Operating instructions ASA espeed B25.13 / B45.13

Transcription

1 Operating instructions ASA espeed B25.13 / B45.13 Version 2.2 for version > C/D17

2 Contents 1. General notes Scope of delivery Specifications Description Installation Opening the stone impact protection (Method 1) Opening the stone impact protection (Method 2) Connecting the ASA tuning module Commissioning and assembly Basic functions User-specific programming of the electronics FAQs Disposal General notes Dear customer, thank you for deciding to acquire a product from ASA Autotechnik. Our products are developed under stringent current European and national directives and safety topics are taken into careful consideration. To ensure damage does not occur due to improper installation or use, please read these operating instructions carefully and completely and then store them. All electronic articles from our production haven been checked to 100 % and can therefore be installed directly. We reserve the right to make changes that serve the purpose of technical progress at any time. For warranty claims, return the device and include the proof of purchase and a detailed description of the error. The statutory warranty regulations apply. The warranty claim will be voided due to: a) unauthorised modifications to the device or accessories which we have not implemented nor approved b) repairs to the device which you have performed yourself c) improper use / not intended use or operation d) device subjected to excessive force (falling, deliberate destruction, accident, etc.) Comply with all safety-related and legal regulations during the installation. Page 2/ 21

3 General safety instructions: - Do not drop the device! Avoid damage! If the device fell down or if the casing is damaged, please contact us. - Risk of fire or short-circuit! Do not expose the device to rain or other forms of moisture. Mount the power electronics in the splash-proof area of your e-bike. Do not direct a high pressure cleaner towards the device. - Risk of fire or short-circuit! Do not stress the adapter cable mechanically by, e.g., extending or crushing it. - Risk of fire or short-circuit! Never insert foreign objects into the housing! The objects could cause short-circuits. - Risk of fire or short-circuit! If the cable or the cable connector of the device is damaged, disconnect the plug and contact us. - If smoke, noise and/or odour develops, shut off the device and disconnect it immediately from the power supply. Do not continue to use the device! - Only use the device in its intended area. Inappropriate use, improper installation or modifications will render the warranty void. Important information on product safety and legal situation (liability): (At the latest) after installation of the tuning module, the ebike is legally no longer classified as a bike, but as a motor vehicle. Furthermore, the use of the tuning module is manipulation of the speed of e-bikes, which is not legally allowed on public roads. The e- bike must not be used on public roads after the installation of tuning module. This may apply in particular cases already in the deactivated mode. (At the latest) after installation of the tuning module has the following duties, which constitute a violation against that could be an offense: Homologation Helmets are mandatory Insurance registration Driving license duty Operating license requirement; a possibly previously granted approval expires. Control and / or compulsory insurance (esp. motor vehicle liability insurance). Personal liability insurance does not apply. Further, another insurance class is possibly applicable. After installing the tuning module, the ebike is used outside of the validated and intended use as an bike. Lifetime specifications of the drive system of the ebike and the ebike itself is no longer valid, since a higher load and a higher wear may be associated with the use of the tuning module. Furthermore, it is impossible to estimate whether the frame, fork, handlebars, brakes, suspension, tires and other safety-relevant components are designed for the increased load, especially for the higher speed. Warranty claims, warranty claims or product liability claims against the seller or manufacturer of the ebike or the drive system can be reduced or extinguished. Page 3/ 21

4 Basically, you bear the civil, criminal and offense responsibility. In particular, the installation and use of the tuning module may result in criminal or administrative offense legal consequences for you. Furthermore, it may cause damage to property or persons due to improper installation and removal as well as improper use. Please read our Terms and Conditions ( Please inform yourself before installing the tuning module on the legal and technical implications arising from the installation and use of a tuning for you. Please drive carefully and always bring you neither yourself nor others in danger! We wish you much success with the installation. For questions, please contact: Autotechnik Saretz e.k. Drosselweg Schopfheim Phone: +49-(0) Fax: +49-(0) [email protected] 2. Scope of delivery - 1x tuning module ASA espeed B25/B45 including cable set - 2x heat shrink tubing - 1x operating instructions 3. Specifications Power supply: 12 V DC Temperature range: -40 C to +130 C Weight: 14 g Dimensions of electronics: 23 x 15 x 5 mm Cable length approx. 150 mm Page 4/ 21

5 4. Description The ASA espeed B25.13 electronics cancels the speed limit of the motor assistance of your Bosch ebike without making concessions to the functionality of your HMI. The speed you are currently driving will always be displayed regardless of whether the tuning is active or deactivated. The motor assistance is not limited to 25 km/h, rather, any speed values can be achieved. Also, no error codes will be generated for 2:1 gear ratios (error code 102). After the installation your ebike will continue to function as you were previously accustomed to, but now the motor assistance will not be switched off as of 25 km/h (ASA espeed B25.13) or 45 km/h (ASA espeed B45.13). After installation, the electronics will automatically adjust to the different tyre sizes. Calibration can be reactivated at any time by activating a special code so that its continued use is possible in future Bosch e-bikes with other tyre sizes. Installation occurs with original Bosch connectors and has been designed in such a way that cable damage is prevented, enabling the re-establishment of the original state at any time. Tuning is activated automatically in the sport and turbo modes and deactivated in the other modes. It is not necessary to activate the light function; also the plug sockets in the motor for the front and rear lights will not be used for our electronics. The individual features of the electronics are in summary: Microprocessor controlled micro-electronics Installation without damaging the cables and thus the possibility of simply converting back to the original Cancellation of the 25 km/h limit in the sport and turbo modes Full HMI functionality, in particular of the speedometer and the additional functions (km, max. speed, average speed, etc.) Self-calibration for different tyre sizes No additional switches, cables, dongles, attachments, etc. necessary or visible Page 5/ 21

6 Sturdy welded structure of the electronics Possibility to check the function during the installation with status LEDs Programmable user-specific functions The ASA espeed B25.13 electronic works also with older HMIs (-2012) and with the newer INTUVIA HMIs including the build year The electronics were optimised for the INTUVIA HMI, so operating the user-specific programming with the older HMI will be less convenient and the display of the older HMIs could jump now and then, as the processing speed of the old HMIs is slower than that of the INTUVIA series. 5. Installation Required tools: - Torx 20 spanner - Hot air gun Additionally Method 1 - ISIS crank puller for Bosch drive unit (e.g. Ebay as of 4.60, Amazon as of 6.99 search term: ISIS crank puller) - Spider Tool / puller / lockring (e.g. Ebay as of 19.90, Amazon as of search term: Bosch Spider tool,) - Torque spanner (operating range 30 to Nm) for right & left-hand thread Additionally Method 2 - Torx 20 bit - Dremel with cutting disc - Flat iron from the D-I-Y store - Drill - Hammer - Vice - 2x CrNi screws (DIN 933 A2 M 4 x 6) - 2x washers for M4 of CrNi steel Before installation, the battery must be removed. For a top-mounted motor you will need to remove the battery holder. Next, remove the stone guard from the motor. This is joined to the motor with 3 Torx screws T20 (article number ). A minor problem is that there are usually 2 screws behind the front sprocket. Page 6/ 21

7 There are two methods of accessing these screws: Disassemble the crank sprocket with the special tools ISIS crank puller and Spider for assembling the front sprocket (Bosch article or ) Build your own Torx 20 flat tool Page 7/ 21

8 6. Opening the stone impact protection (Method 1) Remove the hexagon socket screw with an 8 mm hexagon spanner (normal right-hand thread). You will now need the special ISIS crank puller tool and the Bosch Spider tool. Depending on the version of the Spider screw on your e-bike, there are two different sizes of Spider tool available. Now screw the ISIS crank puller on the thread and turn in the 8 mm hexagon socket screw until the crank loosens. Page 8/ 21

9 The Spider nut can now be unscrewed with the Bosch Spider Nut tool (ATTENTION: LEFT-HAND THREAD!). The Spider Nut can then be removed with the front sprocket. You may not use a hammer for the disassembly. If it becomes stuck on the shaft, you may loosen it from behind with a large screwdriver. LOOSEN LOOSEN LOOSEN Page 9/ 21

10 For top-mounted motors, the battery holder must be removed before removing the stone impact protection. Depending on the version, you may have to remove 1 or 2 screws. Unscrew the 3 stone guard screws with a T20 Torx spanner and remove the stone guard from the side. Page 10/ 21

11 7. Opening the stone impact protection (Method 2) We will only briefly outline this method, as its realisation requires quite a bit of mechanical skill and effort. The T20 flat tool to be made can be used to loosen the Torx screws behind the front sprocket without requiring the expensive special tools (ISIS puller and Bosch Spider). Obtain a flat iron from the D-I-Y store and drill a small hole with the diameter of the T20 bit so that it just barely does not fit. According to the following illustration, the bit must be first shortened with a Dremel to parting line 1 (at the outlet of the gearing): Clamped in a vice, the splined end of the T20 bit can now be hammered into the hole of the iron mounting. Due to the conical form of the grooves in the T20 bit, the increasing penetration of the material results in a press fit so that the T20 bit in the iron mounting is now sufficiently fastened mechanically in order to subsequently loosen the screws. After being driven in, the protruding end of the bit must be shortened to a length of approx. 3.6 mm with the Dremel (cutting disc) (see the following illustration): The Torx screws can now be loosened with this flat tool and subsequently replaced during the assembly with normal hexagon stainless steel nuts to enable better access from the side with a fork spanner. Page 11/ 21

12 8. Connecting the ASA tuning module The ASA espeed B25/45 module has 4 connections which are to be used like adapters and which are looped into the existing cabling. Bosch currently uses plugs that are only available on the market in female form. For the male form, we also use a female connector which has been assigned with contact wires. These contact wires are used for the mechanical connection, and heat shrink tubing is used as protection and locking mechanism. The female connector with the contact wires is to be twisted by 180 degrees and inserted into the original female connector of your bicycle. The connections are used according to the following model: Remove the HMI 4-pin plug and the speed sensor 2-pin plug from the motor according to the following illustration. Depending on the installation situation, it can be helpful to use flat-nosed pliers to pull the plug. Page 12/ 21

13 The figure shows the sequence of connections for a bottom-mounted motor. If the motor is at the top, connection then occurs accordingly twisted by 180 degrees. Place the heat shrink tubing on one line respectively. The heat shrink tubing for the HMI plug has a greater diameter. Now connect the plug of the HMI to the plug of the ASA module. Both connections must be mounted twisted by 180 degrees so that the line colours are identical, meaning red-to-red, black-to-black, yellow-to-yellow and green-to-green. Press them together to ensure no gaps remain between the plugs. If the metal pins are a little bit too long please shorten them to approx.. 8 mm. length outside one connector. ATTENTION: A FALSE CONNECTION CAN DESTROY THE ELECTRONICS OF YOUR E-BIKE! Page 13/ 21

14 Pull the heat shrink tubing over both plugs and heat shrink them with a hot air gun. The heat shrink temperature is: +95 C C. Try to stay within the lower/middle temperature range. The cables at the module for the connections from the speed sensor are different. The cable with the brown wire goes to the motor, and the cable with the white wire goes to the speed sensor. Now connect the cable with the white wire in the same type and manner as the connection to the HMI. Make sure that the wires are connected black-to-black and red-to-white. Shrink the heat shrink tubing at the same temperature over both plugs. Page 14/ 21

15 Now insert the 2-pin plug from the ASA module into the connection of the speed sensor at the motor and the 4-pin plug into the HMI connection. Use double-sided tape to fasten the ASA espeed tuning module in the motor or simply insert it into the frame of the e-bike. Page 15/ 21

16 9. Commissioning and assembly Temporarily connect the battery of the e-bike for a function test. Switch on the HMI. A speed indication will briefly appear, e.g., 10.6 km/h. The 6 represents the software version 6 of your module. Your speedometer should now show a speed of 99.9 km/h (or for the old HMI - build year 2012) for approx. 3 minutes, and the green and yellow LEDs should flash in the electronics. This is a calibration of the electronics to your bicycle and the electronics are determining the parameters in order to work correctly, depending on your e-bike. If the electronics behave otherwise, check the connections. After calibrating the electronics you should set your HMI to sport or turbo mode as a test; the green LED should go on in this mode and indicates that the tuning is active. In addition for the activated tuning on the HMI, 0.1 km/h is displayed instead of 0.0 km/h during standstill so that you have a status display during daily operation. As soon as you go to a different mode, the LED should go off and the HMI display this mode by 0.0 km/h. Note: If the status of the tuning module at standstill is displayed, e.g., with 0.1 km/h, there may be technical reasons that cause it to flicker from 0.1 to 0.0, especially for the old HMI. This is normal and not a malfunction. After the calibration, the e-bike should be briefly switched on and off so that the values can be stored. Fasten all cables with cable ties or additional tape so that the stone impact protection can be mounted easily. Now mount the three screws from the stone guard with a T20 Torx spanner. The tightening torque should be Nm. Method 1: Attaching the front sprocket and the Spider nut: The aluminium Spider nut must be tightened with 40 Nm, or with 30 Nm for plastic (attention: fine-pitch and left-hand thread). The crank screw is to be mounted with Nm. Method 2: Page 16/ 21

17 Mount the stone impact protection and use stainless steel hexagon screws with a washer instead of the concealed T-20 original screws so that the connections can be more easily accessed at a later point. 10. Basic functions Switching on/off When you set the support mode to sport or turbo (or speed), the tuning will be activated. The tuning is deactivated in the other modes. Calibration The electronics calibrate automatically to the tyre size of the e-bike. Calibration can be restarted at any time (see Programming of the electronics) Average speed/trip mileage As soon as you drive faster than 25 km/h there will be deviations in the average speed and in the odometer. The module has a compensation function that can update the kilometres. This can be done at any time during standstill and is activated by selecting a mode with deactivated tuning. This is the ECO or TOUR mode as standard. During standstill, the HMI signals this update of track information by displaying 0.3 km/h and it can also be observed that the odometer continues to run during standstill. Note: Compensation occurs at a very high speed for time reasons so that the maximum speed of the HMI is no longer correct. For that reason we have realised an independent maximum speed display that is briefly shown during standstill. The value of the maximum speed is reset when the HMI or the e-bike is switched off. If the compensation takes too long, it can be ended by switching off the e-bike. The compensation can be performed automatically (see User-specific programming). The advantage to this is that the kilometre update can be automatically compensated during standstill. The disadvantage is that while compensation takes place, the motor only switches in after the first pulse comes from the speed sensor. This can take some getting used to when starting, and the e-bike will behave differently than without the tuning module. Since there are slightly more disadvantages in practice from our point of view, we have activated the manual compensation as standard. Quick deactivation Selecting the Off mode will deactivate the tuning until the next powering on of the ebike. The behaviour during powering on is then oriented towards the programmed parameter of the general tuning. As standard, it is activated again after the switching on. The stored compensation values are also deleted during the OFF mode. This function can be deactivated by user specific programming so that tuning is also activated during OFF mode. Page 17/ 21

18 11. User-specific programming of the electronics Intuvia display (only with walk function as of build year 2013) Programming can only occur directly after the e-bike has been switched on. If a new code is to be entered, then the e-bike must be switched off again first. Parameters are entered by selecting 3 modes and pressing the Walk button or the light button (see old display) for period of 2 seconds. The key codes are always listed by function. Note: The Walk button at the left operating unit must be kept pressed until you get a confirmation in the displayed speed in form of a 8. So you will get 0.8 for the acceptance of the first code, 8.8 for the acceptance of the second code and 88.8 for the third code. Restarting the calibration Calibration and the factory settings can be activated using the following code: Eco -> Walk -> Tour -> Walk -> Sport -> Walk Note: After the calibration the e-bike should be briefly switched on and off General deactivation of the tuning Turbo -> Walk -> Sport -> Walk -> Tour -> Walk Activation of the tuning (default) Tour -> Walk -> Sport -> Walk -> Turbo -> Walk ECO/TOUR with tuning support Off -> Walk -> Eco -> Walk -> Tour -> Walk Page 18/ 21

19 With this function the tuning can be activated in the TOUR mode and also in the ECO mode when the same code is entered again. ECO/TOUR without tuning support (default) Tour -> Walk -> Eco -> Walk -> Off -> Walk Max. speed display during standstill (default) Off -> Walk -> Eco -> Walk -> Turbo -> Walk Maximum speed display switched off Turbo -> Walk -> Eco -> Walk -> Off -> Walk General switching off of the compensation function Sport -> Walk -> Tour -> Walk -> Eco -> Walk The function for the general compensation of the trip mileage can be generally switched off with this function. During the switched off state, neither the trip mileage nor the orginal average speed function will not be correct. However, the advantage is that the time for the compensation will no longer be needed. To switch on again, switch the max. speed either off or on. General tuning activated after the switching off Off -> Walk -> Sport -> Walk -> Turbo -> Walk General tuning deactivated after the switching off (default), i.e., after switching off, the tuning option will have to be reactivated each time. Turbo -> Walk -> Sport -> Walk -> Off -> Walk Automatic compensation activated during standstill The kilometre compensation occurs automatically during bicycle standstill. ECO -> Walk -> Sport -> Walk -> Turbo -> Walk Automatic compensation deactivated during standstill (default) The kilometre compensation occurs during bicycle standstill only when the tuning is deactivated using a mode without tuning support (this is ECO and TOUR as standard). Turbo -> Walk -> Sport -> Walk -> ECO -> Walk Increasing the wheel circumference The function increases the wheel circumference in increments of 2 cm up to a maximum of 20 cm. This enables manual fine calibration of the speed indicator and the kilometre Page 19/ 21

20 measurement. After entering the code, the correction value is displayed briefly as speed. 2.0 means + 2 cm wheel circumference. ECO -> Walk -> Tour -> Walk -> Turbo -> Walk Reducing the wheel circumference Turbo -> Walk -> Tour -> Walk -> Eco -> Walk The function reduces the wheel circumference in increments of -2 cm up to a maximum of -20 cm. This enables manual fine calibration of the speed indicator and the kilometre measurement. After entering the code, the correction value is displayed briefly as speed. 2.1 means - 2 cm wheel circumference. OFF mode deactivates tuning (Default) OFF -> Walk -> Tour -> Walk -> Sport -> Walk Selecting the OFF mode deactivates the tuning functionality. After switching on the ebike the functionality will be in accordance to the setting of the general tuning parameter. As default the tuning will be activated again. The stored values for the comparation functionality will be erased. OFF mode without functionality Sport -> Walk -> Tour -> Walk -> OFF -> Walk In this mode the OFF mode doesn t effect the tuning mode. We recommend this mode if the tuning is also activated on the TOUR and ECO mode because otherwise no mode without tuning is available for the comparation functionality. Older series: Programming with the older HMI series (- 2012) occurs by briefly switching the light on and off instead of the Walk button. Your e-bike dealer may have to activate the light function for this. When switching on for the first time, you will need to briefly acknowledge the appearing error message 103 in order to subsequently use the function. Analogy: Press WALK 1x = Press LIGHT ON 1x and press LIGHT OFF 1x Furthermore, the SPEED mode corresponds with the TURBO mode and the OFF mode corresponds with the support mode 0. Note (model 2012): When programming, ensure that the values of the support mode in the levels ECO, TOUR, SPORT and SPEED respectively do not equal zero, otherwise the code will not be accepted. Page 20/ 21

21 12. FAQs I have a maximum speed of more than 100 km/h. - That is unfortunately true, as the compensation takes place at a high speed. Use the maximum speed function of the module. The maximum speed is briefly displayed during standstill as a result. My trip mileage is clearly too low. - You did not perform the compensation. Please switch to a mode without tuning (ECO or TOUR) during standstill. The missing kilometres will be compensated My trip mileage is counted up even though I am standing. - You have activated the compensation and our electronics is compensating the difference to the actually driven kilometres. The compensation ends when both values are identical (actually driven route and displayed distance). I would like to activate the tuning also for the TOUR and ECO modes. - Enter the described key code according to operating instructions directly after switching on. Attention, manual compensation can then only be performed in the OFF mode; the tuning is generally deactivated at the same time. I cannot program the electronics. - Programming only functions once directly after the e-bike has been switched on. - Keep the WALK button pressed for 2-4 seconds. Do it again until the 8 appears on the HMI. - Do not move you ebike during programming - For the 2012 model, ensure that the support mode in the ECO, TOUR, SPORT and SPEED modes is not equal to zero. After the installation the LEDs do not flash. - Check the connection. - The module is defective and should be replaced - You have acquired the wrong version for your e-bike -> replace I have misadjusted everything and would like to restore the factory settings - Start the calibration My speedometer is inaccurate - Perform a manual fine calibration of your tyre circumference. - Have your e-bike dealer correct the tyre size with the Bosch service tool and perform the calibration again. 13. Disposal European Directive 2002/96/EC applies when disposing of this device. Inform yourself of the local regulations on the separate collection of electrical and electronic devices. Please follow the local regulations and do not dispose of the old device with your household waste. Page 21/ 21