BionX User Manual
Contents
1. Inserting and Removing the Battery Inserting the battery Place battery onto the docking station Slide the battery down the rail gently towards connector The release arm will close automatically as battery slides towards connector Do not force the battery arm closed this can bend the battery connector With the release arm almost closed hold it in place and simultaneously press in the lock cylinder you will hear an audible gt click lt when the battery Is properly inserted gt CLICK lt Removing the battery Turn off the BionX propulsion system no illustration Lightly press on the battery release arm insert the key and turn clockwise The lock cylinder will protract freeing battery release arm no illustration Remove the battery by opening release arm O Lift the battery from dock by sliding upwards O Remove the battery Handling and Charging the Battery A WARNING BionX batteries shall only be recharged with BionX chargers or BionX power supplies Never short circuit the battery by connecting the contacts of the battery Never open the battery This could damage the battery and possibly lead to overheating or ignition of the battery The battery cannot be serviced by the user Opening the battery case voids all warranty and product liability claims Never use a battery which has obvious damage to the housing or the connector Make sure2. 10 The two year warranty period starts with the date of purchase Warranty claims must be reported immediately 11 No warranty claims are accepted without limitation to other reasons in the case of damages due to the following a External influences particularly falling rocks collision accident and other external events with an immediate external effect due to mechanical powers Purpose and or malevolent acts theft and robbery as well as natural hazard events and or acts of mischief Test maintenance repair and replacement work due to normal use If the battery cell pack does not provide full capacity in the course of normal use or for batteries going through a normal aging process or reduction of performance BionX warranty only covers that within the two year warranty period or after 600 charging cycles whichever event occurs first to the condition that the battery still provides at least 70 of its initial capacity In the case of inappropriate use e g the product was exposed to liquids chemicals of any type and or extreme temperatures wetness and humidity and or if the battery suffers damages due to non compliance with the special instructions set forth in the chapter Handling and Charging of the Battery The model serial or product number on BionX product has been changed deleted blurred or removed The seal serial number sticker on the battery housing has been broken or obviously manipulated Use of the
3. The battery state of charge display on the console does not show full after a complete charging procedure Make sure that you have followed all of the instructions for the charging procedure Let the battery cool off for a few hours and then recharge it again If the problem s still not solved let the battery cool again fully deplete the battery and charge it again If the problem persists contact your authorized dealer Warranty Information and Guarantee 1 The BionX warranty covers a two year period for BionX propulsion system s within the framework of the following conditions 2 This warranty exclusively covers systems provided by BionX excluding all the other bicycle components provided by other bicycle manufacturers 3 This warranty covers the repair and or the replacement of BionX propulsion systems provided that the equipment concerned loses its functionality within the agreed warranty period and also provided that the claim is not related to any of the following cases expressly excluded under this warranty 4 Any other legal provisions particularly with respect to warranty regulations are not restricted by this warranty 5 This warranty only covers material and manufacturing defects It is only effective with a valid proof of purchase consisting of the original purchase document or receipt indicating the date of purchase the dealer s name and the designation of the bicycle model BionX reserves the right to reject
4. and average speed values to zero Programming the Basic Settings In general all basic settings for your electric bicycle are pre set If you happen to change tire sizes during service for example you can reset the tire circumference to ensure the precise function of your speedo meter Furthermore you can set the unit to display the speed the strength of the recharge when triggering one of the two brake levers and the arrangement of the main functions This is done by entering programming codes Turn on the programming mode Simultaneously push O and D until the display shows 0000 The first zero blinks Change the value of the selection with or and confirm with C Select the other digits in the same manner until the desired program is displayed z ET SOS 2002 Regeneratonbrake output or magnetic suite 040 eal 3040 2005 Tre crcumferenceifmetes O 2009 Fp Display Pusvinus 0 power et 1 powernght OOOO Code 2001 Code 2002 Select unit km h or mph Select with Default value 30 adapt with or and confirm with O and Confirm with O Code 2005 Code 2009 Set tire size in mm Select digits Current setting of main functions is one after another with or and displayed Flip O assist toggle is on confirm with O the right side of console Flip 1 assist toggle is on the left side of console Confirm with O A WARNING Please do not use other programming codes without consulting
5. battery in systems that are not approved for such use with this particular product Operation of the BionX system with batteries other than the batteries designed for the BionX system Damages to the battery due to overcharging or not adhering to the instructions of battery handling refer to user manual 12 This warranty only covers the above mentioned repair work and or the replacement of defective or compromised components It excludes any claims as to the reimbursement of property damages downtimes expenses for renting or leasing equipment travel expenses lost profit or any other claims BionX liability in connection with this warranty is limited to the respective acquisition value of the product BionX BionX Design and powered by BionX are trademarks of BionX International Corporation 2011 BionX International Corporation All Rights Reserved Your dealer bionxinternational com
6. DERBY CYCLE powered by Bion lt BionX User Manual Congratulations Congratulations on your decision to purchase a product powered by BionX We are sure that your new electric bicycle will exceed your expectations in terms of function design and quality All bicycles powered by the BionX system are manufactured with the latest production methods and high quality materials Please read this manual thoroughly so that you will enjoy your new electric bicycle for years to come Please make sure that your new electric bicycle was professionally assembled and adjusted by your authorized dealer and handed over to you with the instructions This manual serves as a supplement to the bicycle user manual Should you have any questions after you have studied the manual please contact your dealer User Precautions We want you to have a fun ride but also a safe one Carefully read the following information even if you are an experienced rider Please familiarize yourself with your electric bicycle powered by the BionX system before you take your first trip 1 Read all of the enclosed installation and operating instructions from the manufacturer and follow the instructions if any prior to Its first use 2 Familiarize yourself with your electric bicycle and the functions of the BionX system in a safe environment before participating in road traffic for the first time Always wear a helmet when riding an electric bicycle for your own safet
7. e your finger slowly over the touch port e Battery state of charge LED will illuminate Battery state Colour 100 85 green lt 25 red Assist Mode Generate Mode The BionX propulsion system operates in four assist levels in the assistance mode and in four charging levels in the generate mode In the assistance mode your pedalling is assisted proportionally by an electric motor that drives the rear wheel A torque sensor is located on the axle of the electric motor and measures the effort provided by the rider this produces natural feeling assistance from the motor When in generate mode the electric motor functions as a generator and recharges the battery When going downhill you can regulate your speed by varying the generate level This generate function provides a certain braking effect however it does not replace legally required brakes If either one of the two brake levers depending on bike model is pulled the drive system automatically enters generate mode The range can therefore be extended up to 15 depending on the road conditions Assistance Level A Degree of Assist Riding Situation 1 35 Riding on level ground 2 75 Slight inclines head wind 3 150 Steep hills strong head wind 4 300 Very steep roads Generation Level G 1 Slight downhill grade tailwind 2 Significant downhill grade tailwind 3 Steep descent 4 Very steep descent Operating the BionX Propu
8. en recharge the battery at minimum every three months When the battery is depleted to the level where there is risk it could fall into deep discharge the battery will signal that a recharge is needed by beeping Power Supply The delivered power supply is suitable for the voltage ranges 110 115V or 220 230V There is no need to manually set the voltage range Charging procedure LED Ring amber charging LED Ring green charged at e Connect power supply and battery by inserting the charge connector into the touch port the system can be turned on or off e Connect the plug of the power supply with the power outlet e The battery touch port LED ring around the charging connector lights up according to the actual state of charge of the battery and then turns to AMBER during the charging process e After a complete charge the colour of the LED ring changes to GREEN The battery is then fully charged and the charging process is complete e Following this procedure the charging connector should be disconnected e During the charging process you can check the battery state of charge through the console if the battery is connected to the system system can be switched on while it is charged The battery is fully charged after about 3 to 4 hours Make sure that a completely charged battery is no longer connected to the charger after the charging procedure is completed Checking Battery State of Charge e Swip
9. in the key number for your records O BionX Key Number Troubleshooting The system does not turn on Check the battery and make sure that it is charged The battery must be correctly inserted in the docking Station and the lock must be completely closed Also check that all connectors of your wiring harness are properly engaged If the problem persists contact your authorized dealer The system can be turned on but there is no assist Check that the cables running from the battery to the motor are properly connected If the problem per sists contact your authorized dealer The system is continuously in generate mode When the propulsion system is continuously in generate mode and cannot be switched back to assist mode by pushing the key the problem most likely lies with the brake switches that are located at the brake levers In this case try to repair the system by turning it off and then on again If that does not solve the problem you can temporarily bypass it by removing the plug in connection from the console to the brake switch A WARNING If you bypass the brake switches you also disable regenerative breaking In doing so your system will not provide any brake support We recommend that you contact your dealer as soon as possible The motor is not as powerful after a repair or service Tighten the nuts of the rear axle with the specified torque 40Nm 301b ft If the problem is not solved please contact your dealer
10. lsion System Gee run O Power Key Key 49 Cycle State of charge indicator a ae ee e ce HR i 5 L E pe ooo CR mF A a 6 aw bicycle mode 7 Speedometer 8 Trip distance odometer chronometer average speed 9 Assist A or generate level G Turn the system on Briefly push either the O key or key The battery will beep 4 times and you will see a countdown this is the system perfoming a self check After startup the system is always in M mode no motor assist bike operation To turn the system off briefly push The battery will beep 5 times After 10 minutes of no operation the system turns off automatically Select assistance generate level Push key for more less assist see bar fields 1 4 above display A From M mode push key to enter continuous generate mode MINE og Pirr gd a D M1 L 2 CALE er gt loc am e D Dy r Lf LG km km h Alter een Turn on display backlight Push and hold key for 4 seconds display backlight is turned on Turn off display backlight Push and hold key again for 4 seconds Select the cycling computer functions Briefly push the D key to change between Trip Distance DIST Odometer ODO Chronometer CHRONO Average Speed AVSPD To reset cycle computer functions Hold the key for a few seconds to reset the distance chronometer
11. of the specified type The use of the BionX power supply with batteries that are not rechargable may damage those and could lead to overheating or ignition of the battery Keep the power supply away from water or moisture when charging and or connected to prevent electrical shock or short circuits Do not use a power supply that has obvious signs of damage to the cable housing or the connector Extreme temperatures will affect battery life especially during charging Avoid charging in direct sunlight or in very hot or cold temperatures This will reduce the life of the battery considerably We recommend charging the battery at temperatures around 20 C room temperature The battery should be warmed to room temperature before it is charged particularly when it was exposed to cold temperatures during a ride The battery can be charged when mounted on the bicycle or removed from the battery docking station A Lithium Manganese battery does not have a memory effect which means that the battery s maximum energy capacity is not affected if it is repeatedly recharged after only being partially discharged The battery does not need to be completely drained before charging We recommend charging the battery after every ride preferrably when the battery state of charge display shows less than 50 We recommend that you fully charge the battery when it will not be used for a longer period of time for example before storing it for the winter and th
12. rush if necessary It must be ensured that no dirt or humidity penetrates the battery docking station when the battery is removed The electric motor is a brushless DC motor that does not have to be serviced Cleaning CAUTION Never use a high pressure washer or a garden hose to clean the propulsion system The force of a water jet could damage the electrical components of the propulsion system We recommend a soft sponge or a soft brush to clean the bicycle Use a moist rag to clean the battery s docking station Always use very little water and keep water away from the electrical contacts Check the plug in connections for moisture after cleaning and let these dry if necessary before reusing the bicycle Transporting an Electric Bicycle on a Car A WARNING Make absolutely sure that the bike rack on your car is suitable for the increased weight and the unique frame style of your electric bicycle A rack that is not suitable can be damaged or even break during the transport of the electic bicycle The electric bicycle can be damaged by an unsuitable bike rack For transportation of the electric bicycle on a bike rack always remove the battery and the console Repair and Spare Parts For repair of your electric bicycle consult your qualified dealer All of the original spare parts for your electric bicycle can be purchased through your dealer If you 001 need spare keys for the battery please contact your dealer Please reta
13. that the battery is no longer connected to the power supply once the charging operation is complete The Lithium Manganese battery cells have a low self discharge rate therefore a continuous connection of the battery to the power supply is not necessary We recommend that you fully charge the battery when it will not be used for a longer period of time for example before storing it for the winter and then recharge the battery at minimum every three months It is best to store the battery in a cool location at temperatures between 10 C and 25 C Never store the battery in locations where the temperatures can reach more than 45 C or fall below 10 C The battery should never be exposed to extreme temperature fluctuations or humidity and always protect the battery during storage from humidity to prevent corrosion on the connectors Never drop the battery and protect it from physical damage Damage may lead to short circuits and as a result cause overheating or ignition of the battery Used batteries may not be disposed of in regular household trash Be aware that used batteries must be disposed of properly mmm DERBY BionX batteries can be returned at DERBY dealerships free of charge Charging the battery A WARNING Only use the BionX power supply that was supplied with the bicycle to charge the battery The use of other power supplies can damage the battery The BionX power supply should be used exclusively for rechargeable batteries
14. the coverage of this warranty if the accompanying documentation of BionX components is not accurate or complete 6 In the case of a warranty claim BionX undertakes to either repair faulty system components and or to replace such components at BionX discretion Service Replacement Unit 7 Warranty repairs have to be exclusively performed by BionX Any component to be repaired under the framework of this warranty has to be transferred to BionX at the client s own expenses and risks and after the completion of such repair has to be picked up at BionX or it has to be shipped at the request of the client to the client s address at the client s own expenses and risks In the case of rightful warranty claims BionX reserves the right to bear or repay transportation expenses In order to have a previous determination whether a warranty claim is justified or not the end user has to submit his claim to the dealer from whom he purchased the product so that the respective dealer handles the shipment to BionX 8 Costs for repair work performed in advance by persons who have not been authorized by BionX will not be reimbursed In such a case any warranty claim will cease 9 Repair work and or replacement of components during the warranty period do not lead to an extension and or a new start of the warranty period Repair work and direct replacement during the warranty period may be performed with functional replacement components of equal value
15. ts and make sure that the brake disc on models with disc brakes is inserted between the brake pads Also make sure that the flat area at the left of the rear axle torque reaction collar is aligned so that it fits into the left dropout Install the rear wheel with both sides of the axle inserted all the way in the dropouts Tighten the axle nuts on the rear wheel with 40Nm 30lb ft VERY TIGHT This torque is essential for the correct function of the propulsion system If you do not have a torque wrench use a normal ring wrench Have your dealer check the torque of the axle nuts as quickly as possible Use only the original axle nuts otherwise you run the risk of damaging the axle threads Keep the motor cables clear of the brake disc on models with disc brakes Plug in the cable connections POWER before COMMUNICATION and place the larger neoprene cover over the plug in connections and the smaller neoprene cover closer to the disc to prevent the cables from wear Now replace the cable pull Re install the cable guide of the rear wheel brake V brakes only and correctly adjust the rear wheel brake Maintenance and Care We recommend to have the spoke tension of the rear wheel and the torque of all screws checked by your qualified dealer after the first 200km In ch order to ensure extended use of the propulsion system all plug in contacts of the system should be ecked every two to three months and cleaned with a soft and dry b
16. y Make sure that the tires have correct pressure before riding the bike Make sure that the brakes are operating properly before riding the bike Make sure that the quick release on the front wheel is securely fastened before riding the bike Do not use a mobile phone or any other electronic devices while riding an electric bicycle it is imperative that you pay attention to traffic 8 If possible ride in bike lanes and always in the correct direction of traffic 9 Adhere to all valid traffic regulations 10 Keep in mind that other traffic participants may underestimate the speed of an electric bicycle 11 Ride with both hands on the handlebars when riding your electric bicycle 12 Ride as defensively as possible a pr oi eS Thank you very much for your attention and we hope you enjoy your new electric bicycle powered by Bionx Your BionX Team Table of Contents User Precautions 2 Description of the BionX Propulsion System 4 BionX Propulsion System Components 4 Inserting or Removing the Console 5 Inserting and Removing the Battery 6 Handling and Charging the Battery 7 Assist Mode Generate Mode 9 Operating the BionX Propulsion System 10 Programming the Basic Settings 12 Installing Removing the Rear Wheel 13 Maintenance and Care 14 Cleaning 15 Transporting an Electric Bicycle on a Car 15 Repair and Spare Parts 15 Troubleshooting 16 Warranty Information and Guarantee 17 Description of the BionX Propulsion S
17. your authorized dealer If you type the wrong code please push C key to exit programming mode Installing Removing the Rear Wheel We recommended the removal and installation of the rear wheel to be done by a qualified dealer Should you have to do this yourself please follow the instructions below A WARNING Always turn off the propulsion system prior to plugging in or unplugging the motor cables CAUTION It is absolutely essential that the axle nuts are tightened with a torque of 40Nm 30lb ft this ensures that the propulsion system functions properly Ensure the torque reaction collar is fully inserted into the dropout Hydraulic disc brake Do not pull the brake lever with the brake disc on the rear wheel removed from the caliper Insertion of the wheel can be difficult or impossible as the brake pads will prevent brake disc from sliding in place To Remove the rear wheel Make sure that the system is turned off Remove the neoprene covers Fig 1 Unplug the two cable connections that lead to the motor Fig 2 First COMMUNICATION then POWER Disconnect the cable guide from the rear wheel brake only on bicycles with V brakes Loosen the axle nut on the rear wheel using a 15mm ring wrench Fig 3 Slide the rear wheel downwards out of the drop out Fig 3 Installing the rear wheel Guide the rear wheel axle into the two dropou
18. ystem Your electric bicycle is an EPAC Electrically Power Assisted Cycle in accordance with EN 15194 and differs from a bicycle that isn t electrically assisted ED Battery e Lithium Manganese LiMn e DC rear hub motor e Removable A8V 6 6Ah 317Wh e Black nom 250W e Illuminated LCD display with e Removable lockable nom 9Nm max 40Nm battery state of charge e Fully charged in 3 4h 4 7kg e 4 assistance levels e Brushless gearless e 4 generate levels e Generate mode for energy e Backlight controls recuperation e Offers cycle computer e Integrated torque sensor functions speed odometer average speed total distance 4 Brake switch e A sensor integrated with the brake lever connected to the BionX console e Upon activation assistance is shut off kill switch generate mode is activated Power Supply e Power supply to recharge the LiMn battery e Input voltage 100 240V e Output voltage 26V e Max charge current 3 45A e Output 90W Inserting or Removing the Console Inserting the console e Slide the console into the console mount on the handlebar e Make sure that the console engages securely When inserted correctly you will hear an audible click Removing the console e Release the console by pushing the release lever on the console mount e Slide the console out of the console mount
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