cadence Rider weight (overall
weight consisting of
rider incl. eBike and
luggage)
Rider type/
rider performance
Bosch
eBike system
Shifting
system
Tire tread Wheel type Terrain type Surface Starting up
frequency
Wind conditions
50–70 rpm 231 lbs
331 lbs Cargo Line
Average Drive unit,
battery and
Intuvia
Derailleur
system
Trekking tires Touring bike Hilly Mainly gravel
and paved
forest paths
Bike ride with
occasional standing
starts
Slight wind
Rider eBike Environment
Batteries
Batteries
Batteries
Batteries
Batteries
Batteries
Batteries
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
625
625
625
625
625
625
625
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
500
500
500
500
500
500
500
400
400
400
400
400
400
400
Cargo Line Speed
Batteries
625
1250
DualBattery
500 400
* These drive units are not available in Canada.
Active Line Plus Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Cargo Line Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Cargo Line Speed*
0
Battery Size (Wh)
2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Performance Line Cruise Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Performance Line Sport*
0
Battery Size (Wh)
2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Performance Line Speed* Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Performance Line CX
0
(80 km) (160 km)
Battery Size (Wh)
2010 4030 6050 8070 10090 120 miles110
625
1250
500 400
Active Line
Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Bosch eBike Systems
Model year 2021
Estimated range
of Bosch batteries (mixed modes)*
Active Line Plus
Cargo Line
Performance Line
Performance Line Speed
Performance Line Sport
Performance Line CX
Active Line
* Average of combined use of all four modes and favorable conditions.
**The ranges are typical values of the new batteries, which may decrease if one of the conditions listed above deteriorates.
Favorable conditions**
Cadence Rider weight (overall
weight consisting of
rider incl. eBike and
luggage)
Rider type/
rider performance
Bosch
eBike system
Shifting
system
Tire tread Wheel type Terrain type Surface Starting up
frequency
Wind conditions
50–70 rpm 231 lbs
331 lbs Cargo Line
Average Drive unit,
battery and
Intuvia
Derailleur
system
Trekking tires Touring bike Hilly Mainly gravel
and paved
forest paths
Bike ride with
occasional standing
starts
Slight wind
Rider eBike Environment
Batteries
Batteries
Batteries
Batteries
Batteries
Batteries
Batteries
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
625
625
625
625
625
625
625
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
500
500
500
500
500
500
500
400
400
400
400
400
400
400
Cargo Line Speed
Batteries
625
1250
DualBattery
500 400
Bosch eBike Systems
Model year 2021
Estimated range
of Bosch batteries (mixed modes)*
Active Line Plus
Cargo Line
Performance Line
Performance Line Speed
Performance Line Sport
Performance Line CX
Active Line
* Average of combined use of all four modes and favorable conditions.
**The ranges are typical values of the new batteries, which may decrease if one of the conditions listed above deteriorates.
Favorable conditions**
Cadence Rider weight (overall
weight consisting of
rider incl. eBike and
luggage)
Rider type/
rider performance
Bosch
eBike system
Shifting
system
Tire tread Wheel type Terrain type Surface Starting up
frequency
Wind conditions
50–70 rpm 231 lbs
331 lbs Cargo Line
Average Drive unit,
battery and
Intuvia
Derailleur
system
Trekking tires Touring bike Hilly Mainly gravel
and paved
forest paths
Bike ride with
occasional standing
starts
Slight wind
Rider eBike Environment
Batteries
Batteries
Batteries
Batteries
Batteries
Batteries
Batteries
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
625
625
625
625
625
625
625
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
500
500
500
500
500
500
500
400
400
400
400
400
400
400
Cargo Line Speed
Batteries
625
1250
DualBattery
500 400
* These drive units are not available in Canada.
Active Line Plus Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Cargo Line Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Cargo Line Speed*
0
Battery Size (Wh)
2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Performance Line Cruise Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Performance Line Sport*
0
Battery Size (Wh)
2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Performance Line Speed* Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Performance Line CX
0
(80 km) (160 km)
Battery Size (Wh)
2010 4030 6050 8070 10090 120 miles110
625
1250
500 400
Active Line
Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Performance Line
Performance Line Sport**
Performance Line Speed**
* The ranges are typical values of new rechargeable batteries, which may
vary if one of the conditions listed above changes.
Bosch eBike Systems
Model year 2021
Estimated range
of Bosch batteries (mixed modes)*
Active Line Plus
Cargo Line
Performance Line
Performance Line Speed
Performance Line Sport
Performance Line CX
Active Line
* Average of combined use of all four modes and favorable conditions.
**The ranges are typical values of the new batteries, which may decrease if one of the conditions listed above deteriorates.
Favorable conditions**
Cadence Rider weight (overall
weight consisting of
rider incl. eBike and
luggage)
Rider type/
rider performance
Bosch
eBike system
Shifting
system
Tire tread Wheel type Terrain type Surface Starting up
frequency
Wind conditions
50–70 rpm 231 lbs
331 lbs Cargo Line
Average Drive unit,
battery and
Intuvia
Derailleur
system
Trekking tires Touring bike Hilly Mainly gravel
and paved
forest paths
Bike ride with
occasional standing
starts
Slight wind
Rider eBike Environment
Batteries
Batteries
Batteries
Batteries
Batteries
Batteries
Batteries
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
625
625
625
625
625
625
625
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
500
500
500
500
500
500
500
400
400
400
400
400
400
400
Cargo Line Speed
Batteries
625
1250
DualBattery
500 400
Bosch eBike Systems
Model year 2021
Estimated range
of Bosch batteries (mixed modes)*
Active Line Plus
Cargo Line
Performance Line
Performance Line Speed
Performance Line Sport
Performance Line CX
Active Line
* Average of combined use of all four modes and favorable conditions.
**The ranges are typical values of the new batteries, which may decrease if one of the conditions listed above deteriorates.
Favorable conditions**
Cadence Rider weight (overall
weight consisting of
rider incl. eBike and
luggage)
Rider type/
rider performance
Bosch
eBike system
Shifting
system
Tire tread Wheel type Terrain type Surface Starting up
frequency
Wind conditions
50–70 rpm 231 lbs
331 lbs Cargo Line
Average Drive unit,
battery and
Intuvia
Derailleur
system
Trekking tires Touring bike Hilly Mainly gravel
and paved
forest paths
Bike ride with
occasional standing
starts
Slight wind
Rider eBike Environment
Batteries
Batteries
Batteries
Batteries
Batteries
Batteries
Batteries
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
25 50 75 100 1250 150 miles
625
625
625
625
625
625
625
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
1250
DualBattery
500
500
500
500
500
500
500
400
400
400
400
400
400
400
Cargo Line Speed
Batteries
625
1250
DualBattery
500 400
* These drive units are not available in Canada.
Active Line Plus Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Cargo Line Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500
400
Cargo Line Speed*
0
Battery Size (Wh)
2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Performance Line Cruise Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Performance Line Sport*
0
Battery Size (Wh)
2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Performance Line Speed* Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500 400
Performance Line CX
0
(80 km) (160 km)
Battery Size (Wh)
2010 4030 6050 8070 10090 120 miles110
625
1250
500 400
Active Line
Battery Size (Wh)
0 2010 4030 6050
(80 km) (160 km)
8070 10090 120 miles110
625
1250
500
400
Battery Size (Wh)
750
(160 km)
0 10 20 30 40 50 60 70 80 90 100 110 120 miles
(80 km)
Performance Line CX
1514

Overview of riding modes
The range of the Bosch eBike system is largely dependent on the level
of support. A choice of different riding modes is available. The graphic
shows their effect on the range in favorable (light blue) and difficult
(dark blue) conditions.
Range and riding modes
How they relate
Eco Efficient support for maximum range
Tour Consistent support for longer rides
Tour +* Continuous support for energy-saving rides
Sport Powerful support for all types of riding
eMTB** Dynamic support for a natural feel
Turbo Maximum support for challenging rides
*Contact your local dealer to find out whether your eBike can be updated with Tour+ mode.
**The eMTB mode replaces the Sport mode on eBikes with the Performance Line and the
Performance Line CX drive units.
Range based on the example of the Active Line with PowerPack 500
or PowerTube 500 taking account different riding modes.
* The ranges are typical values of the new rechargeable batteries, which may vary
if one of the conditions listed above changes.
Difficult conditions* Favorable conditions*
For a definition of conditions, see p. 14.
10 20 30
56 km 113 km
40 50 60 700 100 miles
Turbo
Sport
Tour
Eco
Mix*
80 90
1716 17

▶ Cadence
Cadences above 50 revolutions per
minute optimize the efficiency of the
drive unit. Very slow pedaling, espe-
cially in high gears, on the other hand,
costs the battery more energy.
▶ Weight
Weight should be minimized by keeping
the total weight of the bicycle and cargo
from being unnecessarily high.
▶ Starting & braking
As with a car, frequent starting and
stopping is less economical than long
distances at almost constant speed.
▶ Shifting system
Correct gear shifting also makes eBiking
more efficient. It is best to start off and
tackle inclines in a low gear, then shift
to a higher gear in accordance with the
terrain and speed. The computer pro-
vides shift recommendations.*
▶ Tire pressure
Rolling resistance can be minimized with
the right tire pressure. Tip: To maximize
the range, inflate the tires to
the maxi-
mum permissible pressure.
▶ Motor performance indicator
Use the motor performance indicator
on the Intuvia, Kiox and Nyon computers
to monitor the motor and adapt your
riding style accordingly. A longer bar
indicates higher power consumption.
▶ Battery & temperature
With decreasing ambient temperature,
the
performance and range of a battery
is temporarily reduced, as the electrical
resistance increases. Therefore, in cold
temperatures, a temporary decrease in
the usual range is to be expected.
Tips & tricks
To maximize range
* Except Purion, SmartphoneHub, and Kiox 300.
1918 19

Charging
At home and on the road
Charging on the eBike
PowerPacks and PowerTubes are easy to charge directly on the eBike
itself. Simply insert the plug on the charger into the socket in the battery
mount and insert the power plug into the wall outlet. The batteries
should be charged at room temperature in a dry location where a smoke
detector is installed.
Charging a removed battery
If the battery cannot be charged directly on the eBike, the PowerPack
and PowerTube can be easily removed.
HANDLING,
CARE AND
TRANSPORT
High-tech can still be simple
Batteries are highly complex components
and some simple rules and instructions
should be followed for handling, caring
for and transporting them. This makes it
easy to handle batteries and also has a
positive effect on their service life.
212020

1 2
3 4
5
Open the frame cover, if applicable. When the battery is unlocked using a key
(depending on the manufacturer), it auto-
matically drops into the restraint support.
Push the top of the battery to detach it
from the restraint support. The battery
then lowers into your hand.
Remove the battery from the frame.
Inserting the battery
The battery is inserted by following
steps 1 to 5 in the reverse order.
Depending on the manufacturer, the
key must be turned (5) to insert the
battery. Finally, the battery must be
checked for a secure fit.
Removal and installation
A few simple steps
Bosch batteries are seated securely in their mounts, even when riding
over rough terrain. They can, however, be easily removed for storage or
charging purposes: Simply open the lock and remove the battery from
the mount.
Bosch batteries also can be reinserted just as easily and intuitively.
Their low weight, handy dimensions and the precise fit of battery and
mount make this possible. The battery engages positively in its holder
and thus sits firmly in the frame or on the eBike.
▶ PowerPacks
All PowerPacks are equipped with an
ergonomic handle, which enables the
battery
to be conveniently inserted,
removed, carried and charged.
▶ PowerTube
A convenient function means that the
PowerTube moves approximately .78 in
(2 cm) out of the frame when unlocked,
making it easier to handle. In addition, a
safety mechanism prevents the battery
from falling out of its mount. The bat-
tery is also protected by the frame.
Removing the battery
2322

Care
How to increase the service life of the battery
Cleaning & care
A damp cloth is recommended for cleaning
the battery. Plug connections should be
cleaned occasionally and lightly greased.
The battery should be removed before clean-
ing the eBike. To protect the electronic com-
ponents, the battery must never be cleaned
with a direct jet of water or high pressure hose.
Storage during winter
Store the battery in a dry location at room
temperature. Fully charging or fully discharging
results in higher loading of the battery. The
ideal charge status for lengthy periods of
storage is
approximately 30-60% or two to
three LEDs on the battery indicator.
Winter use
During winter use, particularly below 32°F (0°C), charge and store
the
battery at room temperature and insert it in the eBike immediately before
a ride. For longer journeys in cold conditions,
use thermal protective covers.
The Bosch battery is an important component of the eBike. With the
correct handling and care, its service life can be lengthened.
Service life
Tips for maximizing your charge
The service life of Bosch batteries is influenced mainly by the type and
duration of use. Like every lithium-ion battery, a Bosch battery also ages
over time, even if you do not use it. Over time, it loses capacity.
Factors that shorten the
service life:
▶ Heavy-duty use
▶ Storage at more than 86°F (30°C)
ambient temperature
▶ Prolonged storage in below 32°F (0°C)
charged or fully discharged state
▶ Exposure to direct sunlight
▶ Regular complete discharge
of the battery
Factors that extend the
service life:
▶ Low load
▶ Storage at temperatures
between 32°F (0°C) and 68°F (20°C)
▶ Storage at approximately 30-60%
charge status
▶ Storage in a shaded or cool location
The figure shows typical curves for energy content
over usage duration and frequency.
Energy content Wh
Age/charging cycles
2524

Transport
Safety while on the go
Lithium-ion batteries store large amounts of energy. That's why some
precautions are necessary during transport. Ideally, the battery should
be set to approx. 30 % discharged and only fully charged again at the
destination.
By car
If the eBike is being transported with a bike rack, remove the
battery first and place it in a safe location inside the car.
By plane
The International Air Transport Association has forbidden the
transportation of eBike batteries on passenger planes. Renting a
Bosch eBike battery at your destination is recommended. C
heck
in advance whether the airline will transport eBikes without
a battery.
By train
In trains with bicycle compartments, most eBikes may be trans-
ported without any hassle. eBikes often need an extra ticket and
a reservation. The eBike
battery must remain permanently
installed during the journey and
must not be charged. Contact the
respective service provider for precise information on the trans-
port conditions. In some cases, it is not possible to take eBikes
on all routes.
On commuter services and long-distance buses
On commuter services—light rail services, for example— it is often
permissible to take a bike on board at regional off-peak
times,
provided you have purchased a bicycle ticket. It is advisable
to
obtain information from the relevant transport authority before
traveling. The policies for transporting pedelecs on long-distance
buses varies from company to company. In this case, you should
also inquire in good time before starting your journey.
A eBike battery is a hazardous item. When shipping,
the special regulations of the hazardous goods law apply.
It is therefore practically impossible for private individuals to ship
a battery.
272626

REPLACE
OR REPAIR?
When the battery starts to run down
Risks attached to repairing or refreshing Bosch eBike batteries
Lithium-ion batteries are complex, finely tuned systems with a high
energy content. In the case of repair or “refreshing,” i.e. when replacing
originally installed cells with supposedly identical individual cells as part
of a repair, correct function and optimum interaction with the Battery
Management System can no longer be guaranteed. There is a risk that
the Bosch eBike battery pack, once opened, will catch fire due to a short
circuit as a result of improper repair. After it is broken, the seal of the hous-
ing can no longer be guaranteed. Ingress of water or dust can damage
the monitoring electronics or the cells themselves. Here, too, there is a
risk that the Bosch eBike battery could catch fire due to short circuiting.
These dangers also exist at a later point in time if an eBike battery, once
opened, is used again.
In addition, there is a safety risk, and opening or modifying the battery
may void any warranty or guarantee claims. Furthermore, approval for
transport and safety of the battery, which has been carefully developed
and tested as a type according to international regulations, will be
rendered void.
For safety reasons, batteries must pass an elaborate series of tests in
which the test specimens are pushed to their load limits. Only then may
the batteries be brought to market. These series tests are not feasible
for an individual repaired battery due to the number of test samples
required. All of this can have safety-relevant consequences.
eBike batteries are wearing parts and all
lithium-ion batteries lose capacity over
time. For safety reasons, faulty, old or
“worn-out” batteries should not be
repaired or refreshed, but should be recy-
cled in the appropriate manner.
For safety reasons, Bosch strongly advises against having
batteries repaired. In such cases, it is necessary to replace
the entire product.
292828

Recycling
Once a battery has reached the end of its lifetime, it must be disposed
of appropriately. Bosch urges eBike users to take defective or disused
batteries to their local dealer, who can ensure they are disposed in the
appropriate manner. Appropriate recycling practices save resources,
and valuable raw materials are returned to the materials cycle.
Responsibilities
Responsibility for recycling lies with the battery manufacturer. As
soon as the eBike crosses a national border, however, the importer (in
countries
outside of Germany, this means the bicycle manufacturer or
bicycle
retailer) automatically becomes the manufacturer. Because of
this, Bosch
eBike Systems can only provide a direct solution for battery
recycling in Germany. We support eBike manufacturers in the other
countries as best we can.
Recycling efficiency
Bosch eBike Systems supports new and sustainable recycling methods.
The efficiency of recovery depends on the recycling process. In the
recycling processes used by the German GRS industry solution, many
valuable raw materials are recovered to more than 80% and can be
reused for new products. As a result, these recycling processes are
considered to be very environmentally friendly.
Second use
Our batteries are specially designed and certified for use with eBikes.
We cannot guarantee reliable operation in other application areas.
RECYCLING
Sustainable use of raw materials
The CO₂ footprint of an eBike is largely
determined by the production, use and
recycling of the battery. The longer an
eBike is used and the more trips by other
means of transport it replaces, the better
for the environment. To ensure that valuable
raw materials can be reused at the end of
their lifetime, the battery must be properly
recycled.
More on sustainability:
bosch-ebike.com/sustainability
313030

▶ Double the protection
Each individual cell in a Bosch battery
is protected by a rugged steel cup and
held in a plastic or aluminium housing.
This housing must not be opened. Direct
impact, major shocks, dropping and
excessive heat (including unnecessary
direct sunlight) must also be avoided
at all costs, as this could damage the
battery cells and cause flammable
contents to leak.
▶ Safe charging
In conjunction with the Battery Manage-
ment System integrated within the bat-
tery, Bosch chargers protect the battery
against overload during charging, as
well as damage caused by extreme
overcharging and short circuits. Bosch
batteries are to be charged exclusively
with authentic Bosch chargers because
these are designed exclusively for eBikes
with Bosch drives and the components
ensure a perfectly coordinated charging
and discharging process. Batteries
must only be charged in a dry state and
must not be charged in the vicinity of
heat sources or flammable materials.
We recommend storage in dry, well-
ventilated and uninhabited rooms with
smoke detectors that are not designated
for use in escape routes. After charging,
batteries and chargers should be dis-
connected from the power supply.
▶ Storage
Excessive heat and direct sunlight must
be avoided. Bosch batteries and chargers
must not be stored in the vicinity of
heat sources or flammable materials.
We recommend removing the battery
from the eBike for storage purposes
and keeping it in well-ventilated rooms
fitted with smoke detectors. Dry loca-
tions with an ambient temperature of
approximately 68°F (20°C) are the most
suitable. Bosch batteries must not be
stored at below 50°F (10°C) or above
104°F (40°C).
▶ Inspection
Using the Bosch DiagnosticTool, the
bicycle dealer can check the status of
the eBike, especially the battery, and
determine the number of completed
charging cycles. The CapacityTester
can also be used to determine the
current energy content of the battery.
▶ Cleaning
Cleaning with a damp cloth is recom-
mended. To protect the electronic
components, the batteries must never
be cleaned with a direct jet of water
or high pressure hose.
▶ Disposal
Used batteries must be disposed of
properly at the end of their service life.
Some bicycle dealers will accept the
return of used or defective batteries
free of charge and take care of their
proper disposal. eBike batteries do not
belong in the household waste or in
ordinary battery collection containers.
SAFETY
Safe handling of batteries
Bosch batteries are lithium-ion cells, which are developed and manu-
factured to the state of the art. In their charged state, these batteries
have a high energy content. The constituents of lithium-ion cells are
flammable under certain conditions. The operating manual contains
instructions on safe handling.
Bosch eBike batteries must never be opened, not even if
they are being repaired. Opening the battery always means
interfering with its certified condition and entails safety risks.
Further important information about safety risks and risks from
battery repairs can be found on Pages 28 and 29.
3332

▶ What should I do if water gets
into the battery mount?
The mount is designed in such a way
that water can drain off and the contacts
can dry. To ensure that this happens,
the mount and plug area should be kept
clean. The contacts are supplied with
a coating which protects the surface
against corrosion and wear. Terminal
greases or technical Vaseline may also
be used to maintain the contacts if
required.
▶ What happens to defective
batteries?
Heavily damaged batteries should not be
touched with bare hands as electrolyte
may leak out, causing skin irritation.
Damaged batteries are best stored in a
safe place outdoors with the connection
contacts taped over before being taken
to the dealer for disposal.
▶ Can I use replacement batteries
from other manufacturers?
Original Bosch spare parts are the only
way to guarantee your safety. Bosch
eBike Systems components are precisely
matched and certified as a complete
system. They offer the highest level of
reliability and efficiency.
▶ Are chargers from other manu-
facturers safe to use?
Bosch chargers are adapted specifically
to the Bosch eBike system and have
the correct software for charging and
managing Bosch batteries optimally.
Using a different charger may reduce
the service life of the battery or cause
other damage or malfunctions in the
eBike system.
▶ I have found a used battery for
the Bosch eBike system online.
Can I use it?
When purchasing used batteries,
always make sure that they have not
been damaged by their previous owner.
Damaged or repaired batteries are
offered online from time to time, but
these may pose a possible high safety
risk and can lead to dangerous mal-
functions. Sometimes illegal, e. g. sto-
len goods, also are sold online. If appli-
cable, ownership of such goods cannot
be acquired legally in accordance with
§935 BGB [Bürgerliches Gesetzbuch,
German civil code].
In order to be able to measure the range of eBikes in a
standardized way for comparison purposes, Bosch eBike
Systems, working in cooperation with ZIV (Germany's
bicycle industry association) and other companies from the bicycle
industry, has developed a standardized range test, R200. This will
enable manufacturers, dealers and customers to compare the range
of different eBikes on an objective basis.
The same conditions for transparent values
Previous test results for eBike range depended heavily on the rider
and the external conditions (total weight, tires, air pressure, surface,
weather, etc.). The R200 measurement method compares eBike perfor-
mance with a uniform support factor of 200% (hence the name, R200).
This means that the tested drive system supports an average rider
performance of 70 watts with 140 watts, which corresponds to a medium-
to-high-support
factor.
R200 provides practical
comparison
The result of the test is a specific
indication of how many miles an
eBike will cover under these
standard conditions. Manufac-
turers need, however, to test
each
model individually using the
R200
method. The operator sim-
ply enters the values from the
list of requirements.
QUESTIONS & ANSWERS
Everything you need to know about batteries
TEST BENCH MEASUREMENT
R200
Making battery performance comparable
3534 35

4054289006686
August 2021 | EN Subject to change
Connect with us:
bosch-ebike.com
/BoscheBikes
/boschebikesystems.us
/BoscheBikeUS
Robert Bosch LLC
Bosch eBike Systems
27211 Burbank
Foothill Ranch, CA 92610
USA