Bion X D-Series User manual

USER MANUAL

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Welcome
Thank you for choosing BionX™. It is our goal to provide you with the highest quality electric
propulsion systems available, and offer you the best possible after sales experience. 
This document serves as a supplement to your bicycle user manual. Please read this manual
thoroughly, even if you are an experienced cyclist. Should you be unable to find an answer in
the manual, please contact your dealer for immediate assistance. 
We have always believed that a bike should remain a bike. It is our love of cycling that drives
us, and a passion that we continue to share with our customers. We hope you enjoy your
new electrically assisted bicycle for many years to come.
If you ever have concerns or questions that your dealer cannot provide answers to, or have
comments relating to this user manual, feel free to contact
us in Europe at [email protected], in North America at
[email protected], and anywhere else in the world at
[email protected]
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User Precautions
We want you to have a fun ride, but also a safe one. Carefully read the following information,
even if you are an experienced rider. Take the opportunity to familiarize yourself with your
BionX electric propulsion system before you take your first trip.
1. BionX recommends that you have your system installed professionally by an authorized dealer. 
2. Read all of the enclosed installation and operating instructions from the manufacturer
and follow the instructions, if any, prior to its first use.
3. Familiarize yourself with your electric bicycle and the functions of the BionX system in a safe
environment before participating in road traffic for the first time.
4. Always wear a helmet when riding an electric bicycle for your own safety. In some jurisdictions,
this is the law.
5. Make sure that the tires have the pressure recommended by the manufacturer before riding the bike.
6. Make sure that the brakes are operating properly before riding the bike.
7. Do not use a mobile phone or any other electronic devices while riding an electric bicycle; it is
imperative that you pay attention to traffic.
8. If possible, ride in bike lanes and always in the correct direction of traffic.
9. Adhere to all valid traffic regulations.
10. Keep in mind that other traffic participants may underestimate the speed of an electric bicycle.
11. Ride with both hands on the handlebars when riding your electric bicycle.
12. Ride as defensively as possible.
Enjoy your new BionX electric propulsion system!
Your BionX Team
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Table of Contents
User Precautions 4
Description of the BionX D-Series System 6
Description of the BionX S-Series System 8
Description of the BionX P-Series System 10
Inserting or Removing the Console 12
Inserting or Removing the Battery 13
Handling and Charging the Battery 14
Power Supply 16
Chargers 17
Assist Mode / Generate Mode / Mountain Mode
(where applicable) 18
Operating the BionX Propulsion System 19
Operating the G2 Throttle 21
Programming the Basic Settings 22
Removing and Installing the Rear Wheel 23
Maintenance and Care 24
Optimizing the Range of the Battery 25
Cleaning 26
Transporting an Electric Bicycle 26
Repair and Spare Parts 26
Troubleshooting 27
Warranty Information and Guarantee 28
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Description of the BionX D-Series System
1G2 Console
• Removable G2 console
• Illuminated LCD display with battery state-of-charge
• 4 Assistance levels
• 4 Generate levels
• Backlight, and bicycle light controls (if applicable)
• Offers cycle computer functions (speed, odometer,
clock, average speed, trip distance)
Remote throttle (where applicable)
• Assistance/Generate toggle
• Variable control throttle lever
248V Down Tube Battery
• Lithium Ion (Li-Ion)
• Removable, lockable
• TOUCH PORT state-of-charge indicator
• DV – 48V / 11.6Ah / 555Wh
• DC Output: Default 6V (adjustable from 6V to 12V
where applicable). Maximum current: 2amps.
Connector: Type Jack 2.1mm
3D-Series Motor
• DC rear hub motor
• Power – (nom.) 200W (AU & UK), 250W (EU), 500W
(NA)
• Torque – (nom./max.) 25Nm/50Nm (18.4/37lb-ft)
• Weight – 4.0kg (8.8lb)
• Brushless, gearless
• Generate mode for energy recuperation
• Integrated torque sensor
• 8, 9, and 10 speed cassette compatible
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4Brake switch
• A surface mounted reed switch and magnet –
connected to the BionX console
• Upon brake application, assistance is shut off
(“kill switch”) and Generate mode is activated
Power Supply
• Power supply to recharge the 48V Li-Ion battery
• Input voltage: 100-240V
• Output voltage: 26V
• Max. charge current: 3.45A
• Output: 90W
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Description of the BionX S-Series System
1G2 Console
• Removable G2 console
• Illuminated LCD display with battery state-of-charge
• 4 Assistance levels
• 4 Generate levels
• Backlight, and bicycle light controls (if applicable)
• Offers cycle computer functions (speed, odometer,
clock, average speed, trip distance)
Remote throttle (where applicable)
• Assistance/Generate toggle
• Variable control throttle lever
2a 48V Down Tube Battery
• Lithium Ion (Li-Ion)
• Removable, lockable
• TOUCH PORT state-of-charge indicator
• DV - 48V / 11.6Ah / 555Wh
• DX – 48V / 8.8Ah / 423Wh
• DL – 48V / 6.6Ah / 317Wh (where available)
• DC Output: Default 6V (adjustable from 6V to 12V
where applicable). Maximum current: 2amps.
Connector: Type Jack 2 .1mm
2b 48V Rear Rack Battery
• Lithium Ion (Li-Ion)
• Removable, lockable
• TOUCH PORT state-of-charge indicator
• RX - 48V / 8.8Ah / 423Wh
• RL - 48V / 6.6Ah / 317Wh (where available)
• DC Output: Default 6V (adjustable from 6V to 12V
where applicable). Maximum current: 2amps.
Connector: Type Jack 2 .1mm
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3S-Series Motor
• DC rear, high torque (HT) hub motor
• Power – (nom.) 200W (AU & UK), 250W (EU), 350W
(NA)
• Torque – (nom./max.) 9Nm/40Nm (6.6/29lb-ft)
• Weight – 3.5kg (7.7lb)
• Brushless, gearless
• Generate mode for energy recuperation
• Integrated torque sensor
• 8, 9, and 10 speed cassette compatible (NA only,
where available)
4Brake switch
• A surface mounted reed switch and magnet –
connected to the BionX console
• Upon brake application, assistance is shut off
(“kill switch”) and Generate mode is activated
Power Supply
• Power supply to recharge the 48V Li-Ion battery
• Input voltage: 100-240V
• Output voltage: 26V
• Max. charge current: 3.45A
• Output: 90W
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Description of the BionX P-Series System
1G2 Console (systems 2011 to present)
• Removable G2 console
• Illuminated LCD display with battery state-of-charge
• 4 Assistance levels
• 4 Generate levels
• Backlight, and bicycle light controls (if applicable)
• Offers cycle computer functions (speed, odometer,
clock, average speed, trip distance)
Remote throttle (where applicable)
• Assistance/Generate toggle
• Variable control throttle lever
2a 22, 26, 37 or 48V Down Tube Battery
• Lithium Ion (Li-Ion)
• Removable, lockable
• DV - 48V / 11.6Ah / 555Wh
• DX - 48V / 8.8Ah / 423Wh
• DL - 48V / 6.6Ah / 317Wh
• L - 37V / 9.6Ah / 355Wh
• M - 26V / 9.6Ah / 250Wh
• S - 22V / 6.4Ah / 141Wh
2b 37 or 48V Rear Rack Battery
• Lithium Ion (Li-Ion)
• Removable, lockable
• RX - 48V / 8.8Ah / 423Wh
• RL - 48V / 6.6Ah / 317Wh
• RR L - 37V / 9.6Ah / 355Wh
• RR M - 37V / 6.4Ah / 237Wh
• DC Output: Default 6V (adjustable from 6V to 12V
where applicable). Maximum current: 2amps.
Connector: Type Jack 2 .1mm
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3250, 250HT, 350HT, or 500HS* P-Series Motor
• DC rear hub motor
• 250: nom. output 200 (AU & UK) or 250 watt –
nom. 7Nm / max. 25Nm (5.2/18.4 lb-ft) torque
• 250HT / 350HT: nom. output 200 (AU & UK),
250 (EU), 350 (NA) watts – nom. 9Nm / max. 40Nm
(6.6/29.5lb-ft) torque
• 500: nom. 500 watt – nom. 9Nm / max. 25Nm
(6.6/18.4lb-ft) torque
• Weight - 4.7kg (10.4lb)
• Brushless, gearless, with integrated torque sensor
• Generate mode for energy recuperation
• 8, 9, and 10 speed cassette compatible (EU only,
where available)
4Brake switch
• A surface mounted reed switch and magnet –
connected to the BionX console
• Upon brake application assistance is shut off
(“kill switch”) and Generate mode is activated
Power Supply
• Power supply to recharge the 48V Li-Ion battery
• Input voltage: 100-240V
• Output voltage: 26V
• Max. charge current: 3.45A
• Output: 90W
37V Single LED Battery Charger
(PL systems 2011 to present)
• To recharge the 37V Li-Ion battery
• Input voltage: 100-240V
• Output voltage: 37V
• Max. charge current: 2A
• Output : 75 watts
22V, 26V or 37V Two LED Battery Charger
(PL systems 2011 and earlier)
• To recharge the 22V, 26V or 37V Li-Ion battery
• Input voltage: switchable between 115-230V
• Output voltage: 22V, 26V or 37V depending
upon model
• Max. charge current: 2A
*Note: the 500 watt motor is not legal in all jurisdictions. Check with your local BionX dealer for local legislation and/or availability.
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Inserting or Removing the Console
Inserting the console
• Slide the console into the console mount on the handlebar
• Make sure that the console engages securely. When inserted correctly, you will hear a “click”
Removing the console
• Release the console by pushing the release lever on the console mount
• Slide the console out of the console mount
“click”
WARNING
Never unplug any connection with the system turned on - this includes the console. Pulling
a live part can render it inoperable!
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Inserting or Removing the Battery
Inserting the down tube battery
1Place the battery onto the docking station
2Slide the battery down the rail gently towards the connector
3The release arm will begin to move to the closed position as the battery slides towards the connector
4When the release arm is almost closed, hold it in place and simultaneously push in the lock cylinder –
you will hear a “click” when the lock cylinder is properly closed
Removing the down tube battery
1Turn off the BionX propulsion system via the console (no illustration)
2Lightly press on the battery release arm, insert the key and turn clockwise
The lock cylinder will pop out, freeing the battery release arm
3Remove the battery by opening the release arm
4Slide the battery upwards on the rail
5Lift the battery to remove
25.4mm (1”)
001
001
25.4mm (1”)
001
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1” (25.4mm)
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WARNING
Do not force the battery release arm closed, or force the battery onto the battery dock.
This can damage the battery connector. Never unplug any connection with the system
turned on - this includes the battery. Pulling a live part can render it inoperable! If a bat-
tery is removed while the system is turned on, wait 5 minutes until it turns off before re-
installing. A series of 5 beeps will indicate the battery has shut off and it is safe to install
again.
25.4mm (1”)
001
001
25.4mm (1”)
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25.4mm (1”)
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1” (25.4mm)
001
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“click”
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Inserting the rear rack battery:
1Open the lock cylinder: please ensure that the key is removed from the lock cylinder
2Place the battery onto the battery docking station
3Gently push the battery in a forward direction, towards the battery connector
Make sure the battery is inserted all the way, flush with the docking station cover
4Push in the lock cylinder until a ‘click’ is heard
Removing of the rear rack battery:
1Turn off the system via the console (no illustration)
2Turn the key in the lock cylinder until it pops out
3Remove the key from the lock cylinder
4Pull the battery backwards, along the battery rail
Handling and Charging the Battery
WARNING
BionX batteries shall only be recharged with BionX chargers or BionX power supplies. The
use of other power supplies/chargers can damage the battery. Never short circuit the bat-
tery by connecting the contacts of the battery. Never open the battery, as this could dam-
age the battery and possibly lead to overheating. The battery cannot be serviced by the
user. Opening the battery case voids all warranty and product liability claims. Never use a
battery which has obvious damage to the case(s) or the battery connector.
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WARNING
Do not force the battery onto the battery docking station. This can damage the battery
connector, or damage the rear light. Never unplug any connection with the system turned
on - this includes the battery. Pulling a live part can render it inoperable! If a battery is re-
moved while the system is turned on, wait 5 minutes until it turns off before re-installing.
A series of 5 beeps will indicate the battery has shut off and it is safe to install again.
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CLICK
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It is best to store the battery in a cool location at temperatures between 10 °C (50 °F) and 25 °C (77 °F).
Never store the battery in locations where the temperatures can reach more than 45 °C (113° F) or
fall below -10 °C (14 °F). The battery should never be exposed to extreme temperature fluctuations
or humidity, and always protect the battery during storage from humidity to prevent corrosion of the
connectors. Never drop the battery. Always protect it from physical damage. Damage may lead to short-
circuits, and as a result cause overheating of the battery.
Do not dispose of used batteries in regular household trash, be aware that used batteries
must be disposed of properly! BionX batteries can be returned to BionX to be recycled.
WARNING
The BionX power supply/charger should be used exclusively for BionX rechargeable
batteries of the specified type. Keep the power supply or charger away from water or
moisture when charging and/or connected to prevent electrical shock or short-circuits.
Do not use a power supply or charger that has obvious signs of damage to the cable,
housing, or the connector.
Extreme temperatures will affect battery life, especially during charging. Avoid charging in direct sunlight
or in very hot or cold temperatures as this will reduce the life of the battery considerably. We recommend
charging the battery at room temperature (approximately 20 °C / 68 °F). The battery should be warmed to
room temperature before it is charged, particularly if it was exposed to cold temperatures during a ride.
The battery can be charged when mounted on the bicycle or removed from the docking station.
A Lithium Ion battery does not have a memory effect, which means that the battery’s maximum energy
capacity is not affected if it is repeatedly recharged after only being partially discharged. The battery does
not need to be completely drained before charging. We recommend charging the battery after every ride,
preferrably when the state-of-charge display shows less than 50%. When the battery is fully depleted it will
signal that a recharge is needed by beeping. The battery is fully charged after approximately 4 to 5.5 hours.
CAUTION
All classic BionX batteries must be charged when not in use for a long period of time (i.e.
before winter storage) and then must be charged at minimum every three months. Not
charging the battery can lead to potential damage of the battery cells. This is a lack of
maintenance on behalf of the owner, which can incur a loss of warranty.
NOTE
New 48V BionX batteries are equipped with “Deep Sleep” mode, a function that preserves battery
energy depending on either the state of charge or significant inactivity. A fully charged battery will
automatically enter Deep Sleep after 2 months, while a partially discharged battery will enter it in
increasingly faster time frames. This results in minimal energy consumption during standby and enables
a shelf life of up to 6 months for a fully discharged battery, and up to 18 months for a fully charged
battery. To activate a battery that has entered Deep Sleep mode, connect it to the 26V BionX power
supply and allow it to complete a full charge cycle. BionX still recommends charging these batteries at
minimum every 6 months.
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Power Supply
48V battery charging procedure (power supply)
• Connect the power supply and the battery by
inserting the charge connector into the TOUCH PORT
– the BionX system can be on or off
• Connect the power supply to a power receptacle
• The battery TOUCH PORT (LED ring around the
charge connector) lights up red upon insertion and
then turns to amber during the charging process
• When fully charged, the colour of the LED ring
changes to green. The battery charging process is
then complete
• Following this procedure the charging connector should be disconnected from the battery
• During the charging process you can check the battery state-of-charge through the console if the
battery is connected to the system – a 48V system can be switched on while it is charging
This has my vote :)
Battery state-of-charge Colour
100-75 % Green
75-20 % Amber
< 20 % Red
Checking the 48V Battery state-of-charge
• Swipe your finger slowly over the TOUCH PORT
• Battery state-of-charge LED will illuminate
• Allow ten (10) seconds before checking state-of-charge again
NOTE
The power supply is suitable for line voltage ranges of 110-115V or 220-230V, and com-
pensates automatically. The 48V battery is designed to be charged by a 26V BionX power
supply. The battery has an integrated charger which permits the use of a small, portable
power supply.
Ensure that a completely charged battery is no longer connected to the power supply after the charge
procedure is completed.
TOUCH PORT green =
fully charged
TOUCH PORT amber =
charging
TOUCH PORT red =
upon insertion
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37V battery c harging procedure,
systems 2011 to present (single LED charger)
• Connect the charger and battery by inserting the
charge connector into the charge port. The BionX
system should be turned off
• Connect the charger to a power receptacle
• The light on the charger will turn red automatically
• The same light will then turn yellow to indicate
charging
• The light will turn green when the battery is fully
charged and the charging process is complete
• Following this procedure, the charger should be
disconnected from the battery
22V, 26V, and 37V battery charging procedure,
systems 2011 and earlier (two LED charger)
• Connect the charger and battery by inserting the
charge connector into the charge port. The BionX
system should be turned off
• Connect the charger to a power receptacle
• The power switch must be set to ‘on’ and the red
LED will illuminate
• The LED to the right of the red LED will illuminate
yellow to indicate charging
• When the right LED turns green the battery is fully
charged and the charging process is complete
• Following this procedure, the charger should be
disconnected from the battery
WARNING
Check input voltage when travelling with
the two LED charger. Failure to adjust the
voltage switch on a two LED charger to
the correct voltage range can result in
damage to the charger.
001
115
FUSE
This notch is very important
NOTE
The 37V single LED charger is suitable for line voltage ranges of 110-115V or 220-230V,
and compensates automatically.
001
115
FUSE
This notch is very important
Left LED =
red, charger on
Right LED =
yellow, charging
Right LED =
green, fully charged
001
115
FUSE
This notch is very important
Left LED =
red, charger on
Right LED =
yellow, charging
Right LED =
green, fully charged
Chargers
001
115
FUSE
This notch is very important
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Assist Mode / Generate Mode / Mountain Mode (where applicable)
The BionX propulsion system offers four levels of assist in the Assistance mode, and four levels of
regeneration in the Generate mode. In the Assistance mode, your pedaling is assisted proportionally by
an electric motor that drives the rear wheel. A torque sensor is located on the axle of the BionX motor
and measures the effort provided by the rider; this produces a natural feeling assistance from the motor.
A cadence of roughly 80 RPM is ideal, this allows for effective response from the torque sensor and
efficient use of battery energy.
When in Generate mode, the BionX motor functions as a generator and recharges the battery. When
going downhill, you can regulate your speed by varying the Generate level. This Generate function
provides a level of braking, however it does not replace legally required brakes. If the rear brake lever is
pulled, the drive system automatically enters Generate mode. The range can therefore be extended up to
15%, depending upon road conditions.
The Mountain mode uses an intelligent algorithm based upon the effort and the assistance level required.
The Mountain mode provides the rider with an assistance level optimized for climbing long steep hills.
Without this mode, the motor can automatically revert to an overheat protection mode thereby dimin-
ishing the assistance provided. The Mountain mode can be activated (where available) by your dealer
through a software update of the system. Note that level 4 assist is more powerful than Mountain mode.
NOTE
It is recommended that the BionX system should always be turned ON while riding.
It allows the rider to use the regenerative braking feature, speedometer and odometer
functions. Speeds in excess of 60km/h (37mi/hr) are not recommended.
250HT (EU) / 350HT (NA) / D-Series Motor performance
Assistance Mode (A) Level of Assist Riding Situation
135% Riding on level ground
275% Slight inclines, head wind
3150% Steep hills, strong head wind
4300% Very steep roads
250/500 Motor performance
Assistance Mode (A) Level of Assist Riding Situation
125% Riding on level ground
250% Slight inclines, head wind
3100% Steep hills, strong head wind
4200% Very steep roads
Mountain Mode (where available) Long, steep climbs
Generation Mode (G)
1Slight downhill grade, tailwind
2Significant downhill grade, tailwind
3Steep descent
4Very steep descent
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Operating the BionX Propulsion System
Turn the system on
Briefly push either top button on the console. The
battery will beep 4times and you will see a countdown,
this is the system perfoming a self check. After startup,
the system is always in mode (no motor assist/
bike operation). To turn the system off, briefly push .
The battery will beep 5 times. After 5 minutes of “no
operation” the system turns off automatically.
Select Assistance/Generate level
Push / key for more/less assist (see bar “fields 1-4”
above display “A”). From mode push key to
enter continuous Generate mode.
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1. Power
2. Key
3. Key
4. Cycle
5. State-of-charge
indicator
6. (bicycle) mode
7. Speedometer
8. Trip distance/average speed/
chronometer/odometer/clock
9. Assist level (A)
10. Generate level (G)
11. Wrench symbol
G2 Console
NOTE
The system performs a self check approximately every hour. Do not be alarmed if the
system turns itself on briefly, and off again, or if the TOUCH PORT flashes momentarily.
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Turn on backlight and bicycle light (if applicable)
Push and hold key for 4 seconds - display backlight
and bicycle light (if available, battery integrated) are
turned on.
Turn off backlight
Push and hold key again for 4 seconds.
Select the cycling computer functions
Briefly push the key to change between:
Trip Distance DIST
Odometer ODO
Clock CLOCK
Average Speed AVSPD
Chronometer CHRONO
To reset the cycle computer functions
Hold the key for a few seconds to reset the distance,
chronometer, or average speed values to zero.
4s
WARNING
If this symbol appears please contact your BionX dealer for service.
Mountain Mode (where available)
Hold the button from any level of (A) or (G) to
engage. The four assist levels will flash, MOUNTAIN
will appear briefly. Press to disengage.
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