SR Suntour HESC User manual

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Owners Manual 2012.2
HESC - pedelec/ebike components

SR SUNTOUR OWNERS MANUAL HESC components
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Table Of Contents
Quick Start Guide ........................ 2
1. How do Iturn the
system on?.........................................2
2. Support modes?..........................2
Factors that inuence the
cruising range ..................................2
3. What information does the
system oer you? ............................3
Information mode ..........................3
4. How do Iremove the
display unit?......................................3
5. How do Icharge the
battery?...............................................4
6. How to reset trip distance .......5
7. Error Code 05 / E05.....................5
Important Safety Information!... 6
Before Each Ride!..........................7
Foreword ...................................... 8
Drive Unit Components ............ 10
Display / User Interface............. 11
How to remove the display....... 12
How to operate the display/user
interface ..................................... 13
General Information.................... 13
How to switch ON/OFF ............. 14
Headlamp control........................ 14
Push-up support switch ............ 15
How to change the
“Assist Mode”................................... 15
Operating Range.......................... 15
Range Inuencing Factors ........ 16
How to change the
“Information Modes”.................... 16
How to reset the trip distance..17
How to reset the trip time
(total time).......................................17
How to reset the maximum
speed................................................17
Display Indications.................... 17
Speed.................................................17
Total Distance ................................ 18
Trip Distance .................................. 18
Trip Time (Total Time).................. 19
Max. Speed..................................... 19
Average Speed .............................. 20
Motor status................................... 20
Remaining capacity(fuel gauge)21
Battery - General information .. 22
Always keep in mind! ........................ 24
Battery Charging (upright type
battery) ...................................... 25
Charging status..............................27
Battery indication .........................27
Battery Charging (at type bat-
tery) ............................................ 28
Charging status............................. 30
Battery indication ........................ 30
Error Codes................................. 32
Maintenance and cleaning ....... 32
Cleaning .......................................... 32
How to dissamble the front
wheel................................................ 33
How to assemble front wheel.. 35
Limited Warranty....................... 37
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Quick Start Guide
press
press
press
press
1. How do Iturn the system on?
Press the “modus”(M) key for about 2 seconds.
The system turns on and shows you all of the
important information about the current status.
Support mode
Cruising range 66 km 48 km 40 km
Please note that the chapter “Quick Guide” is here to provide you with an initial overview. It
does not purport to be complete. For more information, please read the individual chapters
of the enclosed user manual (handbook on DVD).
2. Support modes?
Factors that inuence the cruising range
The points stated below can inuence the cruising range.
►Driver characteristics & driver concentration
►State of maintenance
►Topography
PRESS
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For more information about cruising range, please read the chapter“cruising range”.
3. What information does the system oer you?
Information mode
Information about total kilometers, trip distance, travel time, maximum speed, and average speed
is displayed in succession when you push the info“I” button.
►Average speed vs. variation of speed
►Trac conditions
►Type and condition of tires & tire pressure
►Driver weight
►Direction of wind & wind speed
►Battery temperature while charging (the lower = the better)
►Battery operating temperature while not in use (the higher = the better)
►Ambient temperature while driving (the higher = the better)
►Battery age (the newer = the better) & battery charge cycle
►Battery state of charge
►Battery storage (cold and dry storage is recommended)
4. How do Iremove the display unit?
PRESS SLIDE
Always close the cover panel after removing the display.
Always turn o system to avoid data loss
For more detailed instructions, please read the chapter
“how do Iremove the display”
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= Battery is charging.
= Battery is fully
charged.
= Battery isn't charg-
ing, please check
all connections.
= Error
(re-connect).
= Error with battery
charger
(re-connect).
= Above charging
temperature.
1. Open the cover of the charging socket.
2. Connect the battery with the battery charger.
3. Connect the battery to the power supply.
Next, turn on the battery charger.
The status indicator should light up “red”, if not,
check the connection.
5. How do Icharge the battery?
Both battery types shown below can be charged in the installed position and don't need to be
disassembled. For more information about “charging the battery” please read the chapter on
“charging the battery”
In order to avoid damage, shut o the system before charging.
1. Open the cover of the charging socket.
2. Connect the battery with the battery charger.
3. Connect the battery to the power supply. Next, turn on the battery charger.
The status indicator should light up “red”, if not, check the connection.
= battery is not getting
charged, please check all
connections.
= battery is getting charged
= battery is fully charged
Flat battery type / carrier
Upright standing battery type / rear seat tube
TURN
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7. Error Code 05 / E05
6. How to reset the trip distance
Error report 05 should be interpreted as a“security measure”and protects the system from over-
loading.
Your system is equipped with a“torque sensor”. After pressing the pedal, the sensor measures
the force used and sends the measurement to the controller. In order to oer you abalanced
and natural ride, the sensor is very nely adjusted. There are several points to keep in mind so
that problem-free operation may be ensured.
Turn on the system before placing your foot on the pedal. If you depress the pedal before turning
on the system, the controller may interpret this as asystem overload and report this as“error 05”.
Solution:
Turn o the system and release the pedal. Afterwards turn the system back on (remove your foot
from the pedal). If “error 05” still appears, contact your retailer.
During driving operation:
The front brake lever is equipped with a“disruption sensor”. When you pull the brake lever, asignal
is sent to the controller. The controller subsequently disrupts the current supply to the motor and
tells the torque sensor that no measurements are necessary.
In order to avoid an “error 05”, you should always make sure to pull the front brake lever, i.e. while
waiting at ared light. This way the system always knows that no assistance is necessary at that
moment.
Battery keys
Your ebike system battery is secured with alock to avoid theft. Your bike should
beequipped with 3 matching keys. Please keep one of these keys in asecure place.
Inthe case that all 3 keys are lost, the entire lock must be replaced.
1. Change the display to“trip distance”.
2. First press the “mode” button and then the “info” button. Afterwards release the buttons (but-
tons are not allowed to remain pressed down).
Please note! When resetting the trip distance, the travel time will also automatically be reset.
In order to reset the maximum speed, change the display to“max speed”and do as stated in the
instructions above.
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Caution
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Important Safety Information!
► Be sure to read this manual carefully before using your electric bicycle. Inappropriate usage
of your electric bicycle may cause damage to the product, serious injuries or even death
to the rider.
►
Do not use damaged components – consult your authorised SR SUNTOUR dealer imme-
diately.
►
The battery of the electric bicycle contains chemicals which can be dangerous when used
improperly, warnings included in this manual must be followed in order to reduce the
possibility of dangerous situations resulting in injuries or possible death. Never try to open
any SR SUNTOUR device of the electric bicycle, especially not the battery. Opening any SR
SUNTOUR battery implies the risk of getting seriously injured.
►Do not let the battery come into contact with water or any other liquid other than rain or
snowfall. The guarantee will be void if the battery gets in contact with water. Whenever
the battery gets in contact with liquid immediately disconnect it to prevent dangerous
situations.
►
Do not store the battery above room temperature. The battery life expectancy will be
signicantly reduced if the battery is stored under higher temperatures.
►
Do not place the battery immediately close to a ame or any other heat source. Extreme
heat can cause the battery to explode. Keep the area where the battery is charged well
ventilated. Keep it free from litter and anything combustible to avoid re from sparks or
overheating.
►
The battery must only be charged with the supplied charger. Using a dierent charger can
result in malfunction and reduced lifecycle of the battery.
►
Charge the Li-ion battery indoors at a temperature between 0ºC to 40ºC (32ºF -104 ºF).
The Li-ion battery charger cannot charge a battery with a temperature above 60º C or less
than -3 ºC.
►
If you notice a strange smell or smoke, un-plug the charger immediately from the power
socket and disconnect the battery from the charger! Take your battery and charger to your
authorized dealer for service or replacement.
►Disconnect the charger when the battery is fully charged.
►Use only genuine SR SUNTOUR parts. The use of non-designated aftermarket accessories,
replacement and spare parts voids the warranty of the electric bike drive unit and might
cause failure to the system.
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WARNING !
Failure to comply with the given warnings and instructions may cause
damage to the product, injuries or even death to the rider and user.

Caution
Caution
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Before Each Ride!
►Do not disassemble or modify any of the parts of the drive unit. The warranty will be void
in case of any modication.
►
SR Suntour electric bike units are designed for the usage on single seated bicycles for
regular and common use on regular city- and trekking bikes. The intended use of the drive
unit is accordingly.
►
This instruction sheet contains important information about the correct installation, service
and maintenance of your drive unit. Nevertheless please be informed that special knowl-
edge and tools are essential to install, service and maintain SR SUNTOUR drive units for
electric bicycles. Common mechanical knowledge may not be sucient to repair, service or
maintain the devices. Therefore we strongly recommend getting your system serviced and/
or maintained by a trained and qualied bicycle mechanic. Improper installation, service or
maintenance can result in failure of the product, accident, injury or even death.
►
Always be equipped with proper safety gear. This includes a properly tted and fastened
helmet. Make sure your equipment is in awless condition.
►
Make sure to learn about the electric power assistance, the changed bicycle behaviour
and handling of your bike. Learn how to ride and train your skills. Know your limits and
never ride beyond those.
►
The torque sensor of your HESC system even detects slight pressure on the pedal. If the
torque sensor detects and pressure on the pedal, it will give the motor the instruction to
start running. Therefore you should always slightly pull your front brake lever towards the
handlebar while standing/waiting. e.g. in front of a trac light with your foot placed on
the pedal. You brake lever is equipped with a cut of sensor which will avoid the motor to
start running unexpectedly.
►
Never lock your front wheel while the system is active as the motor might get damaged.
Besides this it could result into a short circuit which might set the system on re.
►Always make sure to fold center stand while moving the bike backwards.
Do not ride your bike, if one of the following test criteria can’t be passed!
Riding your bike without eliminating any defect or carrying out the neces-
sary adjustments can result into an accident, fatal injury or even death.
►Do you notice any cracks, dents, bent or
tarnished parts at your suspension fork
or any other part of your bicycle? If so,
please consult a trained and qualied
bicycle mechanic to check your fork or
bike.
► Can you notice any oil leaking out your
fork? Also check out hidden areas like
the bottom side of your fork crown. If
so, please consult a trained and qualied
bicycle mechanic to check your fork or
bike.
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Foreword
► Compress your fork with your body
weight. If it feels too soft, relating to the
proper pressure to achieve an accurate
SAG, inate it until you have reached the
required value. Please also refer to chap-
ter “ SETTING SAG”
►
Make sure your brakes are properly in-
stalled/adjusted and work appropriate.
This also applies to every other part of
your bike like handlebars, pedals, crank
arms, seat post, saddle etc. Also refer
to the owner‘s manuals provided by all
other component manufacturers.
►
Make sure your wheels are centered per-
fectly in order to avoid any contact with
your suspension fork or brake system.
►
If you are using a quick release system
to fasten your wheel set, make sure that
all levers and nuts are adjusted properly.
In case you are using a through axle sys-
tem, make sure that all xing bolts are
tightened with the appropriate torque
values.
►
Check the cable length and routing of
your components. Make sure they do not
interfere your steering actions.
►
If you are using reectors for on-road
cycling, make sure they are clean and
properly installed.
►
Bounce your bike slightly on the ground
while looking and listening for anything
which might be loose.
Dear customer,
congratulations on your new electric bicycle purchase. The bike is equipped with the SR SUNTOUR
SRS-pedelec drive unit with a rechargeable Lithium-Ion battery, a display and user interface, a
torque sensor, a controller and a brushless front hub motor..
To make your ride smooth, safe and fun please take some time to read this manual carefully. It
contains information on the proper care of the drive unit of your electric bicycle and advice on
how to achieve the bikes’ and batteries’ full lifespan.
In case of any enquiries not covered by this manual please contact your local dealer.
Enjoy the ride!
What is a Pedelec?
It is legally considered a conventional bicycle, where the rider is enjoying some electrical
power assistance based on the human power brought up by the rider. Just ride like on a
conventional bike, the system will add some extra power. It feels like having tailwind or a
continuous descending ride.
In European Countries the assistance is legally limited to 250W nominal power and a max.
speed of 25km/h. Riding faster than that is possible, but there will be no assistance when
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Caution
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The below stated graphic gives you a better understanding how all HESC com-
ponents interact with each other.
riding faster than 25km/h.
A Pedelec is sometimes called EPAC, Light-Electric-Vehicle (LEV),
Hybrid Bicycle or eBike or electric bicycle with Pedal-Assisted-
System (PAS).
fuel
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Hub motor
Suspension fork
Upper holder and lock
Controller
Torque sensor crank-
assembly
Display
Battery
* Shown on a virtual bike which may look dierent to the bike which this owners manual came along with
Drive Unit Components
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ON/OFF Button
Mode Button
Info-Button
Display / User Interface
Assist Mode
Motor Assist
Battey Capacity
Speed
Data corresponding
to the information
mode
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How to remove the display
To remove the display o the docking station, carry out the steps like indicated above.
To install the display onto the docking station, slide the display onto the docking station.
To protect the pins of your docking station against moisture and dirt it is is equipped with a cover,
which can be slid over the pins. Always cover the pins after you take o the display!
Always close the cover after removing the display
Do never expose the pins to any kind of metal like tools, coins or hairpins.
This could result into a short circuit and might cause permanent damage. As a result of
this massive heat might build up, this could result into a burning of the display unit.
More over you might expose yourself to an electric shock.
PRESS SLIDE
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How to operate the display/user interface
The user interface / display is located on the handlebar. When the system is switched on by using
the on/o-switch, you can choose among the options below.
• Battery capacity
• Motor status
• Speed
• Assist mode
• Total distance
• Trip distance
• Trip time
• Max speed
• Average speed
The system will switch o automatically after 10 minutes of inactivity.
During the rst setup of the bike the wheel size have to be set on this user interface(please refer
to the chapter“how to set wheel size”).
The display is connected to the conntroller(brain), the cut o sensor and the push-up support
switch.
The power cut o sensor will automatically cut of the power supplied to the motor when pull-
ing the brake lever. The cut o sensor is connected to the front brake. Always use booth brakes
when braking.
Make sure to turn o the display before removing it
Removing the display before turning o may result into a failure of the system.
The display will save all data, like trip distance and average speed, on a ash memory.
Removing the display before it has been turned o may result in a loss of stored data.
Never expose the display to any kind of static electricity or strong radio waves as it
might erase all data on your display.
General Information
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How to switch ON/OFF
To turn ON/OFF the display/user interface press the “MODE” button for at least 3 seconds.
The display will automatically switch o after 10 minutes if non of the below stated operations
are carried out:
- Pushing the Mode Button
- Pushing“push up” support switch
- Applying pressure on the pedal
Headlamp control
The controller of the SR Suntour HESC pedelec/ebike system is equipped with a power supply
mechanism which will automatically supply power to the the light system of our bike if the
system is turn on. As this is not a standard feature, it might not being used on every pedelec or
ebike which is equipped with SR Suntour HESC components, please refer to owner’s manual of
the manufacturer’s bike. Before each ride, especially during dawn and darkness, please always
check the proper function of your light system.
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press
press
press
press
How to change the “Assist Mode”
The user can choose the ratio of assistance depending on his personal wish by pressing the
Mode-button “M” on the user interface. He can use between 4 dierent modes: No assistance,
ECO Mode, Standard Mode and High Power Mode.
The percentage of assist power varies from 50%(ECO-Mode), 100%(Standard Mode) and
150%(High-Power-Mode).
Operating Range
Push-up support switch
Your HESC equiped ebike/Pedelec features a so called„push-up“support switch which helps you
starting up on gradients, while waiting in front of the trac lights etc. The push up knob supports
you until 4-5km/h, beyond this is will be cut o automatically.
Please note! When using the push up support
switch, always hold your handelbar with both
hands.
Assist Mode
cruising range 66km 48km 40km
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How to change the “Information Modes”
The ride information total distance, trip distance, trip time, maximum speed and average speed
are shown one after another when pressing the Information-Button“I”.
Range Inuencing Factors
The riding distance might vary as it is inuenced by the following factors:
►Operating Temperature of Battery when not in use (higher = better)
►Ambient Temperature while riding (higher = better)
►Battery Age (newer = better) & Battery charge cycles (number of time charged)
►Battery Condition (state of charge)
►Battery Storage (Cool, dry place recommended)
►Driver ability & Driver concentration
►Condition/repair state
►Topography
►Speed – Average / Speed – Variability
►Trac conditions
►Tire style, Tire condition & Tire Pressure
►Weight of rider
►Wind direction & Wind speed
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How to reset the trip distance
1. Switch to“trip distance”
2. Press the “Mode”button that followed press the “Info” button. Afterwards release both
buttons ( the buttons should not remain pressed)
How to reset the trip time (total time)
1. Switch to“trip time”
2. Press the “Mode”button that followed press the “Info” button. Afterwards release both
buttons ( the buttons should not remain pressed)
How to reset the maximum speed
1. Switch to“maximum speed”
2. Press the “Mode”button that followed press the “Info” button. Afterwards release both
buttons ( the buttons should not remain pressed)
Display Indications
Speed
The speed is shown in kilometres per hour.
Display speed range: 0.0 - 60.0km/h * (28inch)
Display accuracy: 0.1km/h
*(The system needs approx. 2.5seconds to recognize the speed of the wheel)
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Total Distance
The total distance is counted when the system is activated and is displayed in kilometres.
Numerical values will get stored on the non-volatile memory. Value can not be reset manually.
Display range: 0.0 .. 9999.9km / Display accuracy: 0.1km
Trip Distance
The trip distance is counting when the system is activated and the front wheel is turning.
Display range: 0.0 .. 999.9km / Display accuracy: 0.1km
The trip distance can be reset, please refer to “How to reset the trip distance”
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Trip Time (Total Time)
The trip time (total time) is recorded when the system is turned on and the wheel is running.
Display range: 00:00 .. 99:59 hh:mm / 1 unit = 1 minute
The trip distance can be reset, please refer to “How to reset the trip time”
Max. Speed
The “max speed” indicates the maximal ever ridden speed.
Display range: 0.0 .. 60.0km/h / Display accuracy: 0.1km/h
The trip distance can be reset, please refer to “How to reset the maximum speed”
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