FiT 500128 User manual

INSTRUCTION MANUAL
Biketec GmbH
Luzernstrasse 84
CH-4950Huttwil
T [phone]
[e-mail]
fit-ebike.com
BATTERY ULTRACORE FIT 36 V
NETWORKED
CUSTOMISED
INTELLIGENT
500128 | 500082 | 500083

INSTRUCTION MANUAL ULTRACORE FIT 36 V
TABLE OF CONTENTS
1 PREFACE 4
2 ABOUT THESE OPERATING INSTRUCTIONS 5
2.1 MANUFACTURER................................................. 5
2.2 LANGUAGE..................................................... 5
2.3 DECLARATIONOFCONFORMITY ........................................ 5
2.4 ONINFORMATION ................................................ 5
2.5 WARNINGS IN THESE OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 SAFETY INSTRUCTIONS 6
3.1 GENERALINFORMATION............................................. 6
3.2 RECHARGEABLEBATTERY............................................ 6
4 PRODUCT AND TECHNICAL SPECIFICATIONS 7
4.1 ULTRACOREFIT36V............................................... 7
4.2 PROPERUSE ................................................... 7
4.3 IMPROPERUSE.................................................. 7
4.4 TECHNICALDATA................................................. 7
4.4.1 ULTRACOREFIT36V .......................................... 7
5 TRANSPORTATION AND STORAGE 8
5.1 TRANSPORTATION ................................................ 8
5.1.1 TRANSPORTINGE-BIKES........................................ 8
5.1.2 TRANSPORTINGTHEBATTERY..................................... 8
5.1.3 SHIPPINGTHEBATTERY ........................................ 8
5.2 STORAGE...................................................... 8
5.2.1 STORAGEMODE............................................. 8
5.3 BREAKINOPERATION .............................................. 9
5.3.1 PREPARING FOR A BREAK IN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3.2 CARRYING OUT A BREAK IN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 FITTING 10
6.1 FITTINGTHEBATTERY.............................................. 10
6.1.1 REMOVINGTHEBATTERY........................................ 10
6.1.2 INSERTINGTHEBATTERY........................................ 10
7 OPERATION 11
7.1 CHARGINGTHEBATTERY ............................................ 11
7.1.1 CHARGINGOPTIONS........................................... 11
7.2 DISPLAYANDSETTINGS............................................. 11
7.2.1 CHARGE LEVEL CHECK ON BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8 ERROR MESSAGES 12
8.1 BATTERYERRORCODES............................................. 12
9 CLEANING AND SERVICING 13
9.1 BASICCLEANING ................................................. 13
9.1.1 CLEANINGTHEBATTERY ........................................ 13
10 TROUBLESHOOTING, FAULT CLEARANCE AND REPAIR 14
10.1 TROUBLESHOOTING AND FAULT CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
10.1.1 DRIVE SYSTEM OR DISPLAY DOES NOT START UP . . . . . . . . . . . . . . . . . . . . . . . . . . 14
10.1.2 ERRORS IN THE ASSISTANCE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
10.2REPAIR....................................................... 15
10.2.1ORIGINALPART ............................................. 15
10.2.2REPLACINGTHELIGHTS ........................................ 15
10.2.3ADJUSTINGTHEHEADLIGHT...................................... 15
FIT_Manual_Battery_Ultracore_36V_V1_en | Version 01 | 04.04.2022 2

INSTRUCTION MANUAL ULTRACORE FIT 36 V
11 RECYCLING AND DISPOSAL 16
11.1DISPOSAL ..................................................... 16
FIT_Manual_Battery_Ultracore_36V_V1_en | Version 01 | 04.04.2022 3

INSTRUCTION MANUAL ULTRACORE FIT 36 V
1 PREFACE
Dear FIT customer,
The FIT system offers many useful functions and options and we are pleased that you have decided to choose our
system.
Please read through the operating instructions carefully to ensure you use the system safely and get off to a quick
start.
We hope you enjoy discovering the FIT’s functions and have a fun ride every time you use it.
Thank you for placing your trust in FIT.
Your FIT Team
FIT_Manual_Battery_Ultracore_36V_V1_en | Version 01 | 04.04.2022 4

INSTRUCTION MANUAL ULTRACORE FIT 36 V
2 ABOUT THESE OPERATING INSTRUCTIONS
2.1 MANUFACTURER
Biketec GmbH
Luzernstrasse 84
CH-4950 Huttwil
fit-ebike.com/en-en/
2.2 LANGUAGE
The original operating instructions are written in German. A translation is invalid without the original operating in-
structions.
2.3 DECLARATION OF CONFORMITY
Biketec GmbH hereby declares that the products described in these operating instructions comply with EU directives.
The complete EU Declaration of Conformity is available online at: fit-ebike.com/en-en/service/declaration/
2.4 ON INFORMATION
Different markings are used in the operating instructions to make them easier to read.
2.5 WARNINGS IN THESE OPERATING INSTRUCTIONS
Warnings indicate hazardous situations and actions. You will find the following warnings in the operating instructions:
DANGER
May lead to serious or even fatal injuries if ignored. Medium-risk hazard.
CAUTION
May lead to minor or moderate injuries if ignored. Low-risk hazard.
NOTICE
May lead to material damage if ignored.
FIT_Manual_Battery_Ultracore_36V_V1_en | Version 01 | 04.04.2022 5

INSTRUCTION MANUAL ULTRACORE FIT 36 V
3 SAFETY INSTRUCTIONS
3.1 GENERAL INFORMATION
Please read all safety instructions carefully. Failure to comply with the warnings or to take residual risks into ac-
count may result in electric shock, fire and/or serious injury.
Keep the operating instructions in a safe place and have them readily available to consult. Pass these instructions
on if you provide your e-bike for someone else’s use.
When used in these operating instructions, the word “battery” refers to all original FIT e-bike batteries.
3.2 RECHARGEABLE BATTERY
Remove the battery from the e-bike before you start working on the e-bike (e.g. inspection, repair, fitting, mainte-
nance, work on the chain), transport it by car or plane or if you are not going to use it for extended period of time.
There is a risk of injury if the e-bike system is activated unintentionally.
Do not open up the battery as you risk causing a short circuit.
Protect the battery from heat (e.g. including continuous direct sunlight), fire and being submerged in water. Do not
store or operate the battery in close proximity to hot or flammable objects as this pose a risk of explosion.
Keep the unused battery away from paper clips, coins, keys, nails, screws or other metal objects which could cause
an electrical arc between the contacts. A short circuit between the battery contacts can cause fire or burns.
Avoid any physical loads on the battery. They may inflict damage to the battery cells and cause flammable substances
to leak out.
Do not put the charger and battery down next to flammable materials. Only charge batteries when they are dry and
in a fireproof place. There is a risk of fire due to heat accumulating during charging.
The e-bike battery must not be left unattended while it is charging.
If the battery is used incorrectly, liquid may leak from it. Avoid coming into contact with the liquid. Rinse off with
water in the event of accidental contact. If the liquid gets into eyes, seek medical attention. Leaked liquid can cause
skin irritation and burns.
Vapours may be emitted if the battery is damaged or used improperly Ventilate with fresh air and consult a doctor if
you suffer any pain or discomfort. The vapours can irritate the airways.
Charge the battery with original FIT chargers only. Risk of fire cannot be ruled out if non-original FIT chargers are used.
Use the battery in e-bikes with the FIT system only. This is the only way that the battery will be protected from dan-
gerous overloading.
Only use original FIT rechargeable batteries which the manufacturer has approved for your e-bike. Using other bat-
teries can result in injuries and risk of fire. FIT accepts no liability and offers no warranty if other batteries are used.
Keep the battery away from children.
Our e-bike rechargeable batteries are lithium-ion batteries which are developed and manufactured to the latest tech-
nical standards. Lithium-ion batteries have a high energy content when charged. In the event of a defect, possibly not
visible on the outside, lithium-ion batteries may catch fire in very rare instances and under unfavourable conditions.
FIT_Manual_Battery_Ultracore_36V_V1_en | Version 01 | 04.04.2022 6

INSTRUCTION MANUAL ULTRACORE FIT 36 V
4 PRODUCT AND TECHNICAL SPECIFICATIONS
4.1 ULTRACORE FIT 36 V
Ultracore batteries were developed for integration into the down tube and are easy to fit and remove without tools.
The batteries are perfectly matched to the FIT system and work safely and reliably. They cover a wide range of appli-
cations for short or long distances.
The intelligent battery management system protects the battery against overloading, overheating, overcurrent, un-
dervoltage and other sources of error.
1. Battery level indicator
2. Charging socket
4.2 PROPER USE
All check lists and instructions for actions in these operating instructions met.
Only use original FIT rechargeable batteries which the manufacturer has approved for your e-bike.
The rechargeable batteries are designed to supply power to the e-bike motor only and must not be used for other
purposes.
4.3 IMPROPER USE
Improper use refers to use which is not described under proper use or goes beyond proper use.
4.4 TECHNICAL DATA
4.4.1 ULTRACORE FIT 36 V
Rechargeable battery Ultracore 555 FIT 36 V Ultracore 740 FIT 36 V Ultracore 925 FIT 36 V
Product code 500128 500082 500083
Cell configuration 10S3P 10S4P 10S5P
Capacity (minimum) Ah 14.55 19.8 24.2
Energy (nominal) Wh 555 740 925
Voltage (nominal) V 36.9 36.9 36.9
Charging current (nom-
inal)
A 6 6 6
Discharging tempera-
ture
°C -20 to +55 -20 to +55 -20 to +55
Charging temperature °C 0 to +45 0 to +45 0 to +45
Storage temperature
(recommended)
°C 10 to +25 10 to +25 10 to +25
Weight about kg 3.3 3.7 4.5
FIT_Manual_Battery_Ultracore_36V_V1_en | Version 01 | 04.04.2022 7

INSTRUCTION MANUAL ULTRACORE FIT 36 V
5 TRANSPORTATION AND STORAGE
5.1 TRANSPORTATION
CAUTION
Remove battery before transportation.
There is a risk of injury if the drive system is switched on unintentionally.
5.1.1 TRANSPORTING E-BIKES
Never use bicycle racks which use the e-bike’s handlebars or frame to hold the e-bike in an upside-down position.
They can exert inadmissible forces on components during transportation. This can cause the supporting parts to
break. The specialist dealer will advise you on how to select a suitable rack system properly and how to use it safely.
Take the weight of the ready-to-use e-bike into account when transporting. Protect the electrical components and
connections on the e-bike from the elements with suitable protective covers. Transport the battery in a dry, clean
position where it is protected from direct sunlight.
5.1.2 TRANSPORTING THE BATTERY
Batteries are subject to hazardous goods regulations. Private individuals may transport undamaged batteries in road
traffic. Commercial transport operators must comply with regulations on packaging, labelling and the transportation
of hazardous goods. Open contacts must be covered and the battery securely packaged.
5.1.3 SHIPPING THE BATTERY
The battery is considered a hazardous good and only trained persons may pack and ship a battery. Contact your
specialist dealer.
5.2 STORAGE
CAUTION
Store e-bike, display, battery and charger in a clean, dry place where they are protected from sun-
light.
Do not store outdoors to ensure a long service life.
The optimum storage temperature for your e-bike is between 10 °C and 20 °C.
Temperatures under -10 °C or above +40 °C must generally be avoided.
Store e-bike, display, battery and charger separately.
5.2.1 STORAGE MODE
The battery features a power-saving CHARGE TO STORAGE mode, which minimises discharge from the battery. Con-
figure the CHARGE TO STORAGE mode in the battery settings.
FIT_Manual_Battery_Ultracore_36V_V1_en | Version 01 | 04.04.2022 8

INSTRUCTION MANUAL ULTRACORE FIT 36 V
5.3 BREAK IN OPERATION
NOTICE
The battery discharges when not in use. This can cause irreparable damage to the battery.
The battery must be recharged every 6 months.
The battery may become damaged if it is connected permanently to the charger. Never connect the battery to the
charger permanently. If you remove the e-bike from service for longer than four weeks, you need to prepare it for a
break in operation.
5.3.1 PREPARING FOR A BREAK IN OPERATION
Remove battery from the e-bike.
Charge battery to around 30–60% (storage mode).
Before longer periods without use, it is recommendable to have your specialist dealer carry out an inspection
and basic cleaning and apply preservative agent.
5.3.2 CARRYING OUT A BREAK IN OPERATION
Store the e-bike, battery and charger in a dry, clean environment. We recommend storing them in uninhabited rooms
with smoke alarms. Dry locations with an ambient temperature between 10 °C and 20 °C are ideal. Check the battery
level after 6 months. If only one battery level LED indicator lights up, recharge the battery to around 30–60%.
FIT_Manual_Battery_Ultracore_36V_V1_en | Version 01 | 04.04.2022 9

INSTRUCTION MANUAL ULTRACORE FIT 36 V
6 FITTING
6.1 FITTING THE BATTERY
6.1.1 REMOVING THE BATTERY
1. Turn safety lever to the right.
2. Push the battery up into the frame using your right hand.
⇒The lock hook in the frame is now released.
3. Support the battery from below with your right hand. Push the key towards the down tube.
⇒The lock hook releases the battery.
4. Depending on how much play the battery has in the down tube, the battery will fall out of the frame or can be
pulled out of the down tube.
5. Remove the key from the lock.
6.1.2 INSERTING THE BATTERY
1. Use the contacts to place the battery in the lower holder.
2. Use the key to open the lock.
3. Push the key towards the down tube and hold it.
⇒The lock hook in the frame clears the way for the battery.
4. Tilt the battery into the down tube. Press the battery into the frame with some pressure.
5. Let go of the key.
6. The lock hook moves to the holding position and holds the battery.
7. Lock the lock. Remove the key.
8. Turn the safety lever to the left.
9. Check the battery for a secure fit.
FIT_Manual_Battery_Ultracore_36V_V1_en | Version 01 | 04.04.2022 10

INSTRUCTION MANUAL ULTRACORE FIT 36 V
7 OPERATION
7.1 CHARGING THE BATTERY
7.1.1 CHARGING OPTIONS
The battery can be charged while inserted in the e-bike or after it has been removed. Look in the e-bike manufac-
turer’s original operating instructions to find where the e-bike charging socket is. Connect the charger to the e-bike
charging socket (or directly to the battery) to charge. The charge indicator will automatically appear on the e-bike
display screen if the battery is fitted into the e-bike. The display backlight will go out after a certain period of time.
However, you can press the On-Off button to switch it back on again at any time.
7.2 DISPLAY AND SETTINGS
7.2.1 CHARGE LEVEL CHECK ON BATTERY
1. Checking button for the battery charge level
Lights up the battery charge LEDs to check the remaining battery capacity or a possible fault with the battery
itself.
2. Battery level LEDs
Indicate how much e-bike battery capacity is left. An error code is displayed in the event of a fault. You will find
the error table later in these instructions.
Each lit battery level light represents around 20% of the battery capacity. If the battery is completely discharged, this
is indicated by a rapidly flashing LED.
FIT_Manual_Battery_Ultracore_36V_V1_en | Version 01 | 04.04.2022 11

INSTRUCTION MANUAL ULTRACORE FIT 36 V
8 ERROR MESSAGES
8.1 BATTERY ERROR CODES
Flash sequence for the battery
charge level LEDs after pressing
the battery charge level button
Description Action
LEDs go out briefly in sequence
from left to right.
Permanent Error
The battery has a permanent error
The battery needs to be replaced.
Take your e-bike to your specialist
dealer. The battery is considered
to have an unknown defect in this
state and must not be transported
in a vehicle or by air. It is best if
you contact your dealer.
LEDs flash on briefly in sequence
from left to right.
Charge Error
The battery has been overcharged
and the charger may have a fault
Take your e-bike to your specialist
dealer.
Current Error
There may be a fault in the motor
or charger, or the battery may
have gone into deep discharge.
Take your e-bike to your specialist
dealer.
Temperature Error
The battery temperature is
outside the permitted range.
If flashing persists after the
system has not been used for a
long time, the battery needs
replacing. Take your e-bike to your
specialist dealer. The battery is
considered to have an unknown
defect in this state and must not
be transported in a vehicle or by
air. It is best if you contact your
dealer.
Authentication Error
An authentication error may have
occurred.
Check the connections for dirt. If
the flashing still persists after
cleaning the connections and after
the battery has not been used for
a while, take the e-bike to your
specialist dealer.
FIT_Manual_Battery_Ultracore_36V_V1_en | Version 01 | 04.04.2022 12

INSTRUCTION MANUAL ULTRACORE FIT 36 V
9 CLEANING AND SERVICING
9.1 BASIC CLEANING
9.1.1 CLEANING THE BATTERY
CAUTION
Risk of fire and explosion due to penetration by water
The battery is only protected against simple spray water. Penetration by water can cause a short
circuit.
The battery may self-ignite and explode.
Never clean the battery with a pressure washer, water jet or compressed air.
Keep contacts dry and clean.
Never immerse the battery in water.
Never use cleaning agents.
Remove the battery from the e-bike before cleaning.
NOTICE
Never clean the battery with cleaning agents or with solvents, such as oil, thinners, alcohol or cor-
rosion protection.
Clean the battery electrical connections with a dry cloth or paintbrush only.
Wipe off the decorative sides with a damp cloth.
FIT_Manual_Battery_Ultracore_36V_V1_en | Version 01 | 04.04.2022 13

INSTRUCTION MANUAL ULTRACORE FIT 36 V
10 TROUBLESHOOTING, FAULT CLEARANCE AND REPAIR
10.1 TROUBLESHOOTING AND FAULT CLEARANCE
10.1.1 DRIVE SYSTEM OR DISPLAY DOES NOT START UP
If the display and/or the drive system do not start up, proceed as follows:
1. Check whether the battery is inserted correctly. If it is not, insert the battery correctly.
2. Start the drive system.
3. If the drive system won’t start, remove the battery.
4. Clean all the contacts with a soft cloth.
5. Insert the battery.
6. Start the drive system.
7. If the drive system won’t start, remove the battery.
8. Fully charge the battery.
9. Insert the battery.
10. Start the drive system.
11. If the drive system won’t start, press the on-off button (operating element) for at least 8 seconds.
12. If the drive system does not start after about 6 seconds, press the on-off button (operating element) for at least
2 seconds.
13. Contact your specialist dealer if the drive system does not start.
10.1.2 ERRORS IN THE ASSISTANCE SYSTEM
Symptom Cause Remedy
Assistance is not
available.
Is the speed too high? 1. Check display screen. The motor assistance is
only active up to the maximum speed for which
the e-bike is approved.
Is the battery charged sufficiently? 2. Check battery is charged.
3. Recharge the battery if it is almost flat.
The motor may become too hot
during rides at high temperatures,
up long inclines or when carrying a
heavy load for a long time.
4. Switch off the drive system.
5. Wait a moment and then check again.
The rechargeable battery, display
or operating element may be
connected incorrectly, or one or
more of them may have a problem.
6. Contact your specialist dealer.
Assistance is not
available.
Are the pedals being pushed? 1. Your e-bike is not a motorbike. Push the pedals.
Is the system switched on? 2. Press on-off button (operating element) to
switch on the system.
Is the level of assistance set to
OFF?
3. Set the level of assistance to HIGH,STD,ECO or
AUTO.
4. Contact your specialist dealer if you still feel that
the no assistance is being supplied.
FIT_Manual_Battery_Ultracore_36V_V1_en | Version 01 | 04.04.2022 14

INSTRUCTION MANUAL ULTRACORE FIT 36 V
Symptom Cause Remedy
The assisted
journey distance
is too short.
The battery does not perform as
well in winter weather.
This does not indicate a problem.
The journey distance can be
shorter depending on the road
conditions, the level of assistance
and the total light usage time.
1. Check battery is charged.
2. Recharge the battery if it is almost flat.
Is the battery fully charged? 3. If the distance covered with a fully charged
battery has become shorter, the battery may be
affected. Replace the battery with a new one.
The battery is a consumable.
Repeated charging and long
periods of use cause the battery to
degrade (loss of power).
4. If the distance you can cover with one single
charge is very short, replace the battery with a
new one.
It is difficult to
pedal.
Are the tyres pumped to an
adequate pressure?
1. Pump up tyres.
Is the level of assistance set to
OFF?
2. Set the level of assistance to HIGH,STD,ECO or
AUTO.
The battery charge might be low. 3. Check battery is charged.
4. Recharge the battery if it is almost flat.
Have you switched on the system
with your foot on the pedal?
5. Switch on the system again without applying
pressure to the pedals.
6. If assistance is still not supplied, contact your
specialist dealer.
10.2 REPAIR
Special expertise and tools are required for many repairs. That is why only a specialist dealer may perform repairs.
10.2.1 ORIGINAL PART
The individual e-bike parts have been carefully selected and matched to one other. Only original parts must be used
for maintenance and repair. Observe the operating instructions for the new components.
10.2.2 REPLACING THE LIGHTS
Replace components with ones in the right power class.
10.2.3 ADJUSTING THE HEADLIGHT
The headlight must be positioned so that its beam hits the road surface 10 m in front of the e-bike.
FIT_Manual_Battery_Ultracore_36V_V1_en | Version 01 | 04.04.2022 15

INSTRUCTION MANUAL ULTRACORE FIT 36 V
11 RECYCLING AND DISPOSAL
11.1 DISPOSAL
Mechanical and electrical devices, accessories and packaging should be taken for recycling in an environ-
mentally responsible manner. Do not dispose of them in the household waste!
For EU countries only: According to the European Directive 2012/19/EU on waste electrical and electronic
equipment and its implementation in national law, chargers that can no longer be used must be collected
separately and recycled in an environmentally responsible manner.
FIT_Manual_Battery_Ultracore_36V_V1_en | Version 01 | 04.04.2022 16