Raleigh Array User manual

Electrical System Technical Manual
Raleigh Array E-Bike
Electrical System Technical Manual

Electrical System Technical Manual
2
1 Parts overview .................................................................................................................................... 2
1.1 Handle bar control ........................................................................................................................... 2
1.2 Charger for battery pack under rear rack ........................................................................ 3
2Handle bar control unit .................................................................................................................. 4
2.1 Functions of the handle bar control unit .......................................................................... 4
3Throttle ...................................................................................................................................................... 7
4Battery pack and charger ........................................................................................................... 8
4.1 Advice for charging ......................................................................................................................... 8
4.2 Charge the battery pack ............................................................................................................. 9
4.3 Take out the battery pack under rear rack ..................................................................... 11
4.4 Place back the battery pack under rear rack .............................................................. 12
4.5 Range ....................................................................................................................................................... 13
5Technical data .................................................................................................................................... 14
6Guarantee conditions and legal requirements .......................................................... 15
Manual electric system
Table of contents

3
Electrical System Technical Manual
AHandle bar control unit
BThrottle
CHandbrakes
Parts overview
1.1 Handle bar control
1
B
C
C
A
A

Electrical System Technical Manual
4
Parts overview (continued)
1.2 Charger for battery pack under rear rack
ACharging point
BKey
CDocking station contact point
DCharging plug
ECharger
FIndicator
D
F
E
B
A
C

5
Electrical System Technical Manual
ASwitch the peddling assistance
on and o
Use the on/o button (A) to switch the
peddling assistance on and o. You can
switch the peddling assistance on and o at
any moment, even while cycling. To switch
on, press the on/o button for one second.
To switch o, press the on/o button for
three seconds.
BChange the peddling
assistance level
You can set the peddling assistance
level using the + and – buttons (Power
mode). There are five peddling assistance
levels. You can always indicate with the
+ and – buttons whether you want more
or less peddling assistance. The peddling
assistance is by default set to the third level.
When putting away the bicycle it is important
to set the peddling assistance to zero. The
throttle will still work then.
CPeddling assistance level
display
The peddling assistance level is displayed
on the handle bar control unit by means of
five LEDs (C).
DIndication state of charge
display
The indication of the state of charge of the
battery pack is displayed on the handle bar
control unit by means of five LEDs (D).
ASwitch the peddling assistance on and o
BChange the peddling assistance level
CPeddling assistance level display
DIndication state of charge display
The e-bike will switch o automatically when it is not used for over
10 minutes.
Handle bar control unit
2.1 Functions of the handle bar control unit
2
C
D
A
B
NB
When the battery pack has to deliver much energy, for example when using the throttle or a high peddling assistance
level, the charge level may suddenly drop two or three steps because of a temporary drop of the voltage of the battery
pack. This does not necessarily mean that the state of charge has really decreased that much. The best indication of
the state of charge is indicated when the throttle is not used and a low peddling assistance is applied.
NB
The indication of the state of charge is determined by a simple measurement system, which gives the best indication
when the battery pack has been fully charged. As the battery pack discharges, the indication on the display becomes
less accurate. This eect is the strongest when the temperature of the environment is low. The indication of the state
of charge on the batterypack, on the contrary, uses a more advanced measurement system and is more accurate in
all cases.

Electrical System Technical Manual
6
With models equipped with a removable
battery pack, the state of charge (B) is
also indicated on the battery pack itself.
Press button (A) to read the state of charge.
Number of LEDs lit
Indication state of charge
On battery pack On display
5x green 580 - 100%
4x green 460 - 80%
3x green 340 - 60%
2x green 220 - 40%
1x green 10 - 20%
Handle bar control unit (continued)
2.1 Functions of the handle bar control unit
P
O
W
E
R
B
A

7
Electrical System Technical Manual
The throttle (A) is on the left side of the
handle bar control unit. The throttle
can be used as soon as the peddling
assistance has been switched on. The
use of the throttle costs a lot of energy.
This aects the range of the e-bike.
With some models you throttle up by
turning the throttle away from you,
whereas with other models you have to
turn the throttle towards you. Carefully
test what is applicable to your e-bike.
When using the throttle for the first
time, carefully try it out to get familiar
with the power the throttle delivers.
The throttle oers
extra support and
can be used in the
following ways:
•Extra support when you walk beside the bicycle
For instance, when taking the bicycle out of a basement, the throttle can give you some extra support, so you do not have to
push the bicycle up only with your own power.
•Extra support when accelerating from standstill
You can use the throttle when accelerating from standstill. The throttle supports up to 3 km/hour without peddling. After this
you will have to peddle yourself in order to get support.
•Extra support when cycling
The throttle can give the peddling assistance an extra impulse while cycling. This can be useful when you want to pass
someone or when you have to ride uphill. The impulse is felt strongest with a low peddling assistance level.
Throttle
3
A

Electrical System Technical Manual
8
All batteries lose power over time. This process is called ‘self discharge’. If the battery is discharged too much, deep
discharge will occur. A deep discharge can cause permanent damage to the battery pack. In order to prevent this situation,
follow the charge instructions carefully.
Advice for charging
•Always charge the battery pack using the charger delivered with the bicycle. Do not use any other charger.
•Before using the bicycle for the first time, fully charge the battery pack in one go until the indicator on the charger
becomes green.
•The charging will automatically stop after 24 hours when the battery pack is fully charged.
•The battery pack does not need to be completely empty before charging. The battery pack remains in a good condition
when you recharge the bicycle after every use (regardless of the distance).
•An empty battery pack that is not charged, may get damaged.
•The guarantee will be null and void when deep discharge is established
•In the event of long-term storage, charge the battery pack fully and then disconnect the battery pack from its charger.
Charge the battery pack at least once every two months. You can also choose to keep the battery pack connected to the
charger. Disconnect the charger at least one time every two months, and then connect it again to the battery pack.
•The battery pack does not charge with a temperature below 0 °C and above 45 °C.
Warnings
Carefully read the warnings given below. The manufacturer is not responsible for accidents or faults caused
by improper use of (parts of) the e-bike.
•Make sure that no short circuit occurs when connecting the battery pack.
•Do not expose the battery pack to fire or heat. Never place the battery pack into fire.
•Do not drop the battery pack and do not damage it.
•Do not immerse the battery pack in water or in any other liquid.
•Keep the battery pack away from children.
•Never open the battery pack without permission. The battery pack has been sealed. Breaking the seal will make the
guarantee null and void.
•Do not put any liquids or metal into the charger.
•Do not connect the charger with wet hands.
•Do not touch the charger in case of lightning.
•Do not use the charger in an environment with a very high humidity level.
•Do not use the charger for any other purposes.
•Ensure proper ventilation while charging.
•No not connect the charger to the mains voltage when it is not used.
•Do not charge the battery pack in direct sunlight.
•Never open or damage the motor.
Temperature ranges Minimum Maximum
Charge 0 °C 45 °C
Use of peddling assistance -15 °C 45 °C
Storage (minimum state of charge 60 - 80%) -10 °C 35 °C
Battery pack and charger
4.1 Advice for charging
4

9
Electrical System Technical Manual
1. Connect the charger (A) to the mains voltage.
2. Connect the plug (B) of the charger to the contact point of the battery
pack (C).
3. When you charge, the light (D) is red. When the battery pack is fully
charged the light turns green. The charge is stopped automatically
after 24 hours. The light on the charger remains green.
•A full charge will take about 4.5 hours.
•The battery pack can be charged both in and outside
the bicycle.
•When placing back, pay attention to the contact
points of the docking station (E).
The battery pack has been secured
against theft with a lock.
•Insert the key (A) supplied in the
lock of the battery pack (B) and turn
it 180 degrees.
•Make sure that the cover (C) of the
charging plug is closed.
•Carefully slide the battery pack (B)
out of the luggage carrier.
•Always use both hands to pick the
battery pack, to prevent it from
falling.
•If you transport the bike in a car,
always take the battery pack out of
the luggage carrier.
Battery pack and charger
4.2 Charge the battery pack
4.3 Take out the battery pack under rear rack
B
E
C
DA
A
C
BC
B
A
C
BC
B
B
A
A
A
B
•Carefully slide the battery pack (A)
into the luggage carrier. Here pay
attention to the contact points of
the battery pack and of the docking
station (B).

Electrical System Technical Manual
10
4.5 Range
The range (i.e. the number of kilometres that you can ride with a fully charged battery pack) greatly depends on the pedal
assistance setting you use. This table gives an indication of the range for each pedal assistance setting.
Support position Stability speed*
(in km/hour)
Average range
317 Wh (in km)
Average range
418 Wh (in km)
114 54 - 108 71 - 143
216 47 - 63 62 - 83
319 44 - 53 58 - 70
422 37 - 44 49 - 58
525 22 - 34 29 - 45
* Stability speed = speed reached when lightly peddling along.
The values above are measured on a new battery pack. As the battery pack gets older the average range will decrease.
There are also a number of other factors that can aect the range. Follow the instructions below to get the best range from
your e-bike.
•Use the accelerator in moderation.
•Keep pedalling hard enough under your own steam. This will draw less power from the motor.
•Make sure your tyres have enough pressure: at least 4 bar.
•When setting o, use a low gear insofar as possible and change gears as necessary to increase the range.
•As far as possible, cycle at a constant speed. Frequent stops and starts use up a lot of battery power.
•Follow up the charging instructions (see §4.1) carefully and keep your bike and battery pack maintained regularly to keep
them in top condition.
•As far as possible, load and keep the battery pack at room temperature. This will have a positive eect on the range.
Remember that you will get noticeably less range from your e-bike when the ambient temperature is less than 10 °C.
•Keep in mind that the rider’s weight, the age of the battery pack, wind speed and the state of the road all aect the range.
4.4 Place back the battery pack under rear rack
Battery pack and charger
4
•Lock the battery pack (B) with the key
(A) for fixing and to prevent theft.
B
A
A
A
B

11
Electrical System Technical Manual
Technical data
5
Weight and performance Specification
Battery pack
Li-ion battery pack, 36 V
317 Wh 418 Wh
Weight of battery pack 2.45 kg 2.6 kg
Charging time 80% * 3 hours 4.5 hours
Charging time 100% 4.5 hours 6.5 hours
Capacity 8.8 Ah 11.6 Ah
Maximum speed delivered by peddling assistance 25 km/hour 25 km/hour
Maximum power 250 W 250 W
* The charging speed will decrease when the charge level is above 80%.
The e-bike is an EPAC (Electrically Power Assisted Cycle)
in accordance with EN15194.
Compliance
The manufacturer of your e-bike declares that the product meets all requirements and other relevant provisions of directives
2004/108/EC and 2006/42/EC.
The declaration of compliance is attached to the e-bike.

Electrical System Technical Manual
Guarantee conditions and legal requirements
6
The supplier of the battery pack will give a guarantee for any material or construction faults concerning the battery pack if
the following conditions are met:
You only have a right to the guarantee if you can provide a certificate of guarantee or a receipt. The guarantee period
commences on the day of purchase. The guarantee will be null and void when deep discharge is established.
The manufacturer is not responsible for accidents or faults caused by improper use of (parts of) the e-bike.
Guarantee period of the e-bike
The guarantee period of the electronic parts of your e-bike (display, drive system and battery pack) is two years. For the
guarantee period of all other parts we refer to the warranty provisions as specified in the manufacturer’s manual.
•The guarantee does not cover normal wear and aging.
•Do not clean the bicycle with a high-pressure spraying pistol. A too powerful jet of water may damage the electronics.
This will then make the guarantee null and void.
Legal requirements
The described conveyance is a bicycle according to European legislation, because the bicycle complies with the following
rules:
•The support is only active when the user peddles himself as from 6 km/hour.
•The support is active for up to 25 km/hour.
•The supplied power is maximum 250 W.
Environment
We recommend that you return a defective battery pack to your dealer in accordance with the environmental
regulations for collecting and processing batteries drawn up by the Ministry of Housing, Spatial Planning
and the Environment. The dealer is obliged to accept the battery and must ensure further processing of it
by the manufacturer.
Periodical maintenance and faults
Your e-bike needs regular service. Your dealer can advise and inform you on how to make optimum use of your bicycle.
In case of any questions or problems concerning your e-bike, please contact your dealer.
Manual
This manual is version 11-2015.

Raleigh Array/Emotion – Removing front wheel and checking connections
To allow the cabling on the Array models to be as neat as possible all the connections for
the front of the bike (motor, throttle and display unit) are concealed in the down tube.
Therefore to fully remove the front wheel, check connections and replace parts the plastic
strip running down the underside of the down tube will have to be partially or completely
removed. This is done by simply sliding the plastic strip down towards the bottom bracket.
To reinstall slide the strip back up making sure the cables are pushed back up into the down
tube, the strip locates in groves on both sides and there is a hole in the top of the strip to
help get more purchase if necessary.

Alignment of the Raleigh Array chain ring sensor (Derailleur bike)
1. Check the sensor is positioned parallel to the chain ring. If the sensor is not parallel to the
chain ring adjust accordingly.
2. Adjust the bracket by loosening the prop stand and sliding the bracket until the sensor is
approximately 1mm away from the chain ring. Rotate the cranks making sure the sensor
doesn’t contact the chain ring at any point of its rotation.
3. Adjust the sensor along the slot of the bracket. The right hand edge of the sensor should sit
5 –8mm inside the outer diameter of the chain ring.
4. Test ride the bike, the motor when adjusted correctly will give continuous power while
pedalling below 25km/h.
Tip –Start with the screws in
the central position as shown
above
1mm
5 –8mm

Alignment of the Raleigh Array chain ring sensor (Hub gear bike)
1. Check the sensor is positioned perpendicular to the chain ring. If the sensor is not
perpendicular to the chain ring adjust accordingly.
2. Adjust the bracket by removing the prop stand, loosening the two fixing screws and sliding
the bracket until the sensor is approximately 1mm away from the chain ring. Rotate the
cranks making sure the sensor doesn’t contact the chain ring at any point of its rotation.
3. Adjust the sensor along the slot of the bracket. The right hand edge of the sensor should sit
5 –8mm inside the outer diameter of the chain ring.
4. Test ride the bike, the motor when adjusted correctly will give continuous power while
pedalling below 25km/h.
Updated 10/10/17
5 –8mm
5 –8mm
1mm