Brose E-TOURING User manual

1
E-TOURING Manual
Brose E-bike system
DE / EN

Read pages 2 to 25 before using the bike
This symbol indicates a possible danger to your life and health if the relevant
instructions are not followed or if appropriate precautions have not been taken.
This symbol warns you of misconduct that may result in damage to property
and the environment.
This symbol indicates information about the handling of the product or
a respective part of the operating instructions that should be given special
attention.
Important!
Notes on this System Manual
Danger
Caution
Attention
Please pay particular attention to the following symbols:

Table of Contents
a) Battery .. ...................................................................
b) Marquardt Comfort Display .......................................
c) Drive Unit ....................................................................
d) Warranty ...................................................................
p. 4 - 11
p. 12 - 20
p. 21 - 23
p. 24 - 25

4
a) Battery
Safety instructions
Read all safety information and instructions
carefully.
Failure to follow the information and instructions
may result in fire, electric shock and/or serious
injury.
The ingredients used in lithium-ion batteries are
flammable under certain conditions.
Therefore, follow the instructions in this manual
carefully.
Keep this manual and its safety instructions in a
safe place for future reference.
• Remove the Simplo Snake battery AST-09
(hereafter referred to as battery) from the frame
before starting any work (repairs, inspections,
etc.) on the e-bike. The same applies if you
transport the e-bike by car or plane. Unin-
tentional activation of the e-bike system may
cause injuries.
• Do not open the battery. This may cause a
short circuit. In addition, any warranty or
guarantee claim is void.
• Protect the battery from heat (including
permanent sunlight), fire and immersion in
water. Do not operate the battery near hot or
flammable objects due to the danger of explo-
sion.
• When not in use, keep the battery away from
any metallic parts that could cause bypass-
ing of the contacts. This may cause burns or
fire. Short-circuit damage caused by foreign
objects will void any warranty or right of
recourse.
• Avoid strong mechanical loads on the battery.
These can damage the cells and release flam-
mable substances.
• Do not store the battery near flammable
materials. Charge the battery only above 0°
Celsius and in dry condition in a fire-safe pla-
ce. There is a risk of fire due to the heat gene-
rated during charging.
• The battery must not be charged when unat-
tended.
• If damaged, liquids may leak from the battery.
Avoid any contact. If contact has nevertheless
occurred, rinse quickly with lukewarm water.
In case of eye contact, seek medical attention
immediately. Leaking battery fluid can cause
skin irritation and burns.
• Batteries must be protected from mechanical
shocks, as there is a risk of damage to the
battery.
• Vapors may escape if the battery is damaged
or used improperly. Immediate supply of fresh
air is required. If you have any discomfort,
contact a doctor as the vapors can irritate the
respiratory tract.
• Only charge the battery with the original
charger. When using an external charger, the
risk of fire cannot be excluded.
• Use the battery only with the original Brose
e-bike drive system. This is the only way to
protect the battery from dangerous overloa-
ding.
• Use only original Simplo Snake batteries
approved by the manufacturer for your e-bike.
Other batteries may cause injury or fire. No
liability or warranty is accepted for the use of
other batteries.
• Keep the battery away from children.
• Read and follow the safety instructions and
notes mentioned in all operating manuals of
the e-bike system and the operating manual
of your e-bike.
Our product safety and the safety of our customers
is our top priority.
We exclusively use lithium-ion batteries that are
developed and manufactured according to the
current state of the art. All safety standards are
met or exceeded.
The high-energy content of a charged battery can
lead to a fire in very rare cases and under unfa-
vorable circumstances in the event of a defect
(possibly not visible from the outside).

5
• Only place the battery on clean surfaces. The
charging contacts should not be soiled by
sand or earth.
Check the battery before using it for the first time.
Check the battery before charging or using it for
the first time.
To do this, press the On/Off button to activate the
battery. If no LED of the charge status indicator
lights up, the battery may be defective.
If not all LEDs of the charge level indicator are lit,
charge the battery fully before using it for the first
time.
• Do not charge a damaged battery and do not
use it. Please contact your authorized bicycle
dealer.
If you transport your bike outside your vehicle, e.g.
on a bicycle rack, remove the battery from the bike
to avoid damage.
The batteries are subject to the requirements of
the dangerous goods law. The private user can
transport intact batteries on the road without any
restrictions.
In the case of transport by commercial users or
transport by third parties (e.g. freight forwarders),
the special regulations on marking and packaging
must be observed (ADR). If necessary, consult
a dangerous goods expert when shipping a
package.
Only send batteries with undamaged housings.
Open contacts must be masked and the battery
must be packed so that it cannot move in the
packaging.
Inform the shipping service provider that the goods
in question are hazardous. Any other national
regulations must be observed.
If you have any questions regarding transport,
please contact your authorized bicycle dealer.
The battery is equipped with 3 LEDs. Each LED
stands for approx. 33% battery charge (see page
7).
In addition, when installed, the charge level is
shown in the display on the handlebar.
Please read the operating instructions of the dis-
play manufacturer.
After charging, disconnect the battery from the
charger and the charger from the mains.
Only use the original charger or an identical origi-
nal charger.
Only use the original charger or an identical origi-
nal charger.
Only these are matched to the lithium-ion battery
used.
Note: The battery is delivered only partially
pre-charged. In order to ensure full capacity and
functionality, fully charge the battery before the
first ride.
Lithium-ion batteries can be charged at any state
of charge. Any interruptions will not damage the
battery.
Due to the integrated temperature monitoring,
charging of the battery is only permitted between
0°C and 40°C.
Lithium-ion battery AST-09
Nominal voltage (V=) 36
Nominal capacity (Ah) 13,9 AH
Energy (Wh) 504
Operating temperature (°C) -5...+40
Storage temperature (°C) -10...+60
Permissible charging temp. (°C) 0...+40
Weight approx. 3 kg
Protection class IP51
Care & Handling
Charging of Battery
Technical Data of Battery Assembly
Transport

6
If you do not use the battery for a long time (> 3
months), charge it to about 30-60% before.
After 6 months, the charge level should be che-
cked and adjusted if necessary.
Note: If the battery is stored empty for a longer
period of time, it may be damaged and the battery
capacity reduced despite low self-discharge.
It is not recommended to leave the battery per-
manently connected to the charger.
The battery must not be immersed in water or
cleaned with a water jet.
Carefully clean the battery with a slightly damp
and soft cloth.
Caution: Do not touch the contacts with a
damp cloth.
Clean the plug poles occasionally and grease
them lightly.
Due to the magnetic closure, the poles may be
contaminated by metal particles. Check and clean
them regularly.
If the battery is no longer in working order, please
contact your authorized dealer.
Batteries, accessories and packaging must be
recycled in an environmentally friendly manner.
Tape the open poles before disposal.
Batteries must not be disposed of with household
waste!
Do not touch damaged batteries with bare hands
as this may cause skin irritation.
Keep a defective battery in a safe place outdoors.
Contact your dealer for assisting you in disposing
of the battery properly.
Storage of Battery Service & Maintenance
Disposal
The battery is equipped with 3 LEDs. Each LED
stands for approx. 33% battery charge.
Furthermore, when installed, the charge level is
shown in the display on the handlebar.
Please read the operating instructions of the
display manufacturer.
After charging, disconnect the battery from the
charger and the charger from the mains.
If you have technical questions about your
batteries, please contact your authorized bicycle
dealer.
Take a note of the manufacturer and your key
number.
If you lose your key, contact your authorized
dealer. Please indicate the key manufacturer and
key number.
Charge Indicator
Customer Service &
Support
The battery should be stored in a well-ventilated
and dry place. Protect it from moisture and water.
In case of unfavorable weather conditions, it is
recommended to dismantle the battery and store
it in closed rooms until the next journey.
We recommend storing your battery between 0°C
and 20°C.
Avoid temperatures below -10°C and above 60°C.
An optimal storage temperature is 20°C.
Make sure that the maximum storage temperature
is not exceeded. Therefore, do not leave the batte-
ry in the car and do not store it in direct sunlight.
We do not recommend storing the battery in a
bicycle.
Storage Conditions

7
According to the European directive 2012/19/EU,
electrical appliances that can no longer be used,
and according to the European directive 2006/66/
EC, defective or used batteries must be collec-
ted separately and reused in an environmentally
friendly manner. Return batteries that can no lon-
ger be used to an authorized bicycle dealer.
Subject to change without notice.
Simplo Snake Battery, Typ AST-09
a) Lever
d) Power button
Retaining lug
Battery cover
Battery management system
b) Battery cells
c) Charge level indicator
Lock hook

8
Step 1
Step 2
Insert the key into the lock on the left side and turn it counterclockwise to loosen the
cover on the right side.
Hold the cover firmly with your other hand to prevent it from falling out.
Remove the cover on the right side to access the battery.

9
Step 3
Step 4
Use the lever to pull the upper battery cell a little outwards.
Pull the battery cell by cell up and out of the opening.

10
Step 5
To replace the battery, proceed in exactly the opposite order.
The battery is automatically connected to the pedelec port by a magnet when fully
inserted.

11
Step 6
To close, insert the cover with the lower lug and press the upper side against the frame.
Turn the key clockwise and to the end and remove the key.

12
b) Marquardt Comfort Display
Control unit: Marquardt Comfort
1) Overview of the Comfort control unit
2) Mounting the Comfort control unit
3) Operating and display elements
3.1) Operating keys
3.2) Displays of the Comfort control unit
4) Operating
4.1) Switching on and off
4.2) Operation
4.2.1) Headlight
4.2.2) Setting support
4.2.3) Walk assist
4.2.4) USB port
5) Error codes
6) Technical data
7) Disposal

13
1) Overview of the Comfort control unit
Switch the pedelec on and off at the Comfort
control unit. Use the two keys and the joystick
to activate and control support from the electric
motor or switch on the headlights.
The Comfort control unit‘s display shows the
current driving speed. You can also see which
support level is active, how long the power for the
support motor will last, the charge level of the bat-
tery and whether the light is switched on. You can
also view the trip kilometers, average speed and
maximum speed for the current tour. The Comfort
control unit also displays the total mileage of the
pedelec and the maximum speed over the entire
distance.
2) Mounting the Comfort control unit
Check the fastening screws at regular intervals.
Shocks, heat and cold may cause the screws to
loosen. Tighten all screws to the required torque.
The Comfort control unit can be mounted on the
left or right handlebar side. The protruding page
faces inwards. It is not above the handlebar grips.
Position the control unit close to the handle. All
keys must be easy to operate with your thumb.
1. Unscrew the hexagon socket screw with a
hexagon socket SW 2.5 on the bracket of the
control unit. Open the mounting bracket.
2. Position the control unit on the left-hand side of
the handlebar.
3. Position the connecting cable in the control
unit bracket. It must lie in the guide troughs on
the inside of the bracket and be guided through a
recess in the bracket to the con-nection.
4. Close the bracket. Pay attention to the
connecting cable. The connecting cable must not
be crushed by the bracket.
5. Turn the hexagon socket screws on the bracket
back in with a hexagon socket SW 2.5. Do not
tighten the screws yet.
Check the position of the Comfort control unit.
Are all keys accessible with the thumb? Is the
advertisement clearly visible?
6. Tighten the hexagon socket screw with the
hexagon socket (min. torque 0.3 Nm, max. torque
0.5 Nm).
7. Connect the purple plug of the control unit to
the socket of the same color on the wiring harn-
ess. Ensure that the cut-outs in the plug and so-
cket meet so as not to damage the connection.
The Comfort control unit is installed.
3) Operating and display elements
Use the keys on the Comfort control unit to
regulate the functions of the pedelec system
ergo-nomically. The hand can remain on the
handlebar grip, while the thumb can operate the
keys on the Comfort control unit. The displays on
the control unit display provide information about
the driving situation and the support aids.

14
3.1) Operating keys
The keys on the Comfort control unit are used to
control the functions of the pedelec system.
Abb. 2 Keys and joystick of the Comfort control
unit
3.2) Displays of the Comfort control unit
The displays of the Comfort control unit offer dif-
ferent information on different pages. The joy-stick
moves sideways to switch between the pages.
Some of the pages offer additional pages that are
controlled by vertical movements of the joystick.
The main page provides the following information:
1. Indication of the current support.
2. Speed
3. Status display for
triangle symbol: Sliding aid active.
Lighting: Symbols show the status.
4. Battery charge status.
The other pages are designed according to the
following pattern:
1. Symbol for the page.
2. Horizontal navigation position.
3. Page content.
4. Vertical navigation position: Refers to further
pages and shows the current position.
Key Function
T1
Increase support level
Hold > 3s: Switch on walk assist until key is no
longer held.
T2 Reduce support level
T3 Joystick:
One page up. Switch to editing mode.
One entry higher in editing mode.
Move to the next page to the left.
In editing mode, exit the mode and confirm the value.
In edit mode, edit the highlighted value.
Switch to the next page to the right.
In editing mode, exit the mode and confirm the
value.
Move one page down. Switch to editing mode.
One entry higher in editing mode.
T4 Switch the Comfort control unit on and off.
T5
Short press: Switch on the light.
Long press: Switch off the light.
In automatic mode: The light is switched on or off
depending on the ambient light. The light can always
be switched on or off manually using this switch.

15
Driver Performance
Fig. 3 Comfort Page Driver performance
Shows the current power output by the user to
drive the pedelec in watts. This value is transmitted
by the motor to the control unit.
Automatic light (setting menu)
Fig. 4 Comfort Page Automatic light
Activate the automatic mode for the headlight here.
The light is then switched on or off depend-ing on
the ambient brightness. If the automatic mode is
switched on, the headlight symbol is displayed
with an „A“ on the main page. The light can be
switched on or off at any time using the T5 key.
Remaining range
Fig. 5 Comfort Page Remaining range
Shows the remaining range of the pedelc with as-
sistance.
Tour Distance
Fig. 6 Comfort Page Tour Distance
Displays the distance travelled since the value was
last reset.
This page contains additional pages.
Tour Distance / Average Speed
Fig. 7 Comfort Page Tour average speed
Medium speed.
Displays the average speed of the current route.
Tour Distance / Maximum speed
Fig. 8 Comfort Page Tour-Max. Speed
Maximum speed.
Displays the highest speed of the current route.
Tour Distance / Reset
Fig. 9 Comfort Page Tour-Reset
Reset - Move the joystick (T3) down to
activate the RESET function (change the
color of the menu item from black to white).
By briefly pressing the joystick, the tour va
lues are reset to „0“.
The values for the distance, average speed
and maximum speed of the current tour
are deleted and set to „0“.

16
Total Distance
Fig. 10 Comfort Page Total Distance
Displays the total distance covered by the pedelec.
Another page belongs to this display.
Total Distance / maximum speed
Fig. 11 Comfort Page Max. Speed.
Shows the highest speed on the total distance
covered by the pedelec.
4) Operating
4.1) Switching on and off
Switching on the Comfort control unit
Press the T4 key for less than 2
seconds.
The display shows the home screen, then
changes to the Main screen.
Switching off the Comfort control unit
Press and hold (>2s) the T4 key.
The display goes out.
4.2) Operation
4.2.1) Headlight
Press the T5 key to switch the light on or off. If
the automatic light function is activated, the light is
switched on or off according to the ambient light.
The main page shows the current status of the
running light with the following symbols:
Switch on the headlight
Briefly press the T5 key.
The headlight is switched on.
The headlight symbol shows the normal
light status.
Switching of the headlight
Press and hold (>2 sec) the T5 key.
The headlight is switched off.
The headlight symbol shows the current status.
Automatic mode Switching the headlights on
and off
You activate the automatic mode for the headlight
on the „Automatic light“ page.
The automatic mode switches the headlight on or
off according to the ambient light.
In automatic mode, you can switch the headlight
on or off at any time with the T5 key.
4.2.2) Setting support
The electric motor of your pedelec supports
your pedaling power. Several support levels
are available. You can also drive without motor
assistance.
You set the support levels on the Comfort
control unit (T4 / T2).
The current support level indicates Comfort
with a scale.
The selected level is immediately effective.
You can see the active level from the bright
segments of the support display on the main page
of the Comfort control unit.
Symbol Headlight
- Headlight off
Headlight on
Automatic mode on - Headlight off
Automatic mode Headlight on
A
A

17
Enable support
The display shows no support level.
1. Press the T4 key on the Comfort control
unit.
The electric motor supports the drive.
The first segment is shown in the support
display.
Increasing support
1. Press the T4 key. You switch to the next
higher level.
The electric motor provides more support
to the drive.
Further segments are displayed in the sup-
port display.
Reducing support
1. Press the T2 key.
The electric motor is less supportive.
In the support display, the number of
segments displayed decreases.
Driving without assistance
1. Press the T2 key until no segment of the
support display is visible.
You are driving without motor support.
4.2.3) Walk assist
Walk assist is available for starting or pushing
the wheel. The drive of the pedelec supports the
movement of the wheel. The sliding aid can be
activated up to a speed of < 6 km/h.
You use the walk assist when pushing the bike,
when starting off or when assisted starting on a
hill. If you push the bike, you move beside the
bike. Use the walk assist as a starting aid when
sitting on the bike.
In both cases, when activated the walk assist
moves the bike.
WARNING!
The walk assist moves the bike.
Hold the handlebar grips and be ready to apply
the brakes.
When sitting on the bike, do not press the pedals.
Your power and the walk assist could accelerate
the pedelec very strongly. The second pedal also
moves and can injure you when you climb up!
Do not use the walk assist for slow driving.
Switch on the walk assist:
Press and hold the T1 key.
The walk assist is active and moves the wheel
The triangle symbol for the walk assist is
displayed on the main page of the display.
Switch off the walk assist:
Release the T1 key.
The walk assist is switched off.
The triangle symbol is no longer
displayed on the main page of the display.
Level Description
None Normal cycling conditions. Motor inactive.
ECO Efficient support for maximum battery range
TOUR Consistent support for long distances with
large battery range
SPORT
Powerful support for sporty driving, on
mountainous roads and in city traffic with
normal battery range
BOOST
Powerful support for sporty driving on steep
and mountainous tracks with low battery
range

18
4.2.4) USB port
The Comfort control unit has a Micro USB AB
plug. The USB plug is located in the tip of the de-
vice above the handlebar and is protected against
dirt and moisture by a rubber cap. A connected
USB device is supplied with max. 1 A charging
current.
Abb. 13 USB-Port
NOTE!
No liability is accepted for damage to the
mobile phone caused by the connection
to the Comfort control unit.
Connecting the USB Device
1. Open the rubber protection cap of the
USB port
2. Connect the USB device to the USB
port - direct connection or with a suitable
USB cable. A so-called OTG USB cable
must be used to charge a device. The
direction of connection must be observed.
The new connection is displayed on the
connected device.
Removing the USB device
1. Disconnect the USB device or the con-
necting cable from the USB port on the
Comfort control unit.
2. Close the USB port with the rubber cap.
NOTE!
Please observe the instructions for di-
sconnecting the USB connection in the
operating manual of the connected
device.
The Comfort control unit is only protected against
water and dirt when the rubber protection is
closed.
To prevent damage to the USB port of the control
unit, it is recommended that the USB cable is
also securely attached to the handlebars.
5) Error Codes
The Comfort control unit displays error codes for
the entire pedelec system. The error codes repre-
sent errors detected by the system. The following
table shows the meaning of the error codes. Plea-
se observe the recommended reaction to the error
codes.
WARNING!
Note the error codes!
Error codes can indicate serious errors in the
pedelec system. These errors prevent safe opera-
tion of the pedelec. Accidents with personal injury
and damage to the pedelec may occur.
Stop using the pedelec. Inform yourself about
the meaning of the error code and observe the
solution approach.
If the meaning of the error code is unclear, stop
the drive and turn off the wheel. Contact the
manufacturer, the dealer or your garage for
information on the next steps

19
Error Code Description Solution
10 The battery voltage is too low Charge the battery pack with the battery charger.
11 The battery voltage is too high
Switch the system completely off and on again using the T4
key on the control unit. If the problem persists, contact your
e-bike dealer.
12 The battery is almost completely discharged Charge the battery pack with the battery charger.
20 Electrical measurements are erroneous Switch the system completely off and on again using the
LED key (28) on the battery pack (26). If the problem per-
sists, contact your e-bike dealer.
21 Thermocouple defective
24 The internal voltage is beyond the operating range Charge the battery pack with the battery charger.
25 Error in the motor current measurement Switch the system completely off and on again using the T4
key on the control unit. If the problem persists, contact your
e-bike dealer.
26 A software reset has been performed
40/41 Detection of overcurrent in the motor Reduce the load on the motor by pedaling less or reducing
the support level.
42 Fault in the engine rotation Switch the system completely off and on again using the T4
key on the control unit. If the problem persists, contact your
e-bike dealer.
43 Short-circuit in the motor
44 Overheating of the motor Reduce the load on the motor by pedaling less or reducing
the support level.
45 The software has corrected an error when turning
the motor Switch the system completely off and on again using the T4
key on the control unit. If the problem persists, contact your
e-bike dealer.
46 No motor movement detected although a current
> 2 A was measured
60 Interruption of data exchange on the CAN-BUS Check the cables and plug connections of all components
of the e-Bike system.
70 Force on the pedal is not within the valid range
Switch the system completely off and on again using the T4
key on the control unit. If the problem persists, contact your
e-bike dealer.
71 Pedal rotation is not detected
72 Force on the pedal is not detected
73 Connection to pedal force sensor is faulty
74 Errors were detected in the data

20
Error Code Solution
80 Erroneous motor parameter
Switch the system completely off and on again using the T4
key on the control unit. If the problem persists, contact your
e-bike dealer.
81 Speed signal is not detected Make sure that the spoke magnet is correctly positioned
opposite the speed sensor.
82 The program has been manipulated
Switch the system completely off and on again using the T4
key on the control unit. If the problem persists, contact your
e-bike dealer.
83 Error in the program flow
84 Erroneous motor parameter
6) Technical Data 7) Disposal
In accordance with the European Directive
2012/19/EU, electrical appli-ances that are no
longer serviceable must be collected separately,
and in accordance with the European Directive
2006/66/EC, defective or used batteries must be
collected separately and reused in an environmen-
tally friendly manner.
Old machines, replacement parts and packaging
are made of recyclable materials. The owner is
obliged to dispose of these properly and in an
environmentally friendly manner in accordance
with the statutory regula-tions.
All plastic injection molded parts are marked with
a recycling symbol.
RoHS Directive (2011/65/EU)
Comfort control unit
Length x width x height 72.8 x 50.2 x 44.6 mm
Operating temperature -10°C to 65°C
Storage temperature -20°C to 85°C
Protection class IP65 (HMI) dustproof, water
spray proof
ESD model Human Body Model (HBM)
USB interface Micro USB Standard 2.0 Full
Speed
USB charging function USB Battery Charging Stan-
dard BC1.2 Max. 1,0 A
CAN Interface ISO 11898-5 High-speed CAN
Description