Technical Manual - BESV LX1
Technical Manual
BESV LX1
V.1.0, May. 2015
Technical Manual - BESV LX1
Contents
1. Electronic components ························································· 1
1.1 Specification ································································· 1
1.1.1 Controller ··········································································· 2
1.1.2 HMI ··················································································· 2
1.1.3 Motor ················································································· 3
1.1.4 Torque Sensor ····································································· 3
1.1.5 Battery ··············································································· 4
2. Operation ·············································································· 5
2.1 Battery ········································································ 5
2.1.1 Installing the Battery ····························································· 5
2.1.2 Charging the Battery ····························································· 6
2.2 HMI ············································································ 8
2.2.1 Display information ······························································· 8
2.2.2 Function Key Description ······················································· 9
2.2.3 Function Settings ································································ 10
3. Disassemble Components ·················································· 12
3.1 Controller ··································································· 12
3.2 Torque Sensor ···························································· 15
3.3 Motor ········································································ 19
3.4 Adjusting the E-Brake ··················································· 21
3.5 HMI ·········································································· 22
3.6 Kickstand ··································································· 24
4. Trouble shooting ································································· 25
4.1 Error Code ································································· 25
4.2 Basic ········································································ 26
4.3 Advanced ·································································· 27
4.3.1 Battery ·············································································· 27
4.3.2 Motor ················································································ 28
4.3.3 Controller ·········································································· 29
4.3.4 Torque Sensor ···································································· 30
Technical Manual - BESV LX1
1. Electronic components
Charging
Plug
Battery HMI
E-Brake
Controller
Motor
F
M
(9 Pin)
Motor
Controller
(6 Pin)
M
F
Torque sensor
Torque sensor
F M
(5 Pin)
(2 Pin)
F M
HMI
E-Brake
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Technical Manual - BESV LX1
1.1 Specification
1.1.1 Controller
1.1.2 HMI
Model B-Type
Operating Temp. -15°C to 50°C (5°F to 122°F)
Storage Temp. -20°C to 100°C (-4°F to 212°F)
Storage Humidity 10% to 85%
ROHS Confirms the ROHS of PTC
1. Over voltage protection
Function
2. Over current protection
3. Stall protection
4. Speed limitation
5. UART communication
6. BLDC driver with hall
Operating Voltage 36V Regular (Range: 30 to 42V)
Efficiency 92%
Model
Active Area
BESV HMI
67.2 mm (L) x 46 mm (W)
Operating Temp. -20°C to 70°C (-4°F to 158°F)
Storage Temp. -30°C to 80°C (-22°F to 176°F)
Display Type
LCD Type
Dot Matrix Display
FSTN Positive; Transflective
Driver Condition 1/240 Duty, 1/16 Bias
Viewing Direction 6 O’clock
Information
Assistance Level; Battery Indicator;
Odometer; Speed; Total distance,
Trip Distance; Trip Time;
Assistant Level
Trip Max. Speed; Trip Avg. Speed
3 Assistance Level
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Technical Manual - BESV LX1
1.1.3 Motor
Model Rear Motor
Operating Temp. -20°C to 85°C (-4°F to 185°F)
Storage Temp. -20°C to 65°C (-4°F to 149°F)
Storage Humidity < 40%
Fork Size
Weight
ROHS
36H
4.5 kg
Yes
Noise
Max RPM
Max Torque
< 45 db
305 RPM
20 Nm
Operating Voltage 36V Regular (Range: 24 to 48V)
Efficiency > 82%
1.1.4 Torque Sensor
Model TDCM Torque
Accuracy Effective range ± 200 Nm
RPM Resolution 32 Impulses / Rotation
Offset +2500 mV at 0 Nm
Analogue
Bandwidth
±23 mV / Nm
250 Hz at -3 dB
Weight 258 g
Torque Detection 180°
Operating Voltage 5 V
Length of
Spindles
120
Clockwise Yes
Counterclockwise Yes
Direction Yes
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Technical Manual - BESV LX1
1.1.5 Battery
Model LX1 Battery
Cell
Typical Capacity
Sony-2850mAh
11200 mAh ± 5%
Nominal Voltage 37.00V
Max Charge Voltage 42V
Voltage at End
Discharge
30V
Max Charge Current 4A
Max Continuous
Discharge Current
16A
Operating Temp.
Storage Temp.
Power Consumption
Fully Charged
Condition
Charge : 0°C to 45°C (32°F to 113°F)
Discharge : -10°C to 60°C (14°F to
140°F)
-20°C ~ 60°C (-4°F to 113°F)
Normal Mode : ≦ 2.97mA
MCU Shutdown Mode : ≦ 32.5uA
Shutdown Mode : ≦ 24.2uA
Need to meet the below condition :
1. 42 ± 0.05V constant voltage
2. Limited charge to current reach
100mA at 25 ± 2°C
3. Humidity max 65% RH
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Technical Manual - BESV LX1
2. Operation
2.1 Battery
2.1.1 Installing the Battery
A. Insert the key and turn it to the “OPEN” position.
B. Pull the battery cover upward.
Slide the battery in and push it until it firmly connects to the socket.
Notice battery direction when sliding in.
C. Close the battery cover. Push the key in and turn it to “OFF” position to lock the battery cover in place.
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Technical Manual - BESV LX1
2.1.2 Charging the Battery
General use instructions
A. Before charging, connect the 3-to-4 pin extension cable to charger cable.
3-to-4 pin extension
B.
If battery is inside bike, connect the cable from charger and insert the charge plug.
C.
If battery is alone, connect the cable from charger to battery, and insert the plug
.
D. LED MODE：
Standby: Solid Green LED Charging: Flashing Red LED
Full: Solid Green LED
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Technical Manual - BESV LX1
Charging time
The charging time depends on the remaining energy in the battery and the charger current. The acceptable charger input voltage is AC 100 - 240 V ~ 2A (50 / 60Hz).
If the battery is completely discharged, you can estimate the charging time by the following calculation example：
The estimated charging time is the battery’s capacity divided by the charger’s current. The standard LX1 battery is 11.2 Ah and the standard LX1 charger is 2A.
Estimated charging time = 11.2 / 2 = 5.6 hours
2.1.3 Safety Instruction/Warnings
1. The e-bike uses a Lithium-ion battery which requires a special charger supplied with the bike. Do not try to charge the battery with a third-party charger. Using an incompatible charger can lead to overheating, fire or explosion.
2. If the e-bike is not used often, charge the battery at least once per 3 months.
3. Please store battery in dry & dark place.
4. Do not store the battery in temperature below -10℃ (14°F) or above 40℃
(104°F).
5. Do not put battery into water.
6. The charger should only be used indoor and kept away from any heat sources.
7. Do not cover the charger or battery during the charging progress, otherwise it may overheat and be a fire hazard.
8. Do not use a defective battery or charger.
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Technical Manual - BESV LX1
2.2 HMI
Power on
Turn the key-switch clockwise (OFFON) and the HMI will turn on.
Note: In order to save battery power, the HMI’s backlight will turn off automatically after being idle for over 10 second.
Power off
Turn the key-switch counterclockwise (ONOFF) and the HMI will turn off.
2.2.1 Display information
Assistant Level Suggestion
Level
0
Riding condition
Riding without assistance.
1
2
3
Riding on a leveled surface.
Riding uphill or against the winds.
Riding up steep hill or against strong winds.
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Technical Manual - BESV LX1
Battery power indicator
The battery sign on HMI will tell you how much capacity is left in your battery when the system is on. The following illustration shows how much power is left.
96~100% 81~95% 61~80% 41~60%
21~40% 6~20% 1~5% 0%
Battery capacity is 0% when the battery light flashes. Please charge immediately.
2.2.2 Function Key Description
Keys： [ ] / [ ] / [ ] / [ ] / [ ] / [ ]
Front light & backlight switch
When power is on, push the [ ] button to turn the front light & screen backlight on/off.
Assistance model setting
Push the [ ] or [ ] button to change the assistance level.
※ [ ]：up [ ]：down
Smart Mode
Push the [ ] button to turn smart mode on/off.
Information selection
Push the [ ] button to toggle the different trip information shown on screen.
For example: speed, trip distance, trip time, maximum speed and average speed.
Function setting
Push the [ ] button to enter setting options.
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Technical Manual - BESV LX1
2.2.3 Function Settings
When entering function setting mode, push [ ] to select different functions.
To toggle different options under each function, you can push [ ] or [ ] to set or push [ ] to leave it.
Setting page
Screen contrast
There are 9 levels; 0 is the lowest and 9 the highest.
Screen backlight
There are 9 levels; 0 is the lowest and 9 the highest.
Beeper
There is beep when entered.
Distance unit
Select km or mile, and the speed and distance are shown in "km/hr" or "mph" and
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Technical Manual - BESV LX1
"km" or "miles" respectively.
Language
The languages available are English, German, French, Italian, Dutch and Chinese.
The languages in "gray font" are not supported.
Information a. Show version of HMI and controller to exit the setting page. b. Push [ ] or [ ] to clear the trip, and press [ ] to confirm.
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Technical Manual - BESV LX1
3. Disassemble Components
3.1 Controller
Controller
HMI
A. Unplug HMI cable and Brake Cable
Brake
B. Loose the screws and remove battery pedestal.
(M4*L8 screw *4, assembly torque spec. 5 - 6 Nm)
Battery pedestal
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Technical Manual - BESV LX1
C. Loose the screws on charge cover to remove it
(M4*L8 screw *8, Torque spec.：5 - 6 Nm)
Charge cover
Screw
D. Loose the screws on L/R down tube cover to remove it
R-Cover (M4*L8 screw *1 + M3*10 screw *1, assembly torque spec. 5 - 6 Nm)
L-Cover (M4*L8 screw *2 + M3*10 screw *1, assembly torque spec. 5 - 6 Nm)
L-Cover
R-Cover
Screw
E. Loose the screws on controller to remove it
(M4*L8 screw *1 + M4*L10*1, assembly torque spec. 5 - 6 Nm)
M4*L8
M4*L10
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Technical Manual - BESV LX1
F. Remove the rear wheel. Refer to chapter 3.3,
G. Unplug the connector
Socket cable
Charger cable
Locker cable
Sensor cable
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Technical Manual - BESV LX1
3.2 Torque Sensor
Parts introduction
A. It’s related to frame’s side when assemble torque sensor. Please notice right or left frame side instruction when assembly.
B. Notice the components’ direction when assembly.
Parts
T Torques Sensor
T1 R- Retaining collar
T2 R- Out Retaining collar
T3 L- Bearing
T4 L- C Circlips
T5 L- retaining collar
T6 L- Out Retaining collar
T7 Rubber
A
B
Tools
C
(T6) (T5)
(T4) (T3)
(T) (T1)
(T2)
(T7)
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Technical Manual - BESV LX1
3.2.1. Disassemble torque sensor
1. Pull out “T7”
R-side
L-side
L-side
4. Remove
“T4” with tool “C”
L-side
R-side
7. Push “T” leftward around 1cm
R-side
2. Rotate to remove “T6” with tool “B”
5. Remove
“T3”
8. Rotate to remove “T1” with tool “A”
L-side
R-side
3. Rotate to remove “T5” with tool “A”
6. Remove
“T2” with tool “B”
9. Pull out “T” from right side.
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3.2.2. Disassemble torque sensor
A. Insert torque sensor (T) into the bottom bracket of frame, from right-side.
Note
Don’t wind cable Don’t touch sensor
R-side
1. Pull out connector and cable through frame
R-side
PIN
Dot
2. Insert cable into the groove, before assembly
3. Rotate & align
“PIN” with “Dot”, and move ”T” into frame’s bottom bracket
R-side
Note
4. Push “T” leftward around 1cm
Keep “PIN” forward when moving “T”
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B. Rotate and assemble R- Retaining collar (T1)
R-side
R-side
1. Manually rotate
“T1” to assembly on frame.
Inner notch
2. Rotate “T1” until
3~4 teeth, and align
“U-mark” with “dot”.
Dot
Note, don’t rotate “T”
U-mark
C. Push torque sensor (T) rightward to touch R- Retaining collar (T1)
Push “T” rightward to touch “T1”
Note, “PIN” must insert into “inner notch” inside frame.
And still keep align “U-mark” with “dot”.
Inner notch
PIN
D. Rotate and assemble R-Out Retaining collar (T2)
R-side
U-mark
Dot
Note, keep tool “A” still when fix “T2”, to align
“U-mark” with “dot”.
Tool
Tool
Rotate to assemble “T2” with tool “A” & “B”.
Note, must keep tool “A” still when operate tool “B”
Dot
U-mark
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Technical Manual - BESV LX1
E. Assemble other parts (T3, T4, T5, T6, T7)
L-side
L-side
1. Insert
“T3”
2. Insert “T4” with tool ”C”
L-side
4. Rotate to assemble “T6” with tool ”B”
R-side
L-side
5. Insert “T7”
6. Rotate axis until “Dot” is
3. Rotate to assemble “T5” with tool ”A”
R-side
7. Assemble right crank upward
Note, “Dot” is forward when assembly
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Technical Manual - BESV LX1
3.3 Motor
A. Place bike upside down. Loose the cable holder screw and unplug the motor cable connector.
1. Place bike upside down
2. Loose the cable holder screw, M4*L8, assembly torque 5-6 Nm
3. Unplug the motor cable connector.
B. Loose the both side crown nut. Assembly torque spec. 40~45 Nm
C. Remove the rear wheel.
1. Release air 2. Remove wheel
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Technical Manual - BESV LX1
3.4 Adjusting the E-Brake
M5*L16.5 brake
Screw type Torque Spec
5 - 6 Nm
M6*L18 brake calipers with washers 9 - 10 Nm
A. Left brake lever B. Right brake lever
C. Front and rear brake calipers
Remark
4 pcs
2 pcs
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Technical Manual - BESV LX1
3.5 HMI
A. Unplug switch connector.
Screw type
M3*L8 switch cover
M2*L5 top case and PCBA
Switch
1. Loose screws to remove lower case.
3. Loose screws on PCBA.
Torque Spec
2 - 3 Nm
2 - 3 Nm
Remark
2 pcs
6 pcs
2. Loose screws to take apart upper case.
4. Unplug connector
B. Unplug HMI connector.
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Technical Manual - BESV LX1
C. Loose the screw on lighting and remove lens, reflector
(M4*L8 screw *1, torque spec. 5 - 6 Nm)
D. Loose the screw on HMI cover
(M3*L6 screw *2, torque spec. 5 - 6 Nm)
E. Remove HMI
Pull out cable
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Technical Manual - BESV LX1
3.6 Kickstand
A. Remove the rear wheel. Refer to chapter 3.3,
B. Remove the kickstand
Screw type Torque Spec
M10*L25
M10*T2.2 spring washer
30~35Nm
N.A
Loose kickstand screw M10*L25
Remark
1 pc
1 pc
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Technical Manual - BESV LX1
4. Trouble shooting
4.1 Error Code
When happens error, please record the error code and turn off power. Contact service center for correct solution.
HMI Code Error Message
3 Battery low or under Voltage.
16
21
31
32
41
11
Motor Hall exception.
Motor current exception
Torque sensor exception..
Torque sensor initial high
Motor or controller temperature high
The connection between HMI and controller fails.
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Technical Manual - BESV LX1
4.2 Basic
Condition
1
The HMI does not display anything.
Possible cause
Battery is out of power.
Bad cable connection.
The HMI is broken.
Action
Charge the battery using the charger supplied with your e-bike.
Disconnect and reconnect the HMI cable.
Contact your local BESV dealer.
2
The HMI screen is flicking
3
4
The assist is not continuous while pedaling.
The assistance level changes to ‘0’ by itself while pedaling.
5
The battery does not charge.
Controller or HMI is damage Contact your local BESV dealer.
Firmware may not be correct. Contact your local BESV dealer.
The brakes interfere with the wheel.
Readjust the brake system.
Bad cable connection.
Disconnect and reconnect the HMI cable.
When bike is backward, the motor has cogged
Contact your local BESV dealer.
Motor is damage.
Insufficient contact with charger connector.
Charger is defective if it is plugged in and the LED indicator is not on.
Battery is defective.
Contact your local BESV dealer.
Disconnect and reconnect the charger.
Contact your local BESV dealer.
Contact your local BESV dealer.
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Technical Manual - BESV LX1
4.3 Advanced
4.3.1 Battery
The following progress is strongly recommended to be executed by technicians.
No. Issue Step
1
2
Unable to discharge
Unable to charge
Check step Action
1
Verify the key is turned to the “ON” position.
If not, turn it to the “ON” position.
2 Check the cable connections.
3 Check the external fuse.
4 Measure the output voltage.
5
Use a thermometer to measure the surface temperature of the battery case.
If no, please make sure the connection is good.
If it is broken, replace it with a new fuse.
If the value is smaller than 25, then charge the battery.
If the value is larger than 68°C, let the battery cool down to room temperature.
6
1
2 Check the external fuse.
3
4
Check if there is short circuit on output pin.
If yes, remove any possible loading which causes short circuit.
Check the cable connectors between Disconnect and reconnect the the battery and the charger. connectors.
Use a thermometer to measure the surface temperature of the battery case.
Open the case and use the meter to confirm if there is any series of cells with voltages larger than 4.3V.
If it is broken, replace it with a new fuse.
If the value is larger than 68°C, let the battery cool down to room temperature.
If yes, please discharge this series until the voltage is equal than the others.
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Technical Manual - BESV LX1
4.3.2 Motor
No. Issue Step
1
Unable to work
2
Abnormal vibration
Check step Action
1 Check the cable connection. Disconnect and reconnect the cable.
2
Verify the 9 pins inside the cable connector are not damaged.
If any of the pins are damaged or bent, replace the cable.
3
Check the core of the cable for any exposed wiring or damages.
Replace the cable if there are any exposed wires or damages.
4
Check the status of Hall sensors.
Connect the motor with a working controller and power source. Then manually rotate the motor backwards,
If no, please replace the hall sensors and measure the signal of thinner wires (yellow, green, blue). Those signals should keep varying between
0 and 5V. and re-check again.
1 Check the cable connection.
If that are not connected well, please reconnect them.
2
Verify the 9 pins inside the cable connector are not damaged.
If any of the pins are damaged or bent, replace the cable.
3 Check the status of bearing.
4 Check the status of axle.
Rotate the motor manually. If there are any abnormal noises or roughness from the bearing, replace the bearing.
Rotate the motor manually. If the axle is rusty or out of shape, replace the axle.
If it is out of shape, replace the
5 Check the housing.
6 housing.
Check the status of Hall sensors.
Connect the motor with sample controller and power source. Then manually rotate the motor backwards,
If no, please replace the hall sensors and measure the signal of thinner wires (yellow, green, blue). Those signals should keep varying between
0v and 5v. and re-check again.
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4.3.3 Controller
No.
1
2
3
Issue
When the e-brake is pressed, the motor is still giving assist.
The display is turned off automatically after three minutes, and HMI is turned off automatically when display reset
When display is turned on, it can't be operated.
As the LCD type, it shows
"initializing…" as the LED type, it is continuously running all LEDs.
Step
1
2
3
Check step
Check the signal between the e-brake and the controller.
Action
Turn the e-bike on.
While pressing the brake,
Verify the e-brake’s LED indicator is on. If the LED is off, replace the e-Brake.
If it’s abnormal, please replace the e-Brake.
Use Diagnosis tool or PC interface to check the e-brake signal when pressing brake.
Replace the e-Brake with a working sample, and go through steps again.
If no problem, please go to the step 3.
If no function, please replace the controller.
If ok, please replace the e-Brake.
1
1
Check 36V switch voltage is 0V when display is turned off; check
36V switch voltage is 36V when display is turned on.
Replace the controller with golden sample, and check the condition is the same or not.
If no, please replace the display.
If yes, please replace the display.
If no, please replace the controller.
4
After long pressing the power on button of display, the display is still
OFF
1
2
Check if the LED indicators of battery is more than or equal to
1.
Use the meter to measure the output voltage of battery.
If no, please charge the battery.
If no, please replace the battery.
3
Replace the display with golden sample, and test again.
If no, please replace the display.
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4.3.4 Torque Sensor
No.
1
Issue
No assistance while pedaling
Step
1
2
3
4
5
6
7
8
9
10
Check step Action
Confirm the assistance level on HMI display is equal to or larger than 1.
Confirm if the function of assistance level adjustment buttons is ok
Check if the connectors of all the cables are well connected
Use Diagnosis tool or PC interface to check the e-brake signal without pressing brake.
If no, please adjust it.
If no, please replace another display.
If no, please turn off the key and reconnect it.
If the e-brake signal keeps on, please replace the e-brake sensor.
Rotate the wheel backwards manually and use Diagnosis Tool or PC interface to If no, please progress step 6.
monitor the hall sensors output.
All of the hall sensors shouldn't be ON or
OFF at the same time, and should keep changing while rotating.
If yes, please progress step
7.
Replace the controller with sample, and repeat the progress of step 5.
Replace the controller with sample, and repeat the progress of step 9.
If no, please replace the motor.
If yes, please replace the controller.
While rotating the pedal forwards manually, the pedal sensor counters of signals in Diagnosis tool or PC interface should be increased.
If no, please progress step 8.
If yes, please progress step
9.
If no, please replace the torque sensor.
Replace the controller with sample, and repeat the progress of step 7. If yes, please replace the controller.
While rotating the pedal forwards manually,
Pedal RPM value in Diagnosis tool or PC interface should be larger than 1.
If no, please progress step
10.
If no, please replace the torque sensor.
If yes, please replace the controller.
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No.
2
Issue
The assist is not smooth and not continuous
Step
1
2
3
1
Check step Action
Confirm the firmware version and model code of the controller.
Update firmware to the current version.
Calibrate the torque sensor with Diagnosis tool or PC interface.
After the calibration, the torque value of
Diagnosis tool or PC interface should be 0.
If yes, please progress the step 3.
While pedaling in the opposite direction, the torque value should be more than 2.
If the torque sensor’s signal numeric value is N, rotate the pedal for 2 circles, and the
If no, please replace the torque sensor.
RPM counters in Diagnosis tool or PC interface should be 2xN or (2N-1).
Dissemble the connector between torque sensor and controller, and use a sample torque sensor to connect it.
Manually rotate the torque sensor. Check if the motor stops while the torque sensor is rotating forwards and the motor actions while the torque sensor is rotating backwards or not.
If yes, please dissemble the original torque sensor and assemble it again with opposite direction (left and right).
Check the cables’ connection between the Connect and reconnect the motor and the controller. connectors.
If yes, please progress step 3.
3
The assist level resets to
0 while starting pedaling
The assistance level resets to initial value while starting pedaling
2 Check any damage in motor cable.
3
If no, please progress step 4.
If no, please replace the motor.
Please skin the cable of motor cable, and check any damage of the wire inside.
If yes, please recover and repair the skin with shrink tube.
31
Technical Manual - BESV LX1
No.
3
Issue
The assistance level resets to initial value while starting pedaling
Step
4
5
6
Check step Action
Rotate the wheel backwards manually and use Diagnosis Tool or PC interface to monitor the hall sensors.
All of the hall sensors shouldn't be ON or
If the result is wrong, please replace the motor.
OFF at the same time, and should keep changing while rotating.
Turn off the switch of battery, and drag the bike backwards. If yes, replace the controller.
Check there is feeling of obstruction.
Replace the controller with a sample, and go through troubleshooting steps again.
If the trouble still happens, replace the controller.
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