MAHLE E185 Manuale utente

Categoria
Accessori per biciclette
Tipo
Manuale utente
e185 Range Extender
User Manual
Always keep your SmartBike
up to date
Scan the QR code for
more info.
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
005
English
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
007
English
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
009
English
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
013
English
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
Always keep your SmartBike up to date
Scan the QR code for more info
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
017
English
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
019
English
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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MAHLE E185 Manuale utente

Categoria
Accessori per biciclette
Tipo
Manuale utente