BESV CF1 User manual

Technical Manual - BESV CF1
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Technical Manual
BESV CF1
V. 1.0, Sep. 2015

Technical Manual - BESV CF1
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Contents
1. Electronic components ·························································1
1.1 Specification··············································································3
1.1.1 Controller ···························································································3
1.1.2 Motor ·································································································3
1.1.3 Pedaling Sensor ················································································4
1.1.4 HMI ····································································································4
1.1.5 Battery ·······························································································5
2. Operation ··············································································6
2.1 Battery·······················································································6
2.1.1 Charge·······························································································6
2.1.2 Important Safety Notes for Battery Charging ·····································7
2.2 HMI····························································································8
2.2.1 Information·························································································8
2.2.2 Operation·························································································10
3. Disassembling Components ···············································12
3.1 EMS (Electrical Manager System) ··········································12
3.2 Pedaling Sensor······································································15
3.3 Motor ·······················································································16
3.4 Switch······················································································18
4. Trouble shooting ·································································19
4.1 Error or warning alert·······························································19
4.2 Basic ·······················································································21
4.3 Advanced ················································································23
4.3.1 Battery ·····························································································23
4.3.2 Motor ·······························································································25
4.3.3 Whole Bike·······················································································28
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1. Electronic components
1. HMI function button
2. Brake lever
3. Front light
4. Charge port
5. Power button and battery indicator
6. EMS (Electrical Manager System)
A. HMI PCBA
B. Battery
C. Controller
7. Pedaling sensor
8. Motor
9. Rear light
B
A
C
7
6
4
3
2
1
5
9
7
12
3
4
5
6
9
8

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1.1 Specification
1.1.1 Controller
Model A-Type
Operating Temp. -15°C ~ 50°C (5°F ~ 122°F)
Storage Temp. -15°C ~ 100°C (5°F~ 212°F)
Storage Humidity 10% ~ 85%
ROHS Confirms the ROHS of PTC
Function
1. Over voltage protection
2. Over current protection
3. Stall protection
4. Speed limitation
5. UART communication
6. BLDC driver with hall
7. Battery Communication
Output Power 250W (Peak 380W)
Operating Voltage 36V Regular (Range: 30 to 42V)
Efficiency 92%
1.1.2 Motor
Model 250W Front Gear
Operating Temp. -15°C ~ 80°C (5°F ~ 176°F)
Storage Temp. -15°C ~ 100°C (5°F ~ 212°F)
Storage Humidity 10% ~ 90%
Fork Size 36 H
Weight 2 kg
ROHS < 45 db
Noise 120 ~ 450 RPM
Max RPM 40 Nm
Max Torque 180 ~ 300W
Max Output 36 V Regular (Range: 24 to 48V)
Operating Voltage > 80%

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1.1.3 Pedaling Sensor
Model Kingmeter RPM
RPM Resolution 12 Impulses / Rotation
Weight 43 g
Operating Voltage 5 V
Clockwise Yes
Counterclockwise No
Direction Yes
1.1.4 HMI
Model BESV HMI
Operating Temp. -15°C ~ 70°C (5°F ~ 158°F)
Storage Temp. -15°C ~ 80°C (5°F~ 176°F)
Storage Humidity 20% ~ 80%
Display Type Handlebar Switch and Power Button LED Indicator
Lighting Control Integrated PWM Headlight + Taillight control
I/O Cable Connector
1  8 Pin Handlebar Switch
2  6 Pin Power Button
3  6 Pin Power + UART communication cable to motor controller
4  2 Pin Rear Light
5  3 Pin Front Light
Information Battery Capacity, Assistance Level, Version Query
Assistant Level 3 Assistance Level
2
1
3
4
5

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1.1.5 Battery
Model CF1 Battery
Cell LG - 2750 mAh
Typical Capacity 7550 mAh ± 5%
Nominal Voltage 37 V
Max Charge Voltage 42.5 V
Voltage at End Discharge 29.03 V
Max. charging current 4 A
Max. Discharge current 12 A
Continuous Discharge
Current 10.8 A
Capacity Led Display No
Communication Type UART
Operating Temp. Charge：0°C ~ 40°C (32°F ~ 104°F)
Discharge：-10°C ~ 40°C (14°F ~ 104°F)
Storage Temp. -20°C ~ 60°C (-4°F ~ 140°F)
Power Consumption Sleep Mode：≦
50mA
Shutdown Mode：≦
1mA

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2. Operation
2.1 Battery
2.1.1 Charge
1. Connect the battery charger
Connect the battery charge as illustrated. Connect the charger to the charge port
on bike and the red indicator light on the power button indicates the charging is
underway. It takes approximately 5 hours to fully charge the battery. Once the
battery is charged, the battery indicator will turn blue.
If you are done charging, disconnect the charger from the battery before removing
the power plug from power socket.
2. Charging time
The charging time depends on the remaining energy in the
battery and the charger current. The acceptable charger input
voltage is AC 100 - 240 V ~ 2A (50 / 60Hz).
If the battery is completely discharged, you can estimate the
charging time by the following calculation example：
The estimated charging time is the battery’s capacity divided
by the charger current. The standard CF1 battery is 8.8 Ah
and the standard CF1 charger is 2A.
Estimated charging time = 8.8 / 2 = 4.4 hours
Hook toward to front light
Blue light : full power Red-breathing light : in charging

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2.1.2 Important Safety Notes for Battery Charging
Use only the battery charger delivered with the product.
Use only dry charger, undamaged power cable and charger.
Replace damaged power cable and charger immediately.
Remove any possible foreign object from the charging socket, such as dusts, ice
or snow before plugging in.
Using any battery charger other than the one delivered with the product may
cause overheating of the batter y or even a risk of explosion.
Deep discharging of battery may result in internal damage.
There is a fire risk if the temperature of batter y rises up to a dangerous level.
Avoid deep discharging of battery while in use or storage.
If not in use, the battery should be charged fully at least every 3 months.
Do not expose the bike in a storage temperature lower than -20°C (-4°F) or
higher than 60°C (140°F). Please note that the internal structure of battery may
be overheated to damage due to high temperature greater than 60°C,
particularly exposed to direct sunlight.
Do not use the charger at a humid place or an ambient temperature lower than
-10°C (14°F) or higher than 40°C (104°F).
The battery and charger are maintenance-free. Do not attempt to disassemble or
modify the battery or charger.
Do not expose the battery to high voltage.
It is advised not use battery with damaged casing.
Do not cover the battery or the charger while charging is in progress.

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2.2 HMI
2.2.1 Information
HMI is separated into two parts, one is power button/status indictor another is
assistance button / assistance level indicator.
Power button LED indicator
(1) Discharge status
Capacity Display Description
Blue light : battery power > 50%
Red light : 50% > battery power > 20%
Red light flash : 20% > battery power > 10%
Please change assistant to level 1.
Red light fast flash : battery power < 10%
Please charge it immediately.
Status Indicto
r
Power Button
(ON / OFF)
A
ssistance Button
(Increase / Decrease)
A
ssistance
Level Indicator
Light Button
(
Front
/
Rea
r
)

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(2) Charge status : Assistant level can’t adjust when the bike is charging.
Capacity Display Description
Blue light : battery power > 95%
The battery is charged near to full capacity.
Red-breathing light : battery power < 95%
The battery is charging.
Assistant Level Suggestion
Level Assistance Display Riding condition
0 Riding without assistance.
1
Riding on a leveled surface.
2 Riding uphill or against the winds.
3
Riding up steep hill or against strong
winds.

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2.2.2 Operation
Turn on/off system
One click the power button and then the system will be turned on immediately.
When power is on, push the power button for 3 seconds and the system will turn off.
Note 1 : Start action is blue-breathing led on status indictor and marquee led on
assistance level indictor.
Note 2 : The system turns off automatically after no operation for 3 minutes.
Turn on/off front and rear light
Using front/rear light button can turn on/off the light on bike. Front light has two
intensities, adjust it to full or half by pressing the light button again and again.
Assistance level setting
There are 3 different assistance levels can be chose by user. According different
conditions on road, press [+] or [-] button to adjust assistant.
※ [ + ]：Increase [ - ]：Decrease
Firmware version in HMI\Controller requiring
The system will enter function mode after pressing [+] and [-] button for 3 seconds.
Please press [+] or [-] button to select the firmware version in which device you
want to know. Then press light button to enter the relative mode.
Function page
Display Function page Description
1 Require firmware version in HMI.
2 Require firmware version in controller.

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Firmware version information
After entering "version information", the "status indicator" will keep flashing with
purple color. At the same time, "assistance indicator" will show main version and
sub version sequentially.
For example : firmware version is 1.003
21
20
22
21
20
22
Main version : 20 = 1 Subversion: 2
0 + 21 = 3

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3. Disassembling Components
3.1 EMS (Electrical Manager System)
1. Turn off the power and place the bike upside down.
2. Loosen the front light screw, take off the front light and then disconnect front light,
charger and main cables.
3. Remove the right side wire cover carefully, pull out the switch connector and
disconnect it.
Charger cable
Front light cable
Main cable
Press to unlock

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4. Remove both side wire cover, push the power button holder up by finger. Then pull
the button connector and disconnect it.
5. Loosen the bottom cover screw, and remove the bottom cover. And then disconnect
motor, pedaling sensor and rear light cables.
Button holder
Rear light cable
Motor cable
Pedaling sensor
cable

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6. Lossen two battery screw.
7. Find the cable ties inside the down tube, hook the cable ties and then pull out the
power kit very carefully. Check if any cable stuck during the whole procedure.
8. Power kit disassemble finished.
Battery
Controller HMI PCBA

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3.2 Pedaling Sensor
1. Place the bike upside down, remove the bottom cover, and then disconnect pedaling
sensor cable.
2. Loosen the left crank screw and then remove left crank.
3. Take apart the pedaling sensor with screw driver.
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Pedaling sensor
cable

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3.3 Motor
1. Place the bike upside down, remove the bottom cover, and then disconnect motor
cable.
2. Remove the both side rubber cap and the flange nut.
3. Shift the derailleur to the highest speed.
Motor cable

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4. Bend the derailleur back and remove the rear wheel.

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3.4 Switch
1. Remove the right side wire cover carefully, pull out the switch connector and
disconnect it.
2. Loosen the screws on the switch and remove it.
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Press to unlock