Symmetry Electronic Components Inspection Guide. 2011/5/4 Page 1

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1 Symmetry Electronic Components Inspection Guide 2011/5/4 Page 1

2 CONTANTS LAMPS INTRO POWER SOURCE INTRO CONTROLLER INTRO SWITCHES INTRO DASHBOARD INTRO MEASUREING INSTRUMENTS INTRO DASHBOARD INSPECTION THROTTLE INSPECTION DC to DC CONVERTER INSPECTION HUB MOTOR INSPECTION HUB MOTOR CONTROLLER INSECTION CHARGER INSPECTION LITHMIUM BATTERY INSPECTION /5/4 Page 2

3 LAMPS LAYOUT: HEAD LIGHT TAIL LIGHT WINKERS LICENCE PLATE LAMP 2011/5/4 Page 3

4 POWER SOURCE: LITHIUM BATTERY(48V) DC to DC CONVERTER (48V to 12V) CHARGER(3A) 2011/5/4 Page 4

5 CONTROLLER: THROTTLE HUB MOTOR CONTROLLER HUB MOTOR (800W) 2011/5/4 Page 5

6 SWITCHES: HEAD LIGHT/WINKER/HORN SWTICH MAIN SWITCH 2011/5/4 Page 6

7 DASHBOARD: 2011/5/4 Page 7

8 MEASUREING INSTRUMENTS: MULTIMETER CLAMP METER BATTERY SIGNAL EXTENSION CORD 2011/5/4 Page 8

9 DASHBOARD INSPECTION PROCEDURE: Replace the dashboard when any indicator malfunctioned. 2011/5/4 Page 9

Twist the throttle and measure the output signal (black cord) with the multimeter.

10 THROTTLE INSPECTION PROCEDURE: RED(DC 5V INPUT) BLACK(SIGNAL OUTPUT) GREEN(GROUND) Apply the power (DC 5V) with the hub motor controller to the throttle. Twist the throttle and measure the output signal (black cord) with the multimeter. The part is OK if the signal measured between DC 0.65V~ 3.85V, increased by the throttle open position. If the voltage didn t verify by the open position of the throttle, replace the throttle. 2011/5/4 Page 10

11 THROTTLE Measure Guide: STANDARD: 0.65V ~ 3.85V Multimeter RED BK BK GR Throttle Output Signal 2011/5/4 Page 11

12 DC to DC CONVERTER INSPECTION PROCEDURE: RED (DC48V INPUT) GREEN/WHITE (DC12V OUTPUT) GREEN (DC 48/12V GROUND) FUSE (5A) Apply the power (DC 48V) from the battery to the DC to DC converter and check the function of the fuse of the input, then, measure the output voltage of the converter with the multimeter. The output voltage should be DC 12V~13.8V, if it didn t, replace the DC to DC converter. 2011/5/4 Page 12

13 DC to DC CONVERTER MEASURE GUIDE: STANDARD: 12V ~ 13.8V Multimeter RED BK GR/WH GR DC to DC Converter 2011/5/4 Page 13

14 HUB MOTOR INSPECTION PROCEDURE: 1. Test the three-phase power circuit of the hub motor with the multimeter to check if the open circuit( Ω) of random two lines(standard: 0~0.5Ω ). If the open loop occurred, replace the hub motor. Three Phase Power Circuit Input Coupler Three Phase Signal Coupler-Motor End 2011/5/4 Page 14

15 HUB MOTOR INSPECTION PROCEDURE: 2. Test the three phase signal of the hub motor with the multimeter to check if the signal response properly. Connect the three-phase signal coupler of the Hub Motor Controller with the Hub Motor, attach the positive end(red) of the multimeter to the blue cord and negative end(black) to the black cord, switch the multimeter to the voltage position, measure the voltage variation of the motor from complete stop to slowly rotate. The standard voltage variation should between 0V~5V. Switch the positive end to other phases( yellow and green cord) to measure the voltage varitation each by each. Three Phase Power Circuit Input Coupler Three Phase Signal Coupler-Motor End 2011/5/4 Page 15

16 Hub Motor Three Phase Signal MEASURE GUIDE: STANDARD: STOP->0V, ROTATE->5V BK BK Multimeter RED BL YW GR Hub Motor 2011/5/4 Page 16

17 Hub Motor Controller Layout : Throttle Coupler Power Input(Battery) Coupler Hub Motor Signal Coupler Three Phase Power Output Circuit Coupler 2011/5/4 Page 17

18 Hub Motor Controller Power Input Inspection: Turn the MAIN KEY SW to ON position, measure if there is 48V power input to the Hub Motor Controller. If it didn t, check the battery for any malfunction. Hub Motor Controller Power Input Measure Guide: STANDARD: 42V~59V Multimeter RED BK RED(Thick) BK Hub Motor Controller Power Input 2011/5/4 Page 18

Hub Motor Controller Power (Throttle ) Inspection: Use multimeter to inspect if there is DC5V power supplied to the throttle. If there didn t, the controller is malfunctioned.

19 Hub Motor Controller Power (Throttle ) Inspection: Use multimeter to inspect if there is DC5V power supplied to the throttle. If there didn t, the controller is malfunctioned. Hub Motor Controller Power (Throttle) Measure Guide: STANDARD: 4.7V~5.8V Multimeter RED BK RED BK Hub Motor Controller Power (Throttle) Note: GR->Power cut (Brake) Signal PU->Speedo Signal YW->Throttle Signal 2011/5/4 Page 19

20 Lithium Battery Charger Inspection: 1. Charge Voltage 2. Charge Current 3. Power Indicator 4. Capacity Indicator 2011/5/4 Page 20

21 Lithium Battery Charger Charge Voltage Measure Guide: SATNDARD: 56.0V~60.0V Multimeter RED BK 1 2 Charger Output 2011/5/4 Page 21

22 Lithium Battery Charger Charge Voltage Measure Guide: STANDARD: 2.8A~3.2A Use Battery Signal Extension Cord connect the battery and the charger and measure the charge current with the clamp meter on RED cord. 2011/5/4 Page 22

23 Power Switch Power Indicator Capacity Indicator 2011/5/4 Page 23

24 Lithium Battery Inspection: 1. Charge End Voltage/Capacity 2. Output End Voltage/Capacity 3. Charge Voltage 2011/5/4 Page 24

25 Lithium Battery Layout: Capacity Signal(+) Input(-) Input(+) Output (+) Capacity Signal(+) Output( -) Battery Charge End Battery Output End 2011/5/4 Page 25

26 Lithium Battery Charge End Voltage Measure Guide: STANDARD: 42V~59V Multimeter RED BK 1 2 Battery Charge End 2011/5/4 Page 26

0V(battery capacity is under 75%), please charge the battery. If the measurement is over 40.

27 Multimeter Lithium Battery Capacity (Charge End) Measure Guide: RED BK Measure Condition: While the Battery Capacity is at 75%, the measurement should be 35.0V ~ 40.0V If the measurement is under 35.0V(battery capacity is under 75%), please charge the battery. If the measurement is over 40.0V(battery capacity is over 75%), please discharge the battery. 3 2 Battery Charge End NOTICE: The Capacity signal can be measured after the battery charged/discharged. 2011/5/4 Page 27

28 Lithium Battery Capacity and the Voltage (Charge End) comparison chart: Battery Capacity Voltage NOTE 30% 20.0V~24.5V (±1V) 50% 24.5V~30.5V (±1V) 70% 30.5V~37.0V (±1V) 85% 37.0V~40.5V (±1V) 100% Over 41.0V and Under 0.3A (±1V) (±0.1A) 2011/5/4 Page 28

29 Lithium Battery (Output End) Voltage Measure Guide: STANDARD: 42V~59V (As the Charge End Voltage Measurement) 2011/5/4 Page 29

30 Lithium Battery Capacity (Output End) Measure Guide: STANDARD: 20V~42V (As the Charge End Capacity Measurement) 2011/5/4 Page 30

31 Lithium Battery Charge Voltage Measure Guide: SATNDARD: 42V~59V 2011/5/4 Page 31

1. SPECIFICATION Typ. HPS EPS Capacity 120 A 140 A. 76/140 A at 1,800/6,500 rpm. 70/120 A at 1,800/6,500 rpm. Normal output.

145300 093 1. SPECIFICATION Typ. HPS EPS Capacity 120 A 140 A Alternator Battery Normal output 70/120 A at 1,800/6,500 rpm 76/140 A at 1,800/6,500 rpm Regulator voltage 14.6 V Brush Length 12.5 mm Wear