Owners Manual
SRS/SY pedelec
SRS/SY pedelec
English
Caution
SR SUNTOUR OWNERS MANUAL SRS/SY pedelec
2
►
Be sure to read this manual carefully before using your electric bicycle.
Inappropriate usage of your electric bicycle may cause damage to the
product, serious injuries or even death to the rider.
►
Do not use damaged components – consult your authorised SR SUNTOUR
dealer immediately.
► The battery of the electric bicycle contains chemicals which can be dan-
gerous when used improperly, warnings included in this manual must
be followed in order to reduce the possibility of dangerous situations
resulting in injuries or possible death. Never try to open any SR SUNTOUR
device of the electric bicycle, especially not the battery. Opening any SR
SUNTOUR battery implies the risk of getting seriously injured.
► Do not let the battery come into contact with water or any other liquid
other than rain or snowfall. The guarantee will be void if the battery gets
in contact with water. Whenever the battery gets in contact with liquid
immediately disconnect it to prevent dangerous situations.
►
Do not store the battery above room temperature. The battery life expectancy will be signicantly reduced if the battery is stored under higher
temperatures.
► Do not place the battery immediately close to a ame or any other heat
source. Extreme heat can cause the battery to explode. Keep the area
where the battery is charged well ventilated. Keep it free from litter and
anything combustible to avoid re from sparks or overheating.
►
The battery must only be charged with the supplied charger. Using a
dierent charger can result in malfunction and reduced lifecycle of the
battery.
►
Charge the Li-ion battery indoors at a temperature between 0ºC to 40ºC
(32ºF -104 ºF). The Li-ion battery charger cannot charge a battery with a
temperature above 60º C or less than -3 ºC.
English
WARNING !
Failure to comply with the given warnings and instructions may cause
damage to the product, injuries or even death to the rider and user.
Caution
SR SUNTOUR OWNERS MANUAL SRS/SY pedelec
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►
If you notice a strange smell or smoke, un-plug the charger immediately
from the power socket and disconnect the battery from the charger!
Take your battery and charger to your authorized dealer for service or
replacement.
► Disconnect the charger when the battery is fully charged.
► Use only genuine SR SUNTOUR parts. The use of non-designated after-
market accessories, replacement and spare parts voids the warranty of
the electric bike drive unit and might cause failure to the system.
►
Do not disassemble or modify any of the parts of the drive unit. The
warranty will be void in case of any modication.
►
SR Suntour electric bike units are designed for the usage on single
seated bicycles for regular and common use on regular city- and trekking bikes. The intended use of the drive unit is accordingly.
►
This instruction sheet contains important information about the correct
installation, service and maintenance of your drive unit. Nevertheless
please be informed that special knowledge and tools are essential to
install, service and maintain SR SUNTOUR drive units for electric bicycles.
Common mechanical knowledge may not be sucient to repair, service
or maintain the devices. Therefore we strongly recommend getting your
system serviced and/or maintained by a trained and qualied bicycle
mechanic. Improper installation, service or maintenance can result in
failure of the product, accident, injury or even death.
►
Always be equipped with proper safety gear. This includes a properly
tted and fastened helmet. Make sure your equipment is in awless
condition.
►
Make sure to learn about the electric power assistance, the changed
bicycle behaviour and handling of your bike. Learn how to ride and train
your skills. Know your limits and never ride beyond those.
English
SR SUNTOUR OWNERS MANUAL SRS/SY pedelec
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Foreword
What is a Pedelec?
It is legally considered as a conventional bicycle, whereas the
rider is enjoying some electrical power assistance based on
the human power brought up by the rider. Just ride like on a
conventional bike, the system will add some extra power. It feels
like having tailwind or a continuous descending ride.
In European Countries the assistance is legally limited to 250W
nominal power and a max. speed of 25km/h. Riding faster than
that is possible, but there will be no assistance when riding
faster than 25km/h.
A Pedelec is sometimes called EPAC, Light-Electric-Vehicle (LEV), Hybrid Bicycle or eBike or
electric bicycle with Pedal-Assisted-System (PAS).
Dear customer,
congratulations on your new electric bicycle purchase. The bike is equipped with the SR SUNTOUR
SRS-SY-pedelec drive unit with a rechargeable Lithium-Ion battery, a display and user interface,
a torque sensor, a controller and a brushless front hub motor..
To make your ride smooth, safe and fun please take some time to read this manual carefully. It
contains information on the proper care of the drive unit of your electric bicycle and advice on
how to achieve the bikes’ and batteries’ full lifespan.
In case of any enquiries not covered by this manual please contact your local dealer.
Enjoy the riding!
Torque Sensor
Motor
Drive
Control
Motor drive
3-Phase
Brushless
Motor Driver
DC Brushless
Motor
Li-Ion Battery
Hall IC
schematic functional diagram
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Table Of Contents
Foreword ...................................... 4
Table Of Contents ........................ 5
Drive Unit Components .............. 6
Display and User Interface ...........7
Battery, Charger and charger
adaptor ......................................... 8
Battery Charging ......................... 9
User Interface and Display ........ 11
Fuel Gauge ..................................... 12
Assist Mode .................................... 13
Information Modes ...................... 13
Speed................................................ 14
Total Distance ................................ 14
Trip Distance .................................. 15
Re-setting the trip distance .................15
Trip Time .......................................... 15
Re-setting the trip time .........................15
Average Speed .............................. 16
Wheel Size....................................... 16
Setting the wheel diameter ................ 16
Error Code ........................................17
Error Codes................................. 18
Error Code Chart ........................... 18
Error troubleshooting guide .... 19
E00 - Controller Communication
Error..............................................................19
E02 - Coil Sensor Error ........................... 20
E03 - Beyond the torque sensor
range ............................................................21
E05 - Torque Sensor Error .....................22
E11 - Beyond the battery voltage sen-
sor- or battery-current sensor-
range ................................................ 23
E12 - Beyond the battery temperature
sensor range .................................. 24
E13 - Beyond the motor temperature
sensor range ...................................25
E21 - Drive Battery over current, low
voltage or overvoltage .............. 26
E22 - Battery Overheating .................... 27
E23 -Motor Overheating ...................... 28
E31 - Hall-IC Error .................................... 29
E32 - Switch Box Communication
Error .................................................. 30
E33 - Battery Communication Error ..31
Operating Range ....................... 32
Range Inuencing Factors ........ 32
Maintenance and cleaning ....... 33
Cleaning .......................................... 33
Tightening Torque ........................ 33
Disassemble and assemble front
wheel ................................................ 34
Technical Specication .............. 38
Motor .......................................................... 38
Controller features ................................. 38
Charger ....................................................... 38
Battery ........................................................ 38
Conformity ................................. 38
Limited Warranty ....................... 39
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Hub motor
Suspension fork
Upper holder and lock
Controller
Torque sensor crank-
assembly
Display
Battery
* Shown on a virtual bike which may look dierent to the bike which this owners manual came along with
Drive Unit Components
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Mode Button
On/O-Button
Info-Button
* Shown display layout may vary compared the display on the bike which this owners manual came along with
Display and User Interface
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Battery charger adaptor
Battery
Battery charger
Battery, Charger and charger adaptor
* Shown devices may vary compared the display on the bike which this owners manual came along with
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Battery Charging
Your bike is delivered together with a charger
and charger adaptor. Please only use these
together and don’t try to combine with other
devices.
Please note: The battery needs an initial full
charge before the rst use of the bike and
after every use, regardless of the remaining
capacity of the battery. The battery doesn’t
need to be empty before charging it.
To charge the battery please follow these
steps:
1.
The system must be switched off by
pressing the “on/o”-button on the display.
2.
Insert the key of the battery lock into
the upper battery holder, turn the key
counter-clockwise and keep it so while
you push the battery out to the left side
of the bike.
3. After you have pushed out the battery a
little bit to the side (depending on the
frame design) the handle can be swinged
out for an easy and safe handling.
4. Pull the battery out upwards.
5.
Connect the charger adaptor to the
charger.
6. Connect the charger to a 110-240V wall
socket.
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7. Connect the battery to the adaptor.
8.
The LED on the charger shows a red con-
tinuous light during charging.
In case the LED starts ashing fast (0.2s
on / 0.2s o) it means there is a abnormal
situation. In this case please disconnect
and reconnect the charger to the battery.
If the same ashing is showing up again
please unplug the charger and battery
and contact your local dealer.
In case the LED starts ashing slowly
(0.5s on / 1.0s o) the temperature of
the battery is not within the specica-
tion for charging. Unplug the battery and
wait until the battery is cooling down to
room temperature.
9.
When the LED is o the battery is fully
charged.
If the battery is completely discharged a
full charge will take approximately 400
minutes.
10.
Insert the battery into the lower cradle
and swing it back into the upper holder.
Check if the lock has snapped in by pushing the battery back out to the left.
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Info-Button
On/O-button
Mode-button
Fuel gauge
Assist-mode indicator
Data corresponding to the choice of
information mode
Information-indicator
User Interface and Display
The user interface and display are located on
the handlebar. When the system is switched
on by using the on/o-switch, the LCD display
is showing the remaining battery capacity, the
chosen assist mode as well as information on
the following features:
• Remaining battery capacity
• Speed
• Average speed
• Total riding distance
• Trip distance
Any information will be displayed only when
the system is activated.
The system will switch o automatically after
10 minutes of inactivity.
The 3-button design is providing a intuitive way
to switch between the available assist modes
and the desired ride information.
When it is dark the backlight of the screen display is turned on automatically when the drive
unit is activated. The backlight is only on as the
system is activated.
During the rst setup of the bike the wheel size
have to be set on this user interface.
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Remaining capacity
100-75%
Remaining capacity
75-50%
Remaining capacity
50-25%
Remaining capacity
10-0%
Remaining capacity
25-10%
Remaining capacity
0%
Fuel Gauge
When the main switch is turned on, the battery
fuel gauge shows up. with its 4 digit icon.
The remaining battery capacity is is represented
by illustration as follows.
Blinking 2 times per second
Blinking 8 times per second
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press
press
press
speed total
distance
trip
distance
trip
time
average
speed
wheel
size setting
press
press
press
press
press
press
press simultaniously
Assist Mode
The user can choose the ratio of assistance depending on his personal wish by pressing the
Mode-button “M” on the user interface.
The percentage of assist power related to the input of the rider is varied from 50%, 100% and
150%.
Information Modes
The ride information Speed, Total Distance, Trip Distance, Trip Time and Average Speed are shown
one after another when pressing the Information-Button “I”.
The setting mode and data re-setting modes are entered by pressing the Information Button “I”
and Mode button “M” simultaneously when the related data is being displayed.
* setting mode
avalable
* setting mode ava-
lable
* setting mode
avalable
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Speed
The speed is shown in kilometres per hour.
Display speed range: 0.0 .. 60.0km/h
Display accuracy: 0.1km/h
Total Distance
The total distance is counted when the system is activated and is displayed in kilometres.
Display range: 0.0 .. 9999km
Display accuracy: 1km
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Trip Distance
The trip distance is counting when the system is activated.
Display range: 0.0 .. 999km
Display accuracy: 1km
Re-setting the trip distance
1.
Reset the trip distance by pressing the mode- (M) and info-button (I) simultaneously while
it is displayed.
Trip Time
The Average Speed is calculated on the trip distance.
.Display range: 00.00 .. 99.59 hh:mm
Re-setting the trip time
1.
Reset the trip time by pressing the mode- (M) and info-button (I) simultaneously while the
trip time is displayed
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Average Speed
The average speed is calculated on the trip distance.
.Display range: 0.0 .. 60.0km/h
Display accuracy: 0.1km/h
Wheel Size
The Wheel Size need to be set in order to show the correct speed.
.Nominal Wheel Diameter: 26inch, 27inch or 28inch
Setting the wheel diameter
1.
Set the wheel diameter by pressing the mode- (M) and info-button (I) simultaneously while
the average speed is shown.
2. The hours start blinking and can value can be increased by pushing the mode button (M)
3. Press the info button (I) to adjust the diameter
4. Exit the setting mode by pressing the info-button (I)
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Error Code
When an error is recognized by the system, it is shown on the display based on the error data
from the controller. When an error is shown, the fuel gauge will not be displayed.
The error codes are shown in the chart on the following page.
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Error Codes
Error code Type of error
E00 Controller communication error
E01 Coil sensor error
E02 Electric potential error
E03 Beyond of the torque sensor range
E05 Torque sensor error
E11
Beyond the battery voltage sensor range or
battery current sensor range
E12 Beyond the battery temperature sensor range
E13 Beyond the motor temperature sensor range
E21 Drive battery over current, lower/over voltage
E22 Battery overheating
E23 Motor overheating
E31 Hall-IC signal error
E32 Switch case communication error
E33 Battery communication error
Error Code Chart
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Error troubleshooting guide
E00 - Controller Communication Error
Problem solved
Problem solved
Display shows
E00
Restart the system after
10s interruption. Does E00
show up?
Check cables and con-
nections between battery,
controller, crank sensor
and display
no
no
Contact SR
SUNTOUR pedelec
dealer
yes
yes
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E01 - Coil Sensor Error
Problem solved
Problem solved
Display shows
E02
Check cables and connec-
tors between controller
and crank
Exchange the coil bobbin
no
no
Contact SR
SUNTOUR pedelec
dealer
yes
yes
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E03 - Outside of the torque sensor range
Problem solved
Display shows
E03
Restart the system after
10s interruption. Does E03
show up?
no
Contact SR
SUNTOUR pedelec
dealer
yes
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E05 - Torque Sensor Error
Problem solved
Problem solved
Problem solved
Display shows
E05
Restart the system after
10s interruption. Does E05
show up?
Check cables and connec-
tors between controller
and crank. Restart.
Check coil bobbin for xa-
tion. When re-tightened
and restart, does E05
show up?
no
no
no
Contact SR
SUNTOUR pedelec
dealer
yes
yes
yes
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E11 - Beyond the battery voltage sensor- or battery-current sensor-range
Problem solved
Display shows
E11
Restart the system after
10s interruption. Does E11
show up?
no
Contact SR
SUNTOUR pedelec
dealer
yes
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E12 - Beyond the battery temperature sensor range
Problem solved
Problem solved
Display shows
E12
Restart the system after
10s interruption. Does E12
show up?
In case the battery is ex-
tremely cold or hot. Wait
for normal temperature
condition. Does E12 show
up?
no
no
Remove the battery from
the bike and Contact SR
SUNTOUR pedelec dealer
yes
yes
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E13 - Beyond the motor temperature sensor range
Problem solved
Problem solved
Display shows
E13
Restart the system after
10s interruption. Does E13
show up?
In case the motor is
unusual cold or hot. Wait
for normal temperature
condition. Does E13 show
up?
no
no
Contact SR SUNTOUR
pedelec dealer
yes
yes
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E21 - Drive Battery over current, low voltage or overvoltage
Problem solved
Display shows
E21
Restart the system after
10s interruption. Does E21
show up?
no
Contact SR
SUNTOUR pedelec
dealer
yes
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E22 - Battery Overheating
Problem solved
Problem solved
Display shows
E22
Restart the system after
10s interruption. Does E22
show up?
In case the battery is
unusually warm. Wait
for normal temperature
condition. Does E22 show
up?
no
no
Remove the battery from
the bike and Contact SR
SUNTOUR pedelec dealer
yes
yes
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E23 -Motor Overheating
Problem solved
Problem solved
Display shows
E23
Restart the system after
10s interruption. Does E23
show up?
In case the motor is
unusually warm. Wait
for normal temperature
condition. Does E23 show
up?
no
no
Contact SR SUNTOUR
pedelec dealer
yes
yes
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E31 - Hall-IC Error
Problem solved
Display shows
E31
Restart the system after
10s interruption. Does E31
show up?
no
Contact SR
SUNTOUR pedelec
dealer
yes
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E32 - Switch Box Communication Error
Problem solved
Display shows
E32
Restart the system after
10s interruption. Does E32
show up?
no
Contact SR
SUNTOUR pedelec
dealer
yes
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E33 - Battery Communication Error
Problem solved
Display shows
E33
Restart the system after
10s interruption. Does E33
show up?
no
Contact SR
SUNTOUR pedelec
dealer
yes
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Operating Range
Assist Mode
Countryside riding 50-70km 40-60km 30-50km
Hilly Area and City
Riding
25-35km 20-30km 15-25km
Range Inuencing Factors
The operating range is inuenced by several factors. By knowing them it can be compensated so that the range will not be limited too much. The factors are the following:
• Temperature
• Wind
• Hill climbs
• Riding style; alternating riding speeds, especially with ongoing braking situations
• Brake friction
• Tire pressure and rolling resistance of the tire
• Riders weight
• Chosen gear ratio
• Age and condition of the battery
• Use of dynamo generator
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Tightening Torque
Maintenance and cleaning
Cleaning
If your bike or any component of the electric bike unit is dirty, be sure to remove the battery
before cleaning the bike. Clean it with a soft, damp cloth and neutral cleaner or a solution of
dishwasing detergent and water. Never use a high-pressure cleaner. Never bring the battery into
direct contact with water. If the battery needs to get cleaned use a moistly sponge or similar to
clean it. Never use industrial solvents or aggresive chemicals for cleaning.
Before inserting the battery make sure to dry the contacts of the lower battery holder and battery.
WARNING !
When the battery gets in contact with more water than it gets during
common rain- or snowfall there is a danger of explosion.
English
Item Bolt dimensions
Torque
[Nm]
Controller xing bolt M5*P0.8 6-8
Controller cover xing bolt M4*P0.7 1-1.2
Display xing bolt M4*P0.7 4-6
Crank xing bolt M8*P1.0 45-50
Coil bobbin xing bolt M4*P0.7 1.7-2.0
Stay plate xing bolt M5*P0.8 6-8
Stay cover xing bolt M4*P0.7 1.7-2.0
Lock cylinder xing bolt M5*P0.8 6-8
Upper battery holder xing bolt Tapping screw 0.8-1.0
Discharge plug xing bolt Tapping screw 0.3-0.5
Lower battery holder xing bolt M5*P0.8 4-6
Hub Axle Nuts M10x1 20
Torque bar bolts M5*P0.8 6-8
Cover bolts M4xP0.7 4
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connection 1
connection 2
cover bolt 1
cover bolt 2
Disassemble and assemble front wheel
As the drive unit consists a front hub motor there are some electrical connections from the con-
troller to the front hub. This means that there are some additional steps to do, in comparison with
a standard bicycle, when removing and inserting the front wheel into the fork.
WARNING !
Remove the battery from the bike before opening any cable
connection and before removing the front wheel.
1. Remove the cable connector cover
2. Open the cable connections
PH3
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3. Take o the torque bar by opening the rest of the bolts and nuts
4. Exploded View
axle nut
torque bar bolt 1
torque bar bolt 1
torque bar bolt 3
5mm
15mm
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5. Remove the front wheel
6. Assemble the torque bar
7. Plug-in the two connectors
torque bar bolt 1
torque bar bolt 1
torque bar bolt 3
connection 1
connection 2
axle nut
5mm
6-8Nm
15mm
20Nm
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8. Attach the cable connector cover.
9. Turn on the drive unit and check the function.
cover bolt 1
cover bolt 2
PH3
4Nm
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Conformity
Hereby, SR SUNTOUR Inc. declares that the drive unit SRS/SY is in compliance
with the essential requirements and other relevant provisions of EN15194.
Technical Specication
Motor
• Brushless Design
• Planetary Gear System
• Max. nominal Assistance Power: ...................250W
• Dropout width: ................................................... 135mm
Controller features
• Legal Constraints: ...............................................EN15194
• Tire Diameter: ...................................................... 26inch and 700c
• max. Speed: ..........................................................25km/h
• Optional relais for Light System Power Supply (6V/3W) can be used also
with additional dynamo
Charger
• Model: ..................................................................... NC-SSC04ST
• Input Voltage and current: .............................. AC100V-240V, 50-60Hz, 1.2A
• Output Voltage and current: ..........................DC29.2V / 2.0A
• Weight: ...................................................................680g
• Operating Temp. and humidity: .................... 0 - 40°C / 20 - 85%RH
• Storage Temp. and humidity: ......................... -20 - 60°C / 20 - 85%RH
Battery
• Model: .....................................................................
• Chemistry: ............................................................ Lithium Ion Manganese
• Voltage: .................................................................24V
• Capacity ................................................................10.8Ah
• Weight: ..................................................................2800g
• Charging Temp.: ................................................. 0 - 60°C
• Best charging Temp.: ........................................ 15 - 40°C
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Limited Warranty
SR SUNTOUR warrants its pedelec drive unit to be free from defects in material and
workmanship under normal use for a period of two years from the date of original
purchase. This warranty is made by SR SUNTOUR Inc. only with the original purchaser
and is not transferable to any third party. Lodging a claim under this warranty must be
made through the dealer where the bicycle equipped with the drive unit was purchased.
To prove the original purchase the original retail invoice has to be provided.
LOCAL LAW:
This warranty gives you specic legal rights. According to the state (USA) or province
(Canada) or every other country you are living in, you may have other rights than explained within these warranty regulations. These regulations shall be insofar adapted
to the local law to be consistent with such law.
LIMITATION OF WARRANTY
This limited warranty does not apply to any defect of the suspension fork caused by:
improper installation, disassembling and re-assembling, intentional breakage, alterations or modication to the fork, any unreasonable use or abuse of the product or any
use for which this product was not intended for, accidents, crashes, improper maintenance, repairs improperly performed.
The obligation of this “Limited Warranty” is restricted to repairs and replacements of the
suspension fork or any parts of it in which there is a defect in materials or workmanship within a period of two years.
SR SUNTOUR makes no express or implied warranties of tness or merchantability of
any kind, except as set forth above. Under no circumstances will SR SUNTOUR be liable
for incidental or consequential damages.
Damages which are caused by the use of other manufacturer‘s replacements parts or
damages which are caused by the use of parts that are not compatible or suitable to
SR SUNTOUR drive units are not covered by this warranty.
This warranty does not apply to normal wear and tear.
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English
SR SUNTOUR HEADQUARTER
SR SUNTOUR INC.
#7 Hsing Yeh Rd.
Fu Hsing Industrial Zone
Chang Hua
Taiwan, R.O.C.
Tel.: +886 4 769115
Fax: +886 4 7694028
email: orders@srsuntour.com.tw
SR SUNTOUR EUROPE
SR SUNTOUR EUROPE GMBH
Am Marschallfeld 6a
83626 Valley
Germany
Tel.: +49 8024 3038152
Fax: +49 8024 4730984
email: service@srsuntoureurope.com
SR SUNTOUR USA
SR SUNTOUR USA
503 Columbia Street,
Vancouver, WA 98660
USA
Tel.: +1 (360) 737 6450
Fax: +1 (360) 60 737 6452
email: service@usulcorp.com
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