Operating instructions ASA espeed B25.14 / B45.14

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1 Operating instructions ASA espeed B25.14 / B45.14 Version 2.4 for software version D 29 and higher

2 Contents 1. General notes Scope of delivery Specifications Description Active- and Performance Line Installation CX Engine Installation Connecting the ASA espeed module Commissioning and assembly Basic functions User-specific programming of the electronics The NYON HMI and Software version > FAQs Disposal General notes Dear customer, thank you for deciding to acquire a product from ASA Autotechnik. Our products are developed under stringent current European and national directives and safety topics are taken into careful consideration. To ensure damage does not occur due to improper installation or use, please read these operating instructions carefully and completely and then store them. All electronic articles from our production haven been checked to 100 % and can therefore be installed directly. We reserve the right at any time to make changes that serve the purpose of technical progress. For warranty claims, return the device and include the proof of purchase and a detailed description of the error. The statutory warranty regulations apply. The warranty claim will be voided due to: a) unauthorised modifications to the device or accessories which we have not implemented nor approved b) repairs to the device which you have performed yourself c) improper use / not intended use or operation d) device subjected to excessive force (falling, deliberate destruction, accident, etc.) Comply with all safety-related and legal regulations during the installation. Page 2/ 22

3 General safety instructions: - Do not drop the device! Avoid damage! If the device fell down or if the casing is damaged, please contact us. - Risk of fire or short-circuit! Do not expose the device to rain or other forms of moisture. Mount the power electronics in the splash-proof area of your e-bike. Do not direct a high pressure cleaner towards the device. - Risk of fire or short-circuit! Do not stress the adapter cable mechanically by, e.g., extending or crushing it. - Risk of fire or short-circuit! Never insert foreign objects into the housing! The objects could cause short-circuits. - Risk of fire or short-circuit! If the cable or the cable connector of the device is damaged, disconnect the plug and contact us. - If smoke, noise and/or odour develop, shut off the device and disconnect it immediately from the power supply. Do not continue to use the device! - Only use the device in its intended area. Inappropriate use, improper installation or modifications will render the warranty void. Important information on product safety and legal situation (liability): (At the latest) after installation of the tuning module, the ebike is legally no longer classified as a bike, but as a motor vehicle. Furthermore, the use of the tuning module is manipulation of the speed of e-bikes, which is not legally allowed on public roads. The e- bike must not be used on public roads after the installation of tuning module. This may apply in particular cases already in the deactivated mode. (At the latest) after installation of the tuning module has the following duties, which constitute a violation against that could be an offense: Homologation Helmets are mandatory Insurance registration Driving license duty Operating license requirement; a possibly previously granted approval expires. Control and / or compulsory insurance (esp. motor vehicle liability insurance). Personal liability insurance does not apply. Further, another insurance class is possibly applicable. After installing the tuning module, the ebike is used outside of the validated and intended use as an bike. Lifetime specifications of the drive system of the ebike and the ebike itself is no longer valid, since a higher load and a higher wear may be associated with the use of the tuning module. Furthermore, it is impossible to estimate whether the frame, fork, handlebars, brakes, suspension, tires and other safety-relevant components are designed for the increased load, especially for the higher speed. Warranty claims, warranty claims or product liability claims against the seller or manufacturer of the ebike or the drive system can be reduced or extinguished. Page 3/ 22

4 Basically, you bear the civil, criminal and offense responsibility. In particular, the installation and use of the tuning module may result in criminal or administrative offense legal consequences for you. Furthermore, it may cause damage to property or persons due to improper installation and removal as well as improper use. Please read our Terms and Conditions ( Please inform yourself before installing the tuning module on the legal and technical implications arising from the installation and use of a tuning for you. Please drive carefully and always bring you neither youself nor others in danger! We wish you much success with the installation. For questions, please contact: Autotechnik Saretz e.k. Drosselweg Schopfheim Phone: +49-(0) Fax: +49-(0) Scope of delivery - 1x tuning module ASA espeed B25.14/B45.14 including cable set - 2x heat shrink tubing - 1x operating instructions 3. Specifications Power supply: 12 V DC Temperature range: -40 C to +130 C Weight: 14 g Dimensions of electronics: 23 x 15 x 5 mm Cable length approx. 100 mm Page 4/ 22

5 4. Description The ASA espeed B25.14 electronics cancels the speed limit of the motor assistance of your Bosch e-bike without making concessions to the functionality of your HMI. The speed you are currently driving will always be displayed regardless of whether the tuning is active or deactivated. The motor assistance is not limited to 25 km/h, rather, any speed values can be achieved. After the installation your e-bike will continue to function as previously accustomed, but now the motor assistance will not be switched off as of 25 km/h (ASA espeed B25.14) or 45 km/h (ASA espeed B45.14). After installation, the electronics will automatically adjust to the different tyre sizes. Calibration can be reactivated at any time by activating a special code so that its continued use is possible in future Bosch e-bikes with other tyre sizes. Installation occurs with original Bosch connectors and has been designed in such a way that cable damage is prevented enabling the re-establishment of the original state at any time. Tuning is activated automatically in the sport and turbo modes and deactivated in the other modes. It is not necessary to activate the light function; also the plug sockets in the motor for the front and rear lights will not be used for our electronics. The individual features of the electronics are in summary: Microprocessor controlled micro-electronics Installation without damaging the cables and thus the possibility of simply converting back to the original Cancellation of the 25 km/h limit in all modes Full HMI functionality, in particular of the speedometer and the additional functions (km, max. speed, average speed, etc.) Self-calibration for different tyre sizes No additional switches, cables, dongles, attachments, etc. necessary or visible Sturdy welded structure of the electronics Page 5/ 22

6 Possibility to check the function during the installation with status LEDs Programmable user-specific functions The ASA espeed B25.14/B45.14 electronics works only with the new motors of the Active and Performance Line as of Active- and Performance Line Installation Required tools: - Torx 20 socket spanner - 8 mm and 3 mm Allen screw driver - Hot air gun - Optional: ISIS crank puller for Bosch drive unit (e.g. Ebay as of 4.60, Amazon as of 6.99 search term: ISIS crank puller) - Optional: Torque spanner (operating range 30 to Nm) Before installation, the battery must be removed. Unscrew the Allen socket screw with an 8 mm Allen screwdriver (normal right-hand thread) until the crank has loosened. Page 6/ 22

7 The crank can be simply removed as normal. If this is not possible for you, then use an ISIS crank puller. The optional stone guard underneath the motor can now be removed with a 3 mm Allen screw driver. Page 7/ 22

8 To do so, first remove both screws in the front area and then the screw serving as swivelling axis in the rear area of the motor. The motor cowling is fastened with 3 Torx screws and can be released with a T20 socket screw driver. Page 8/ 22

9 The motor protection can be simply pulled off, providing access to the electrical connections. Page 9/ 22

10 6. CX Engine Installation Tools required : - Phillips screwdriver or Allen screw driver - optional: heat gun Before installation, the battery must be removed. Please remove the plastic cover by unscrewing the 3 screws and the connector are directly accessible. The CX engine is in a variant also with a smaller cover available, which is fastened with Allen screws. To disassemble, remove the Allen screws as well as the crank because otherwise the cover can t be removed. 7. Connecting the ASA espeed module The ASA espeed B25/45 module has 4 connections which are to be used like adapters and which are looped into the existing cabling. Bosch currently uses plugs that are only available on the market in female form. For the male form, we also use a female connector which has been assigned with contact wires. These contact wires are used for the mechanical connection, and heat shrink tubing is used as protection and locking mechanism. The female connector with the contact wires is to be twisted by 180 degrees Page 10/ 22

11 and inserted into the original female connector of your bicycle. The connections are used according to the following model: In the engine are 4 male sockets, with the following assignment from left to right: 1 = front light 2-pins, only used if your bike is equipped with light 2 = HMI 4-pins 3 = rear light 2-pins, only used if your bike is equipped with light 4 = speed sensor 2 pins. Remove the HMI 4-pin plug and the speed sensor 2-pin plug from the motor according to the following illustration. Depending on the installation situation, it can be helpful to use flat-nosed pliers to pull the plug. Always pull on the plug and not on the cables. The next picture shows an open ebike without lights, so the sockets 1 and 3 are covered with blind plugs. Page 11/ 22

12 The illustration shows the sequence of the connections. Page 12/ 22

13 Place the heat shrink tubing on one line respectively. The heat shrink tubing for the HMI plug has a greater diameter. Now connect the plug of the HMI to the plug of the ASA module. Both connections must be mounted twisted by 180 degrees so that the line colours are identical, meaning red-to-red, black-to-black, yellow-to-yellow and green-to-green. Press them together to ensure no gaps remain between the plugs. If the metal pins are a little bit too long please shorten them to approx.. 8 mm. length outside one connector. ATTENTION: A FALSE CONNECTION CAN DESTROY THE ELECTRONICS OF YOUR E-BIKE! Pull the heat shrink tubing over both plugs and heat shrink them with a hot air gun. The heat shrink temperature is: +95 C C. Try to stay within the lower/middle temperature range. The cables at the module for the connections from the speed sensor are different. The cable with the brown wire goes to the motor, and the cable with the white wire goes to the speed sensor. Page 13/ 22

14 Now connect the cable with the white wire in the same type and manner as the connection to the HMI. Make sure that the wires are connected black-to-black and red-to-white. Shrink the heat shrink tubing at the same temperature over both plugs. Now insert the 2-pin plug from the ASA module into the connection of the speed sensor at the motor and the 4-pin plug into the HMI connection. Use cable binder to fasten the ASA espeed tuning module in the motor. The picture shows the complete connection, for illustrative purposes with the heat shrink tubing. Page 14/ 22

15 8. Commissioning and assembly Temporarily connect the battery of the e-bike for a function test. Switch on the HMI. A speed indication will briefly appear, e.g., 12.6 km/h. The 2.6 represents the software version 26 of your module. Your speedometer should now show this version for approx. 1 minutes, and the green and yellow LEDs should flash in the electronics. This is a calibration of the electronics to your bicycle and the electronics are determining the parameters in order to work correctly, depending on your e-bike. If the electronics behave otherwise, check the connections. After calibrating the electronics you should set your HMI to turbo, back to sport an to turbo mode again to activate the tuning in case the tuning isn t activated automatically. As a test the green LED should go on in this mode and indicates that the tuning is active. In addition for the activated tuning on the HMI, 0.1 km/h is displayed instead of 0.0 km/h during standstill so that you have a status display during daily operation. As soon as you go to the OFF mode, the LED should go off and the HMI display this mode by 0.0 km/h. Note: If the status of the tuning module is displayed with 0.1 km/h during standstill, there may be technical reasons that cause it to flicker from 0.1 to 0.0 now and then. This is normal and not a malfunction. Page 15/ 22

16 After the calibration, the e-bike should be briefly switched on and off so that the values can be stored. If the ebike has the software version 2015 or higher or a Nyon display the wheel size should be changed in the setting of the Intuvia/Nyon once (back and forth) so that the espeed modules can get this value out of the settings. Fasten all cables with cable ties or additional tape so that the plastic housing can be mounted easily. During assembly, ensure that the plastic parts in the lower area of the motor mesh accurately and that a plastic protrusion engages when both halves of the fairing are pushed together. Now mount the three screws from the plastic motor protection with a T20 Torx screw driver. The tightening torque should be Nm. Attach the bottom-mounted stone guard with the 3 mm Allen (hexagon socket) screws and then mount the cranks. The crank screw is to be mounted with Nm. On the CX engine just put on the plastic cover and secure it with the Phillips screws or Allen screw driver if you own the the small cover variant. Page 16/ 22

17 9. Basic functions Switching ON The tuning is activated by a change from Turbo to Sport mode and back to the Turbo mode within 2 seconds. The activation will be visualized by a 0.1 km/h value. Switching OFF The tuning is deactivated by downshifting in the OFF mode. The deactivation will be visualized by a 0.0 km/h value. Note: If you selected the OFF mode and turn on your ebike in OFF mode, the tuning is directly deactivated. Please make sure that is not active at the use of the tuning function of the OFF mode. Calibration The electronics calibrate automatically to the tyre size of the e-bike. Calibration can be restarted at any time (see Programming of the electronics). Average speed/trip mileage As soon as you drive faster than 25 km/h there will be deviations in the average speed and in the odometer. The module has a compensation function that can update the kilometres. This can be done at any time during standstill and is activated by selecting the OFF mode. During standstill, the HMI signals this update of track information by displaying 0.3 km/h and it can also be observed that the odometer continues to run during standstill. Note: Compensation occurs at a very high speed for time reasons so that the maximum speed of the HMI is no longer correct. For that reason we have realised an independent maximum speed display that is briefly shown during standstill. The value of the maximum speed is reset when the HMI or the e-bike is switched off. If the compensation takes too long, it can be ended by switching off the e-bike. The compensation can be performed automatically (see User-specific programming). The advantage to this is that the kilometre update can be automatically compensated during standstill. The disadvantage is that while compensation takes place, the motor only switches in after the first pulse comes from the speed sensor. This can take some getting used to when starting, and the e-bike will behave differently than without the tuning module. Since there are slightly more disadvantages in practice from our point of view, we have activated the manual compensation as standard. Quick deactivation Selecting the Off mode will deactivate the tuning. If you power on your e-bike in the OFF mode the tuning will be deactivated directly. So please power on the e-bike in ECO/TOUR/SPORT/TURBO mode. Page 17/ 22

18 10. User-specific programming of the electronics Programming can only occur directly after the e-bike has been switched on. If a new code is to be entered, then the e-bike must be switched off again first. Parameters are entered by selecting 3 modes and briefly pressing the Walk button for a period of 2-4 seconds and holding the brake for the rear wheel. Important: With the model year 2017 Bosch implemented a 2 step method to activate the walk function, so you have to press first the Walk button followed by the + button. The key codes are always listed by function. Note: The Walk button (Model year 2017 and newer followed by the + button) at the left operating unit must be kept pressed until you get a confirmation in the displayed speed in form of a 8. So you will get 0.8 for the acceptance of the first code, 8.8 for the acceptance of the second code and 88.8 for the third code. Important: The third code is only visible if no programming result is shown on the display, otherwise you will see the result directly (e.g. increase of the wheel circumference). Restarting the calibration Eco -> Walk -> Tour -> Walk -> Sport -> Walk Note: After the calibration the e-bike should be briefly switched on and off General deactivation of the tuning Turbo -> Walk -> Sport -> Walk -> Tour -> Walk Activation of the tuning (default) Tour -> Walk -> Sport -> Walk -> Turbo -> Walk General switching off of the compensation function Page 18/ 22

19 Sport -> Walk -> Tour -> Walk -> Eco -> Walk The function for the general compensation of the trip mileage can be generally switched off with this function. During the switched off state, neither the trip mileage nor the orginal average speed function will not be correct. However, the advantage is that the time for the compensation will no longer be needed. To switch on again, switch the max. speed either off or on. Automatic compensation activated during standstill The kilometre compensation occurs automatically during bicycle standstill. ECO -> Walk -> Sport -> Walk -> Turbo -> Walk Automatic compensation deactivated during standstill (default) The kilometre compensation occurs during bicycle standstill only when the tuning is deactivated using a mode without tuning support (this is ECO and TOUR as standard). Turbo -> Walk -> Sport -> Walk -> ECO -> Walk Increasing the wheel circumference The function increases the wheel circumference in increments of 2 cm up to a maximum of 20 cm. This enables manual fine calibration of the speed indicator and the kilometre measurement. After entering the code, the correction value is displayed briefly as speed. 2.0 means + 2 cm wheel circumference. ECO -> Walk -> Tour -> Walk -> Turbo -> Walk Important: With the software version 2015 it is possible to change the wheel circumference in a Nyon and the Intuvia Display function. Once you call this functionality changes and also actual value takes over to the espeed module. So in this case this feature is no longer really needed. But if you use it then it will work additively to the defined wheel circumference of e-bikes itself. Reducing the wheel circumference Turbo -> Walk -> Tour -> Walk -> Eco -> Walk The function reduces the wheel circumference in increments of -2 cm up to a maximum of -20 cm. This enables manual fine calibration of the speed indicator and the kilometre measurement. After entering the code, the correction value is displayed briefly as speed. 2.1 means - 2 cm wheel circumference. Tuning with frequency reduction (Default) Turbo -> Walk -> Sport -> Walk -> Tour -> Walk With this alternative tuning method the possible speed is limited at 50 km/h (s-ebike higher). Page 19/ 22

20 Tuning with constant speed frequency OFF -> Walk -> Tour -> Walk -> Turbo -> Walk Please use this tuning method to avoid possibly error 503 on longer usages. 11. The NYON HMI and Software version > 2015 From software version 2015 or later the "Performance Line" or "Active Line" message appears in the Intuvia display during power on. With this software version the wheel size can be changed in settings. Once you are changing the wheel size by +1 mm and -1 mm back the espeed module will take this wheel size. So please follow this step after doing the calibration. With NYON Display everything works just like when you own an Intuvia display. The wheel size can be taken to the espeed module under settings by a brief change of the size. Please follow this step by after doing the calibration. Note: The NYON activates the OFF Mode during switching from the individual driving to the default mode. In OFF mode the tuning will be disabled. Page 20/ 22

21 12. FAQs I have a maximum speed of more than 100 km/h. - That is unfortunately true, as the compensation takes place at a high speed. Use the maximum speed function of the module. The maximum speed is briefly displayed during standstill as a result. My trip mileage is clearly too low. - You did not perform the compensation. Please switch to a mode without tuning (ECO or TOUR) during standstill. The missing kilometres will be compensated My trip mileage is counted up even though I am standing. - You have activated the compensation and our electronics is compensating the difference to the actually driven kilometres. The compensation ends when both values are identical (actually driven route and displayed distance). I cannot program the electronics. - Programming only functions once directly after the e-bike has been switched on. - Keep the WALK button pressed for 3-4 seconds. Do it again until the 8 appears on the HMI. - Do not move you ebike during programming After the installation the LEDs do not flash. - Check the connection. - The module is defective and should be replaced - You have acquired the wrong version for your e-bike -> replace I have misadjusted everything and would like to restore the factory settings - Start the calibration My speedometer is inaccurate - Perform a manual fine calibration of your tyre circumference. - Correct the tyre size in your settings or just change it back and forward so that the espeed module can capture the size from the settings. The tuning does not always work - OFF mode was use during riding the ebike probably. The tuning is switched off in the OFF mode. Please activate the tuning by Turbo-Sport-Turbo sequence. I have a NYON display and the OFF mode does not work for programming - Use for programming purpose instead of the OFF mode the Individual Code 1 As soon as I drive off a speed of 99.9 km / h is displayed - The tire circumference is lost or not right. - Start a new calibration - Please wait ( about 3 minutes ) until calibration is finished Page 21/ 22

22 13. Disposal European Directive 2002/96/EC applies when disposing of this device. Inform yourself of the local regulations on the separate collection of electrical and electronic devices. Please follow the local regulations and do not dispose of the old device with your household waste. Page 22/ 22