Intuvia - Bike BOSCH - Free user manual and instructions

USER MANUAL Intuvia BOSCH

Active Line/Performance Line Active Line/Performance Line

1.0 REXCHARGE

Robert Bosch GmbH

Bosch eBike Systems

72703 Reutlingen

GERMANY

www.bosch-ebike.com

1 270 020 XBI (2017.04) T/99 WEU

Intuvia

BUI251:1 270 020 906

BUI255: 1 270 020 909

BOSCH

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Read all safety warnings and all instructions. Failure to follow the warnings and 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 eBike rechargeable battery packs.

▶ Do not use the on-board computer as a handle. Lifting the eBike up by the on-board computer can cause irreparable damage to the on-board computer.
▶ Make sure to not be distracted by the display of the on-board computer. If you do not focus exclusively on the traffic, you risk being involved in an accident. If you want to make entries in your on-board computer other than switching the assistance level, stop and enter the appropriate data.
Read and observe the safety warnings and instructions in all operating instructions of the eBike system and in the operating instructions of your eBike.

Product Description and Specifications

Intended Use

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

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

Product Features

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

1 Display-function button "i"
2 Bike lights button
3 On-board computer
4 Holder for on-board computer
5 On/Off button for on-board computer
6 "RESET" button

7 USB port
8 Protective cap of USB port
9 Operating unit
10 Display-function button "i" on the operating unit
11 Decrease assistance level/scroll down button “-”
12 Increase assistance level/scroll up button “+”
13 Push-assistance button "WALK"
14 Lock latch for on-board computer
15 Locking screw for on-board computer USB charging cable (Micro A - Micro B)*

\* not illustrated; available as accessory

Display elements of on-board computer

a Drive unit assistance indicator
b Assistance-level indicator
c Light indicator
d Text indication
e Value indication
f Speed indication
g Shift recommendation: higher gear
h Shift recommendation: lower gear
i Battery charge-control indicator

Technical Data

On-board computer Intuvia
Article number		1 270 020 906/909
Max. charging current, USB connection	mA 500
Charging voltage, USB connection	V	5
USB charging cable1)		1 270 016 360
Operating temperature	°C -5...+40
Storage temperature	°C -10...+50
Charging temperature	°C 0...+40
Internal lithium-ion battery	V	3.7
	mAh	230
Protection type2)		IP 54 (dust and splash water protected)
Weight, approx.	kg 0.15
1) Not included in standard scope of delivery
2) When USB cover is closed
Bosch eBike system uses FreeRTOS (see www.freertos.org)

Assembly

Inserting and removing the battery pack

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

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

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

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

▶ Remove the on-board computer when you park the eBike.

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

Note: The locking screw is not designed to prevent theft.

Operation

Initial Operation

Requirements

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

• A sufficiently charged battery pack is inserted (see battery pack operating instructions).
• The on-board computer is properly inserted in the holder (see "Inserting and removing the on-board computer", page English-2).
• The speed sensor is connected properly (see drive unit operating instructions).

Switching the eBike System On/Off

Options for switching on the eBike system:

• If the on-board computer is already switched on when you insert it into the holder, then the eBike system will be switched on automatically.
• When the on-board computer and the eBike battery pack are inserted, briefly press the On/Off button 5 of the on-board computer.
• With the on-board computer inserted, push the On/Off button on the eBike battery (bicycle manufacturer solutions are possible whereby there is no access to the battery On/Off button; see the battery operating instructions).

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

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

Options for switching off the eBike system:

• Press the On/Off button 5 of the on-board computer.
• Switch off the eBike battery using its On/Off button (bicycle manufacturer-specific solutions are possible whereby there is no access to the battery On/Off button; see the bicycle manufacturer operating instructions).

- Remove the on-board computer out of its holder.

If the eBike is not moved and no button is pressed on the onboard computer for 10 minutes, the eBike system will shut down automatically in order to save energy.

eShift (optional)

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

Displays and configurations of the on-board computer

Energy supply of the on-board computer

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

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

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

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

Switching on/shutting down the on-board computer

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

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

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

▶ If you are not going to be using your eBike for several weeks, remove the on-board computer from its mount.

Store the on-board computer in a dry environment at room temperature. Regularly recharge the on-board computer's battery (at least every 3 months).

Battery Charge-control Indicator

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

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

The eBike battery pack is fully charged.

The eBike battery pack should be recharged.

The LEDs of the charge-control indicator on the battery pack extinguish. The capacity for assisting the drive has been used up, and assistance is gently switched off. The remaining capacity is made available for the lighting and the on-board computer. The indicator flashes.

The capacity of the eBike battery pack is enough for about 2 hours of lighting. This does not account for other consumers (e.g. automatic gearbox, charging external devices at the USB port).

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

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

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

Setting the Assistance Level

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

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

If the manufacturer has configured the eBike with "eMTB

Mode" and an Intuvia on-board computer is being used on the bicycle, "eMTB Mode" will appear briefly on the display when the "SPORT" assistance level is selected. In "eMTB Mode", the assistance factor and torque are dynamically adjusted as a function of the force you exert on the pedals. "eMTB Mode" is only available for Performance Line CX drives.

The following assistance levels (max.) are available:

• “OFF”: The motor assistance is switched off, and the eBike can be moved as a normal bicycle only by pedalling. The push assistance cannot be activated in this assistance level.
• “ECO”: Effective assistance at maximum efficiency for maximum cruising range
• “TOUR”: Uniform assistance, for touring with long cruising range
• "SPORT"/"eMTB":

"SPORT": Powerful assistance for sportive riding off road as well as for urban traffic

“eMTB”: Optimal assistance whatever the terrain, rapid acceleration when starting from a standstill, improved dynamics and top performance.

- "TURBO": Maximum assistance, supporting highest cadence for sportive riding

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

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

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

Interaction of the eBike System with the Bicycle Gears

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

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

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

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

Switching bike lights on/off

In the model in which the lighting is powered by the eBike system, the front and rear lights can be switched on and off at the same time via the on-board computer with button 2.

When the lighting is switched on “Lights on” appears and when the lighting is switched off “Lights off” appears for approx. 1 s in text indication d. The lighting symbol c is displayed when the light is on.

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

Switching the Push-assistance mode On/Off

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

The push-assistance function may only be used when pushing the eBike. Danger of injury when the wheels of the eBike do not have ground contact while using the push-assistance function.

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

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

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

• You release the "+" 12 button;
• The wheels of the eBike are prevented from turning (e.g. by braking or being hit by your leg);
• The speed exceeds 6 km/h.

Note: On some systems the push-assistance function can be started directly by pressing the "WALK" button.

The push-assistance function is subject to local regulations; the way it works may therefore differ from the description above.

Displays and configurations of the on-board computer

Speed and Distance Indication

The speed indication f always displays the current speed. The following functions are available in the function indication (combination of text indication d and value indication e):

• "Clock": Current time
• “Max. speed”: Maximum speed achieved since the last reset

• “Avg. speed”: Average speed achieved since the last reset

• “Trip time”: Trip time since the last reset

• “Range”: Estimated range of the available battery-pack charge (for constant conditions such as assistance level, route profile, etc.)
• “Odometer”: Display of the total distance travelled with the eBike (cannot be reset)
• “Trip distance”: Distance covered since the last reset

To switch between display functions, press button “i” 1 on the on-board computer or button “i” 10 on the operating unit repeatedly until the required function is displayed.

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

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

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

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

Displaying/Adapting Basic Settings

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

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

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

To change the basic settings, press the On/Off button 5 next to indication “−” to reduce or scroll down, or the lighting button 2 next to indication “+” to increase or scroll up.

If the on-board computer is inserted in the holder 4, it is also possible to change using buttons “-” 11 and “+” 12 on the operating unit.

To exit the function and save a changed setting, press the "RESET" button 6 for 3 s.

The following basic settings are available:

• “- Clock +”: The current time can be set here. Pressing and holding the setting buttons fast-forwards the setting speed.

• “- Wheel circum. +”: You can change this value pre-set by the manufacturer by ± 5 %. This menu item is displayed only when the on-board computer is in the holder.

• “- English +”: You can change the language of the text indications. You can choose between German, English, French, Spanish, Italian, Portuguese, Swedish, Dutch and Danish.

• “- Unit km/mi +”: The speed and distance can be displayed either in kilometres or miles.
• “- Time format +”: The time can be displayed either in the 12 hour or 24 hour format.
• “- Shift recom. on/off +”: You can switch the indication of a shift recommendation on and off.
• “Power-on hours”: Indicates the total travel duration with the eBike (not changeable).
• “Displ. vx.x.x.x”: This is the software version of the display.
• “DU vx.x.x.x”: This is the software version of the drive unit. This menu item is displayed only when the on-board computer is in the holder.
• “DUS xxxxxxxxx”: This is the serial number of the drive unit. This menu item is displayed only when the on-board computer is in the holder.

Error Code Indication

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

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

• “Service MM/YYYY”: This menu item is displayed when the bike manufacturer has set a fixed service appointment.
• “Serv. xx km/mi”: This menu item is displayed when the bike manufacturer has set a fixed service appointment after a certain mileage has been reached.
• “Bat. vx.x.x.x”: This is the software version of the battery pack. This menu item is displayed only when the on-board computer is in the holder.
• “1. Bat. vx.x.x.x”: When using 2 battery packs this is the software version of one of the battery packs. This menu item is displayed only when the on-board computer is in the holder.
• “2. Bat. vx.x.x.x”: When using 2 battery packs this is the software version of the other battery pack. This menu item is displayed only when the on-board computer is in the holder.

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

▶ Have all repairs performed only by an authorised bike dealer.

Code Cause Corrective Measure

410	One or more buttons of the on-board computer are blocked.	Check if any buttons are blocked, e.g. from dirt or debris. Clean the buttons, if required.
414 Connection problem of the operating unit		Have connections and contacts checked.
418	One or more buttons of the operating unit are blocked.	Check if any buttons are blocked, e.g. from dirt or debris. Clean the buttons, if required.
419	Configuration error	Restart the system. If the problem persists, contact your Bosch eBike dealer.
422 Connection problem of the drive unit Have connections and contacts checked.
423	Connection problem of the eBike battery pack	Have connections and contacts checked.
424 Communication error among the components		Have connections and contacts checked.
426	Internal time-out error	Restart the system. If the problem persists, contact your Bosch eBike dealer. In this error status, it is not possible to display or adjust the wheel circumference in the basic settings menu.
430	Internal battery pack of the on-board computer is empty.	Charge the on-board computer (in the holder or via the USB port).
431	Software version error	Restart the system. If the problem persists, contact your Bosch eBike dealer.
440	Internal error of the drive unit	Restart the system. If the problem persists, contact your Bosch eBike dealer.
Code	Cause	Corrective Measure
450	Internal software error	Restart the system. If the problem persists, contact your Bosch eBike dealer.
460	Error at USB connection Remove the cable from the USB connection of the on-board computer. If the problem persists, contact your Bosch eBike dealer.
490	Internal error of the on-board computer	Have the on-board computer checked.
500	Internal error of the drive unit	Restart the system. If the problem persists, contact your Bosch eBike dealer.
502	Bike lighting error	Check the light and the associated wiring. Restart the system. If the problem persists, contact your Bosch eBike dealer.
503	Error of the speed sensor	Restart the system. If the problem persists, contact your Bosch eBike dealer.
510	Internal sensor error	Restart the system. If the problem persists, contact your Bosch eBike dealer.
511	Internal error of the drive unit	Restart the system. If the problem persists, contact your Bosch eBike dealer.
530	Battery pack error Switch off the eBike, remove the eBike battery pack and reinsert the eBike battery pack. Restart the system. If the problem persists, contact your Bosch eBike dealer.
531	Configuration error Restart the system. If the problem persists, contact your Bosch eBike dealer.
540	Temperature error	The eBike is outside of the permissible temperature range. Switch off the eBike system and allow the drive unit to either cool down or heat up to the permissible temperature. Restart the system. If the problem persists, contact your Bosch eBike dealer.
550	An improper load was detected.	Remove load. Restart the system. If the problem persists, contact your Bosch eBike dealer.
580	Software version error	Restart the system. If the problem persists, contact your Bosch eBike dealer.
591	Authentication error	Switch off the eBike system. Remove the battery pack and reinsert it. Restart the system. If the problem persists, contact your Bosch eBike dealer.
592	Incompatible component	Insert a compatible display. If the problem persists, contact your Bosch eBike dealer.
593	Configuration error Restart the system. If the problem persists, contact your Bosch eBike dealer.
595, 596	Communication error	Check the wiring to the transmission and restart the system. If the problem persists, contact your Bosch eBike dealer.
602 Internal battery pack error while charging		Unplug the charger from the battery pack. Restart the eBike system. Plug the charger into the battery pack. If the problem persists, contact your Bosch eBike dealer.
602	Internal battery pack error	Restart the system. If the problem persists, contact your Bosch eBike dealer.
603	Internal battery pack error	Restart the system. If the problem persists, contact your Bosch eBike dealer.
Code Cause	Corrective Measure
605	Battery pack temperature error	The eBike is outside of the permissible temperature range. Switch off the eBike system and allow the drive unit to either cool down or heat up to the permissible temperature. Restart the system. If the problem persists, contact your Bosch eBike dealer.
605	Battery pack temperature error while charging	Unplug the charger from the battery pack. Allow the battery pack to cool. If the problem persists, contact your Bosch eBike dealer.
606	External battery pack error	Check the wiring. Restart the system. If the problem persists, contact your Bosch eBike dealer.
610	Battery pack voltage error	Restart the system. If the problem persists, contact your Bosch eBike dealer.
620	Charging error	Replace the charger. Contact your Bosch eBike dealer.
640	Internal battery pack error	Restart the system. If the problem persists, contact your Bosch eBike dealer.
655	Multiple battery pack errors	Switch off the eBike system. Remove the battery pack and reinsert it. Restart the system. If the problem persists, contact your Bosch eBike dealer.
656	Software version error Contact your Bosch eBike dealer so that he can perform a software update.
7xx	Transmission error	Please observe the operating instructions provided by the transmission manufacturer.
No display	Internal error of the on-board computer	Restart your eBike system by switching it off and back on.

Power Supply of External Devices via USB Connection

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

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

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

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

▶ A USB connection is not a waterproof plug-in connection. When riding in the rain, an external device must not be connected and the USB connection must be completely sealed with the protective cap 8.

Maintenance and Service

Maintenance and Cleaning

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

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

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

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

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

After-sales Service and Application Service

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

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

Transport

If you transport your eBike attached to the outside of your car, e.g. on a bike rack, remove the on-board computer and the eBike battery to avoid damaging them. (If the on-board computer cannot be fitted onto a bracket, it is not possible to remove it from the bicycle. In this case, the on-board computer may remain on the bicycle.)

The battery packs are subject to the Dangerous Goods Legislation requirements. Private users can transport undamaged battery packs by road without further requirements.

When being transported by commercial users or third parties (e.g. air transport or forwarding agency), special requirements on packaging and labelling must be observed (e.g. ADR regulations). If necessary, an expert for hazardous materials can be consulted when preparing the item for shipping.

In case of questions concerning transport of the battery packs, please refer to an authorised Bosch eBike dealer. The Bosch eBike dealers can also provide suitable transport packaging.

Disposal

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

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

Only for EC countries:

According to the European Guideline 2012/19/EU, electrical devices/tools that are no longer usable, and according to the European Guideline 2006/66/EC, defective or used battery packs/batteries, must be collected separately and disposed of in an environmentally correct manner.

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

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

Li-Ion Li

Li-ion:

Please observe the instructions in section "Transport", page English-8.

Subject to change without notice.

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"Active Line/Performance Line".

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