MAHLE E185 Manuale utente

e185 Range Extender

User Manual

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002

003

English

1. Introduction ................................................................................... 4

1.1 General Warnings............................................................................. 4

1.1.1 About Warnings ........................................................................ 5

1.2 Maintenance & Storage ................................................................. 6

1.3 Transporting an e185 Range Extender ............................................ 7

1.3.1 Transporting an e185 for repair ................................................ 7

1.4 Safe Charging Process ................................................................... 8

1.5 Servicing ........................................................................................ 9

1.6 Recycling ........................................................................................ 9

1.7 Product Certiﬁcations ..................................................................... 10

2. Product Overview & Specications ............................................... 11

2.1 Compatible Accessories ................................................................. 12

3. Operation & Use ............................................................................. 14

3.1 Installation Guide ............................................................................ 14

3.2 Operating mode ............................................................................. 16

3.3 Usage ............................................................................................. 16

3.3.1 Intended usage ......................................................................... 16

3.3.2 Prohibited usage ..................................................................... 17

3.3.3 Operating mode (in the event of malfunction) ............................ 17

3.4 Operation ...................................................................................... 19

3.4.1 System ON/OFF Standalone Switch ............................................ 19

3.4.2 System ON/OFF eBike Switch ..................................................... 20

3.4.3 Battery State of Charge (SOC) ..................................................... 22

3.4.4 Charging Process ........................................................................ 23

3.5 Update Process ............................................................................. 25

3.5.1 Uploading ﬁles to the Active Charger ........................................ 25

3.5.2 Uploading the e185 Range Extender ........................................ 25

3.6 Battery Use ................................................................................... 30

4. Application & Services ................................................................. 31

4.1 My SmartBike Phone App .............................................................. 33

5. Service

5.1 Warranty ......................................................................................... 33

5.2 FAQs .............................................................................................. 33

5.3 Error codes ..................................................................................... 38

004

1. Introduction

Thank you for choosing the e185 Range Extender for your new SmartBike.

The e185 Range Extender allows you to go further on your travels, helping

you on long journeys that the eBike cannot complete by itself. The My

SmartBike Range Extender enables fast charging. LED bar displays battery

level or performance mode.

Please read this manual carefully before operating the system. Failure to

do so or misunderstanding of the instructions may lead to serious injury or

death.

Products and speciﬁcations are subject to change without prior notiﬁcation.

This document has been drawn up in English and the content herein shall

prevail in the event of any translation error or misunderstanding in the client’s

interpretation of translations herein.

This manual includes instructions for the e185 Range Extender compatible

with the X20 System (or compatible systems).

All relevant documents for the product or any other compatible system,

including this user manual, can be downloaded from our website:

mahle-smartbike.com

MAHLE e185 Range Extender · Introduction

V.1.0.0 - 09/2022

Components must only be replaced with an original MAHLE SmartBike

Systems replacement to maintain the safety of the entire system. Any

tampering, modiﬁcation or repair by a third party not authorised by MAHLE

shall immediately void the warranty conditions and original certiﬁcation, and

MAHLE shall not be held responsible in regard to civil liability.

Repairs and replacements must only be performed by MAHLE SmartBike

Systems, hereinafter MAHLE, certiﬁed partners.

This manual must not be duplicated except in its entirety, unless prior written

approval has been obtained from MAHLE SmartBike Systems.

1.1. General Warnings

Please pay special attention to any warning symbols on the system, shown

with these graphics.

X

WARNING NOTICE

DANGER CAUTION

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1.1.1. About Warnings

This manual contains DANGER, WARNING, and CAUTION indicators

concerning the consequences of failure to safely use, assemble, maintain,

store, inspect and dispose of MAHLE-equipped eBikes.

The combination of the safety alert symbol and the word DANGER indicates

a hazardous situation that, if not prevented, could lead to death or serious

injury.

Keep all safety warnings and instructions for future reference. Do not open

the e185 Range Extender by yourself. The system is maintenance-free. It

must only be opened by qualiﬁed experts. The unauthorised opening of a

system will void the warranty. All Drive Unit and eBike components may only

be replaced with identical components or components that are speciﬁcally

approved by your eBike manufacturer. This protects your eBike system from

damage. Do not modify the Drive Unit, the battery or any other component

or add any unapproved products to improve performance or tamper with

the product. There is a risk of injury in the event of accidental activation. Be

careful when touching the surface of your Drive Unit. The surface may heat

up considerably and cause burns to the skin. The walk-assistance function

may only be used when pushing the eBike and may require speciﬁc remotes.

There is a risk of injury if the wheels are not in contact with the ground

when using this function. Use only original MAHLE batteries approved by the

eBike manufacturer. Using unauthorised batteries may cause injuries or ﬁre.

Observe your regional and local regulations regarding eBikes and pedelecs.

006

1.2. Maintenance & Storage

The e185 Range Extender and main accessories are designed for long-term

use and require some simple, understandable guidelines to be followed to

extend the lifespan of the MAHLE System by taking proper care during us-

age and cleaning.

These guidelines are as follows:

• Children must not play with the components or full eBike system.

• Contact the place of purchase or a bicycle dealer for information on

installation and adjustment for products not found in the user manual.

• Do not disassemble or alter this product.

• These are small waterproof connectors. Do not repeatedly connect and

disconnect. It may impair the function.

• The components are designed to be fully waterproof to withstand wet

weather riding conditions; however, do not deliberately place them in water.

• Do not clean the bicycle in a high-pressure car wash. If water gets into any

of the components, operating problems or rusting may occur.

• Do not use thinners or similar substances to clean the products. These

substances may damage the surfaces.

• Be careful not to let water get into the terminal.

• Unsupervised children must not carry out cleaning or user maintenance.

Products are not guaranteed against natural wear and tear from normal use

and ageing. The e185 Range Extender can be installed in eBikes for kids.

For this type of use, ensure that your child is supervised and follow the eBike

manufacturer’s safety instructions.

MAHLE e185 Range Extender · Introduction

V.1.0.0 - 09/2022

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3.5. Updating Process

The system can be updated using the micro-USB port on the active charger.

To perform an update, you need to connect the charger to your computer

and transfer the update ﬁles to the charger. Please follow this process.

3.5.1 Uploading ﬁles to the Active Charger

1. Disconnect the charger from the power outlet. There should be no LEDs

lit up.

2. Connect the charger to your computer using the micro-USB port

The charger LED and the HMI will turn BLUE.

Copy the extracted update ﬁles (update_MUT.bin) to the new Drive Unit

(MAHLE_UTOOL), which will appear on your computer, and safely eject the

new drive unit from your computer.

100%

Updating...

008

1.3. Transporting your e185 Range Extender

There are speciﬁc regulations for transporting batteries:

• Transport by car: External batteries need to be removed and transported

in a safe area inside the car, in their original box and properly secured with

straps to prevent damage during transport, as these are hazardous goods.

• Transport by air:

The IATA (International Air Transportation Association) will

not transport any eBike batteries.

• Transport by train: In most cases, external eBike batteries are allowed to

be transported inside trains if the train does not provide a speciﬁc safe area

for transportation. Check your local regulations or ask your transportation

company before setting off on your trip.

• Public transportation: Our products can be transported by public

transport. There are some places where you are not permitted to take your

e185 Range Extender, so ensure that you ﬁnd out about the conditions of

carriage in plenty of time. You should also take into account the regulations

and city rules for carrying it through places you intend to travel to before you

start your trip.

Remember that, in any case, the best option is to transport the battery when

the battery level is under 30%.

1.3.1. e185 Range Extender Shipment

If, for any reason, you need to ship the battery, this must be done through an

ofﬁcial service following the speciﬁc rules for transporting dangerous goods

and the recommendations from MAHLE and the eBike manufacturer. The

battery needs to be placed in a speciﬁc, certiﬁed box and all the ofﬁcial

documentation, i.e., the MSDS (Material Safety Data Sheet) report, must be

included. This process cannot be performed by individuals.

MAHLE e185 Range Extender · Introduction

V.1.0.0 - 09/2022

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1.4. Safe Charging Process

The Active Charger, which sets up a direct connection with the MAHLE

compatible system for both integrated and external SmartBike batteries,

supplying the correct charging current and ideal cell balancing. Please

use only the MAHLE Active Charger for charging MAHLE e185 Range

Extenders. The charger and batteries are fully qualiﬁed for usage under

current regulations in the regions that the X20 System (or compatible

systems) is approved for use.

Before charging the e185 Range Extender, take into consideration the

following:

• Connect the charger directly to a power source. Never use extension

cords.

• Avoid reverse charging.

• Inspect the charger before every use for possible damage to the charger

itself, the wire or the charging plug. Do not cover the charger while charging.

• Regularly inspect the battery. Never charge a battery that you suspect is

damaged or that you know is broken.

• Make sure there is no moisture on the charging socket and plug before

connecting and charging the battery.

• If the battery is very cold or too hot, wait for it to warm up or cool down

before you start charging.

• Keep the connector clean. If any connections have been damaged,

please do not use it.

Be aware of explosive gases. Prevent ﬂames and sparks. Ensure that there

is adequate ventilation during charging. The charger is designed for indoor

use only. Misused other types of batteries may burst, causing personal injury

and damage. Do not incinerate, disassemble, or short circuit batteries or

the charger.

WARNING

010

NOTICE

1.5. Servicing

Servicing and replacement may only be performed by approved Service

Partners. Please remember that our components may contain cells that can

be damaged, or a short circuit may occur from drilling into the external case,

which could result in a ﬁre.

The battery’s capacity will decrease over time. During normal use for 2

years or after 500 full charging cycles, the battery’s capacity may lower

to a minimum of 70% of its initial value. To obtain 100% capacity again,

the battery must be replaced. Waterproofness and integrity of the battery

cannot be guaranteed once the battery has been opened.

1.6. Recycling

It is our responsibility to ensure the correct recycling of the e185 Range

Extender. Together, we are responsible for minimising the CO2 footprint and

environmental impact. Please ensure the battery is properly recycled when

it reaches the end of its lifespan. Get in touch with your dealer or eBike

manufacturer to ﬁnd out about the correct recycling process. If the battery

needs to be replaced, please bear in mind that only approved Service

Partners are allowed to replace the internal battery. They can also handle the

recycling of your old battery.

According to European Guideline 2012/19/EU, electrical devices/tools that

are no longer usable must be collected separately and disposed of in an

environmentally-appropriate manner. Do not dispose of your e185 Range

Extender in the normal household rubbish. It must be disposed of according

to local battery disposal regulations. Dealers must provide used battery

collection and appropriate disposal services. If not, contact your MAHLE

dealer.

By collecting and recycling waste, you are doing your bit to save natural

resources and making sure the product is disposed of in an environmentally-

friendly, healthy way.

MAHLE e185 Range Extender · Introduction

V.1.0.0 - 09/2022

011

English

1.7. Product Certiﬁcations

MAHLE SmartBike Systems SLU hereby declares, under its own

responsibility, that the design and construction of the product complies

with the Safety requirements applicable under European Standard EN

15194:2017 and the following European Directives: [EMC] 2014/53/CE,

[BAT] 2006/66/EU (Battery Packs), [RoHS III] and Regulation [REACH]

012

2. Product Overview & Speciﬁcations

You have bought an e185 Range Extender, which includes:

e185 Range Extender

GTIN: 8435635802019

• Weight: 1,100 g

• Waterproofness IP67

• Capacity: 171 Wh

• Nominal voltage: 36 v

• Rated capacity: 4.73 Ah

• Max. charging current: 2.51 A

• Max. discharging current: 12 A

• Dimensions: 195 x 75 mm (Height x Diameter)

• Operational temperature: 60 °C / -20 °C

• Storage temperature: -10 °C / 20 °C

Bottle holder

GTIN: 8435635800701

• Compatible with standard water bottles

• 4 x 15 mm slotted holes (64 mm standard

distance)

• Weight: 46 g

MAHLE e185 Range Extender · General Overview & Speciﬁcations

V.1.0.0 - 09/2022

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Rubber strap (to close the holder)

GTIN: 8435635800718

User Manual

2.1. Compatible Accessories

Active Charger

GTIN: 8435635800688 (Wall mount included)

GTIN: 8435635800534 (Wall mount not included)

Range Extender e185

User Manual

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014

AD RA2 30º Connector

GTIN: 8435635800725

• Total length: 193 mm (± 7 mm)

• Diameter: 6.5 mm

• Wire length: 100 mm (± 5 mm)

• Weight: 33 g

• Waterproofness IP67

DE RA2 90º Connector

GTIN: 8435635800732

• Total length: 193 mm (± 7 mm)

• Diameter: 6.5 mm

• Wire length: 110 mm (± 5 mm)

• Weight: 33 g

• Waterproofness IP67

Charging port

MAHLE e185 Range Extender · Operation and Use

V.1.0.0 - 09/2022

015

English

3. Operation and Use

Please read the following instructions carefully before using your new e185

Range Extender.

3.1 Installation Guide

Step 1 - Assemble the holder (Recomended torque 4 Nm) Step 2 - Slide in the e185 Range Extender.

016

Step 3 - Attach the rubber strap. Step 4 - Plug the connector in, ﬁrst to the e185 Range Extender and then

to the charging port:

If the holder position is in the Seat Tube, use the AD RA2 30º Connector.

If the holder position is in the Down Tube, use the DE RA2 90º Connector.

MAHLE e185 Range Extender · Operation and Use

V.1.0.0 - 09/2022

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If the wire installation is not neat, please adjust the holder height installation

using the slotted holes.

3.2. Operation Mode

To operate the system correctly, ensure that the eBike system (including the

rear wheel) is fully connected and correctly assembled.

To ensure the proper use of the e185 Range Extender, ﬁrst disconnect the

charging wire from the charging port of the eBike.

Ensure the e185 Range Extender is fully charged before using it for the

ﬁrst time. To do so, we recommend keeping the e185 Range Extender

connected to the power supply and charger for at least 2 hours. For

additional information on how to charge your e185 Range Extender, please

go to chapter “3.4.4 Charging Process”.

Before starting to ride, always ensure your battery is sufﬁciently charged.

3.3. Usage

The e185 Range Extender is designed to be used as an external battery to

provide additional capacity to any MAHLE Smartbike System compatible

eBike system.

3.3.1. Intended Usage

Our product is intended to act as a Range Extender of an Electrically Power

Assisted Cycle (EPAC) (not for any other eBike application). All compatible

components were designed to be incorporated into a complete eBike

produced by a professional bicycle manufacturer.

The system is designed to be used under current standardised norms and

certiﬁcations:

• Europe: EN15194:2017

• US / CAN (in progress): UL2849, UL 1310 (battery charger)

• Australia: EN15194

NOTICE

018

3.3.2. Prohibited Usage

Our system must not be integrated into a non-compatible EPAC certiﬁed

under EN 15494 or into a regular bicycle. It is in breach of MAHLE standards

to manipulate the legal parameters (speed or power), to repair the battery or

to reuse it for any other device or EPAC. It is in breach of MAHLE regulations

to tamper with our components, to change the software and ﬁrmware

designed and approved by MAHLE or to add electronic components which

modify the maximum assisted speed. If MAHLE terms are breached by non-

compliance with the above, MAHLE shall not be held legally responsible for

damages caused to individuals or materials.

The MAHLE e185 Range Extender reserves the right to include functions

which can analyse and record any kind of abnormal behaviour, such as a

maximum speed that is too high or abnormal data communication, which

could be caused by tampering with the system. Any kind of manipulation

shall immediately void all MAHLE warranty terms.

Our product is designed as per the requirements and standards established

for use in EPAC applications and as per the particular environmental

conditions in which these kinds of applications may be used, such as rain,

salty areas, mud, etc.

The MAHLE e185 Range Extender goes beyond what the standards require,

but please also pay attention to what the eBike manufacturer speciﬁes

regarding system integration and design information. In particular:

• Only clean the system as per the speciﬁc MAHLE recommendations set

out in this manual. Never use a power washer to clean your eBike or the

electronic components of your eBike.

• When storing your e185 Range Extender, ensure all of the batteries have

been sufﬁciently charged.

MAHLE e185 Range Extender · Operation and Use

V.1.0.0 - 09/2022

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3.3.3. Operating Mode (In the event of malfunction)

The system can operate in 3 different modes:

• Normal: Everything is OK.

The system indicates the state of charge with the LED bar (Standalone,

eBike) and current assist level (eBike).

• Alert: LED bar ﬂashing ORANGE.

Battery has a degree of malfunction, but your riding and assistance are

not restricted.

• Warning: LED bar ﬂashing RED.

Malfunction that limits assistance. Ebike propulsion system is shut off. In this

case, please contact the MAHLE SmartBike Systems Service or your local

dealer. There are 2 warning (RED) levels.

• System is ON but does not provide assistance

• System is SWITCHED OFF

In the event of an error alert (ﬂashing ORANGE) or warning (RED), the system

sends the error or warning information through Bluetooth® and the ANT+

LEV compatible display. Please pair your smartphone to check the error

using the MAHLE “My SmartBike App” or check the error using the “Pulsar

ONE display” (which will display the error code number). The list of error

codes is included at the end of this document.

Bear in mind that if you remove the e185 Range Extender from the

compatible eBike and the Warning persists in the HMI line, the Warning

might only exist in the eBike.

MAHLE e185 Range Extender · Operation and Use

V.1.0.0 - 09/2022

020

3.4. Operation

3.4.1. System ON/OFF Standalone Switch

When the e185 Range Extender is not connected to the eBike, press the

button on the e185 Range Extender once to turn the system on. The LED

bar will light up and the “Hello” animation will be displayed. If everything is

in order, the LED bar will display the battery charging status in white (state

of charge).

After the brief “Hello” animation, the e185 Range Extender light will turn

CYAN and indicate the battery level status for 10 seconds (see State of

Charge in the battery section).

If no connection to a compatible eBike is made during this time, the e185

Range Extender will automatically switch OFF after a brief “Goodbye”

animation.

MAHLE e185 Range Extender · Operation and Use

V.1.0.0 - 09/2022

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