GWL Power EVBIKE User manual

EV-POWER.EU (GWL/Power group)
i4wi a.s., Průmyslová 11, 102 19 Prague 10
Phone.: [phone], Fax: [phone]
e-mail: e[email protected]
http://www.evpower.eu
INSTALLATION MANUAL

Dear Customer,
Congratulations on purchasing your EV-BIKE, we believe you will be fully satisfied. The electric bike is one of
the most economical types of transport with minimal operating costs. Mounting kit EVBIKE is intended as
conversion kit of your existing bike to the bike with electric drive.
EV-BIKE set is compatible with almost every mass-produced bike. We rocommend you before installation
consult compatibility and extent of adjustments with your nearest EVBIKE service partner. The up to date list
of the partners can be found on the website www.evbike.cz in "Partners" section.
Most bicycles is designed for a maximum load up to 120 kg (weight of the rider, bike and accessories). EVBIKE
set is also designed for such load. In case of exceeding weight limit, it is necessary to select rim with spokes
designed for higher load. Information about special rim will provide you our your service partners.
In rare cases it could happen that you do not like purchased product, or you have found fact in the assembly
manual that would prevent you from using EVBIKE kit, please return back EVBIKE kit before installing in the
original packaging. For the current warranty conditions and the possibility of returning, please contact your
dealer who will advise you on how to proceed.
We wish you many happy kilometers!
INSTALLATION MANUAL
2
EVBIKE SET IS SOLD AS A KIT. FOR SAFETY AND COMPLIANCE WITH LEGISLATIVE
REQUIREMENTS, THE FINAL PRODUCT IS FULLY GUARANTEED BY THE BIKE OPERATOR
OR WHOEVER ASSEMBLED AND SOLD THE BIKE.
WE RECOMMEND ENTRUST THE INSTALLATION TO A PROFFESIONAL BIKE SERVICE.
PLEASE CAREFULLY READ THIS INSTALLATION MANUAL BEFORE YOU START THE EVBIKE
CONVERSION.

Motor power:
Motor weight:
Maximum speed:
Driving range:
Size and material of rim:
Maximum rim load:
Drive:
Battery types:
Battery Weight:
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up to 500 W / 36 V (limited to 250 W)*
6,6 Kg
up to 40 km/h with pedal assistence (limited to 25 km/h)*
30 - 70 km - depending on pedalling intensity, nature of the terrain and
used battery type
26" or 28" x 1,75", Alluminium alloy 6061, (double wall)
50 - 70 kg, total bicycle load up to 120 kg must not be exceeded
(includes the weight of the rider, bike and EVBIKE set)
front/rear
Lithium 36 V, capacities 10 Ah, 7 Ah and 6 Ah
4,8 kg (10 Ah), 3,1 kg (7 Ah) and 3,6 kg (6 Ah)
TABLE OF CONTENTS
SPECIFICATIONS
Due to European laws for electric bikes, maximum speed is limited to 25 km/h. The limitation can be set off for running at private
roads etc.
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1. Changing of rim with motor
2. Pedal assistant
3. Controller and cabling
4. LCD panel instalation
5. Brakes, accelerator, handle
6. Battery installation
7. Charging
page 5
page 7
page 8
page 9
page 11
page 12
page 15
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3
INSTALLATION MANUAL

KIT FOR CONVERSION OF BIKE TO ELECTRIC BIKE (EV BIKE)
Controll unit
Magnet
Sensor
LCD display Pedal assistant
Sensor
Magnet
Accelerator
Brake levers
EVBIKE HUB motor
Baery
For succesful assembly of EVBike, you will also need following:
strip belts (to hold cables)
screws, nuts, washers
usual assembly tools
special bottom bracket tools (Fig. 1a - 1c)
basic technical skills
1
ab c
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EVBike is one of the cheapest vehicles with minimal running costs. This assembly pack is meant for conversion
of your current bike to electric bike.
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INSTALLATION MANUAL

DETAILED MANUAL
Mounting of the rim differs bike to bike. For all bike types we recommend to use the torque arm. See Figures
2, 4, 5. The torque arm will eliminate the reaction torque on axe (Fig. 6). Torque arm is partof the optional
accessories and is not included in basic package.
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2 3
4 5
Remove the original wheel and swap tire to the EVBIKE HUB motor rim.
Insert the EVBIKE HUB motor into the fork. When installing, make sure the correct direction of rotation.
The cable come out on right side of the fork when bike is in the normal position. Otherwise the wheel will
run backwards against direction of way.
1. Installing EVIBIKE HUB motor
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5
INSTALLATION MANUAL

6
Direcon of engine
torque Reacon torque
on axle Axle spinout and spread dropouts
Example of torque arm installaon
7 8
In addition, you must dismount the freewheel shimano gears. To dismount the freewheel use a special pinion
puller (Fig. 1b). The rear hub motor is ready for mounting freewheel with screw pinion. For most bikes
equipped with 7 gears shimano wheel is a screw pinion. For bikes with 8 gears or more gears is not
recommended to use the rear hub motor because here is a potential of many complications during
the installation. For bikes with 8 and more gears we recommend to use the front wheel hub motor.
The cable come out on left side of rear fork when the bike is in normal position.
After installation the hub motor you will need to adjust the sorting of gears. Its needed to avoid a collision
with the hub motor.
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Engine
shaft
Nut
Motor
Fork
spring washer (not included)
In any case, it is necessary to ensure tight connection nuts, washers and fork surface. Insufficient
nut tightening may cause wheel dropping out of the fork. The connection between wheel and fork
must be firm and stable (Fig. 7).
CAUTION
When you install the hub motor to the rear wheel (Fig. 8), proceed the same way. There are only
following differences between front and rear wheel installation.
NOTICE
6
INSTALLATION MANUAL

When you start pedal, the pedal assistant will automatically adjust motor power.
To install this part, you have to remove spindle. Removing requires special tools (Fig. 1a, 1c).
2. Pedal assistant
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2-5 mm
Disassemble the bike parts as shown at the Fig. 9.
Mout plastic wheel with magnets in correct direction of rotation (shown on wheel by arrows).
There must be about 2-5 mm space between plastic wheel and sensor. Depending on the type of bicycle,
the distance between the magnet wheel and sensor could be too small respectively large. Sensor ring sleeve
can be rotated and sensor bolted from the other side (Fig. 10).
Assembly all parts back. Before final tightening you should check the correct function of pedaling
detection.
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If you mount kit on a scooter, or operate it only in accelerator mode, you can skip pedal assistant
assembly.
TIP
9
spindle
bike frame
Crankset
pedal
pedal assistant
sensor
pedal assistant
plastic wheel with magnets
removable
ring
2-5 mm
10
7
INSTALLATION MANUAL

3. Controller and cabling
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Make sure proper cable connection! Conectors have different colors so risk of incorrect
connection is minimised (Fig. 11). In addition, they have locks against turn over. Use adequate
strength to connect connectors. If you use excessive force, you may damage the connectors!
Before connecting cables to the controller, make sure that all the pins inside the connectors are
properly seated. All pins must be in straight direction to the opposite connector body. Before cable
connecting, check the contacts and make adjustments to ensure perfect contact pins
with the opposite connector pins. Wrong cables or pins connecting can cause serious damage
of bike parts - especially the battery, motor and controller. Damages due the incorrect cable or pins
connecting will void your warranty
When connecting the motor connector and controller, make sure that the arrows on the connectors
facing each other (Fig. 13).
WARNING
Battery power
Speed sensor
Motor connector
Main wire for control elements
(LCD display, brakes, accelerator)
Pedal assistant
12
brake
brake
LCD display
accelerator
13
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INSTALLATION MANUAL

4.1. Installation of the LCD panel to the handlebar
The LCD panel (Fig. 14) can be installed on both sides of the handlebar (left or right). Please have in mind
the correct position of buttons – the lettering "MODE" must be read from the perspective of the rider. After
installation of the LCD panel please connect cable to the control unit.
4.2. Installation the wheel speed sensor
Speed sensor (Fig. 15) must be installed as near to the control unit. In most cases this will be to the rear
wheel. Sensor attach to the frame. Magnet must be installed close to the speed sensor. The optimal distance
between the magnet and the speed sensor is about 5 mm. (Fig. 17) If the display does not show information
about speed and distance, the error is in the installation of speed sensor.
4. LCD panel installation
16 17
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INSTALLATION MANUAL
2-5 mm
14
Control buttons 15
Magnet
LCD display
Sensor
If the speed sensor or magnet are not installed correctly EVBIKE set turns off automatically 10
minutes after startup.
NOTICE

THE LCD PANEL IS FULLY FACTORY CONFIGURED TO MEET THE LEGISLATIVE REQUIREMENTS
OF THE E-BIKES. SPEED IS REDUCED TO 25 KM/H AND ENGINE POWER TO 250W.
18
4.3. Basic information about using the LCD panel
The panel displays driving information such as battery status. Displays the current, maximum and average
speed. Stores information about daily and total distance driven. The default rim size is 26 ".
LCD panel communicates with the controller. The panel allows changing the power level in 5 steps. You can
change the power level by pressing the buttons "UP" and "DOWN".
Longer holding the button "DOWN" will activate engine speed of 6 km/h. This feature can be used to start
the EVBIKE in case you have not installed accelerator (throttle).
The panel's backlight can be activated by simultaneously pressing buttons "UP" and "MODE" for 3 seconds.
Long press "UP" button to toggle current, maximum and average speed. Short press "MODE" button to switch
daily (TRIP) and total distance driven (ODO). Daily kilometers (TRIP) is always reset when you turn
off the display. Total kilometers (ODO) remain in the memory of LCD panel.
For detailed setup and use of the LCD panel, search for interactive tutorial at www.evbike.cz in "Operating
the computer" section.
Activation of the LCD panel is required to operate the bike. After switching on the battery, press
and hold the "MODE" button that will display information on the LCD panel and the bike can be
used. If you set engine power level to 0, the pedal assistant is inactive.
NOTICE
10
INSTALLATION MANUAL
POWER LEVEL
TIMER
SPEED
DISTANCE
POWER ASSIST
UP TO 6 KM/H
(WALK)
BATTERY VOLTAGE INDICATOR
The battery indicator shows the approximate
value of the voltage, not the capacity of the
battery! When driving, battery voltage
changes and indicator can show a fully
discharged battery. This is a normal
phenomenon which depends on type
of the battery. For the real status of the
battery voltage is necessary to stop the bike.