150430 Trefecta Owner's Manual.indd

O W N E R ’ S M A N U A L

Trefecta e-bike

O W N E R ’ S M A N U A L

Trefecta e-bike V.1.1

T H E J O U R N E Y S TA R T S H E R E

Perfection starts with a blank canvas.

We are on a constant journey to redefine the ultimate in mobility. Trefecta focuses on technological innovation and intelligent engineering, accepting no compromise in this quest.

We explore, redefine, simplify. Until that rare balance between complete freedom and pure control is reached.

6

Y O U M AY W E L L A S K W H Y ?

Living in Switzerland the local mountains were the next logical step for recreational fun with my e-bike. In this challenging environment I quickly encountered the limits of an e-bike. I realised that the products on offer were little more than bicycles with an added motor with little thought on the potential that they could create. Accordingly, all the available products underperformed in one way or another. Frame breakages, motors overheating and failing, batteries range very optimistic at best, to name but a few of the problems.

The entrepreneur and amateur inventor/engineer in me took up the challenge to find a solution for these issues and developed the concept for the Trefecta DRT/URB. Realising a unique set of circumstances in the market would allow a new entrant to mix it up with the big boys. I decided to go for it! Recalling one of my favourite quotes,

“Life should not be a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside in a cloud of smoke, thoroughly used up, totally worn out, and loudly proclaiming “Wow! What a Ride!” by Hunter S. Thompson.

It all started with a speeding ticket and a gift. The first, a rather unfortunate event resulting in a driving ban; the latter, a very nice gift of an e-bike, a forbearer of things to come! The above-mentioned circumstances made sure I made the most of the e-bikes use where otherwise it may have remained unused.

The experience of riding an e-bike opened my eyes and rekindled in me the simple pleasure of cycling, the freedom of body and mind, while riding in an urban as well as inter-urban environment, often much faster than by car and far more enjoyable to boot. The added benefit of regular exercise on an e-bike was shown in the University of Nebraska Omaha e-bike Physiology Research. Which concluded it to be a no-brainer for easily obtained regular fitness without the sweat!

H A I K O V I S S E RFounder

For the concept to make it to reality it needed to score on a multiple of levels. Through my education and professional background being intertwined with the military it was only natural to take the most demanding of possible clients and design a suitable e-bike for military use. To those ends we built a team of professionals from the aerospace, automotive and biking industries equal to the challenge of designing a disruptive e-bike concept. This allowed us the freedom to take a blank sheet of paper and design a vehicle to purpose, with “Power, Function and Design” as our mantra, knowing this would result in a powerful all-rounder with a wide range of capabilities and unique features.

Team Trefecta invested much blood, sweat and tears over the past two years to create the machine now known as the Trefecta DRT/URB.

The rest, as they say, “Is history!”

8

C O N T E N T S

I N T R O D U C T I O N

S A F E T Y N O T E S

Q U I C K S TA R T G U I D E

G E N E R A L D E S C R I P T I O NProduct description and specificationsOperation

F R A M EProduct description and specificationsAssembly

P O W E R T R A I NProduct description and specificationsAssemblyOperation

S U S P E N S I O NProduct description and specificationsOperationTrailtronic Setup in iOS AppFork Suspension

DRT USD ForkURB Single Leg ForkFrame Suspension Fork

O N - B O A R D E L E C T R O N I C S & V E H I C L E S TAT E SProduct description and specificationsAssemblyOperation

B AT T E R Y PA C KProduct description and specificationsAssemblyOperation

H A N D L E B A R SProduct description and specificationsAssemblyOperation

F I N I S H I N GProduct description and specifications

M A I N T E N A N C E A N D S E R V I C E

9

10

12

141418

222223

24242425

2626262728

293233

34

343535

38384041

42424343

5050

54

11

I N T R O D U C T I O N

Congratulations on your purchase of a Trefecta e-bike. The Trefecta stands for a new category of vehicles. Through advanced engineering and intelligent design we developed unsurpassed excellence. The unique interaction between design, power and function results in a multi-purpose vehicle. Ultimately, providing a unique riding experience, freedom of any constraints and customized to every need.

T R E F E C TA O W N E R S M A N U A L I N T R O D U C T I O N

This manual is intended for operation and maintenance purposes. Please read all safety notes and all instructions. By doing so, you can look forward to the reliable and satisfactory performance of your Trefecta e-bike for years to come. The Trefecta team wishes you an adventurous and safe ride!

Detailed and up-to-date information on the Trefecta e-bike may also be found on our website: W W W.T R E F E C TA M O B I L I T Y. C O M

12

S A F E T Y N O T E S

— Keep the battery pack not being used away from paper clips, coins, keys, nails, screws or other small metal objects, that can make a connection from one terminal to another. Shorting the battery-pack terminals together may cause burns or a fire. For short-circuiting damage caused in this manner, any and all warranty claims through Trefecta shall be invalid.— Under abusive conditions, liquid may be ejected from the battery pack. Avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery pack may cause skin irritations or burns.— Battery packs must not be subjected to mechanical impacts. — There is a risk that the battery pack will be damaged causing vapours to escape. The vapours can irritate the respiratory system. Provide for fresh air and seek medical attention in case of complaints.— Vapours can escape in case of damage and improper use of the battery pack. Provide for fresh air and seek medical attention in case of complaints. The vapours can irritate the respiratory system.— Use only original battery packs approved for your e-bike by the manufacturer. Using other battery packs can lead to injuries and pose a fire hazard. When using other battery packs, Trefecta shall not assume any liability and warranty.

Please read all safety notes and all instructions in this user manual. Failure to follow these warnings and instructions may result in electric shock, fire and/or serious injury. Save this user manual for future reference.

— All components mounted to the e-bike may only be replaced with identical components or components specifically approved for your e-bike by the manufacturer. This protects the HSP 2-14 (Hybrid Synchronised Powertrain) against overload and damage.— Do not open the HSP yourself. It must be repaired only by qualified experts and only with original spare parts. This will ensure that the safe operation of the HSP is maintained. Unauthorised opening of the powertrain will void warranty claims.— Remove the battery pack from the e-bike before beginning work on the e-bike (inspection, repair, assembly, maintenance, etc.), transporting it by car or plane (For transport by plane the battery must be installed in the frame), or storing it. Unintentional activation of the e-bike system poses a risk of injury.— Do not open the battery pack. There is danger of short-circuiting. Opening the battery pack voids any and all warranty claims.— Protect the battery pack against heat (e.g., also against continuous intense sunlight), fire and immersing into water. There is danger of explosion.

T R E F E C TA O W N E R S M A N U A L S A F E T Y N O T E S

13

— Use only the supplied Trefecta battery packs with the Trefecta e-bike.— Charge the battery pack only with original battery chargers that were advised by the manufacturer. When using other chargers, the danger of fire cannot be excluded.— Keep the battery pack out of reach of children.— Before every use of your e-bike inspect the bike for cracks or other damage. Do not use the e-bike when you notice cracks in the wheels, the frame or in the drivetrain– check with your dealer about the safety to use the e-bike.— Check the visible bolts and nuts, especially the wheel-nuts, to see if they are correctly tightened. If not, make sure that you tighten these bolts before using the e-bike.— Stop using the e-bike when you hear unusual noise (e.g. in the drivetrain). Make sure that you inspect the chain yourself, or consult the dealer before using the e-bike again.— The on-off button may only be used when pushing or starting the e-bike. There is danger of injury if the wheels of the e-bike do not have ground contact while using the push/start aid feature.

13

T R E F E C TA O W N E R S M A N U A L S A F E T Y N O T E S

— Do not make any modifications to your e-bike system or fit any other products that would be suitable for increasing the performance of your e-bike system. This normally reduces the lifetime of the system and risks damage to the powertrain and the e-bike. There is also a risk of losing the guarantee and warranty claims on the e-bike you have purchased. By handling the system improperly you are also endangering your safety and that of other road users, thus running the risk of high personal liability costs and possibly even criminal prosecution in the event of accidents attributable to manipulation.— Do not exceed the maximum load of 120 kg on the bike saddle and 40 kg on the cargo rack.— The use of a suitable helmet and protective clothing is recommended strongly, even when not required by applicable law.— Please observe all national regulations on registering and using e-bikes.

14

B e f o r e E a c h R i d e

B E F O R E E A C H R I D E , P L E A S E C H E C K T H E S E P O I N T S :

— Quick release clips and nut of front and rear wheels are fastened properly.— All bolts and nuts are tightened properly.— Brakes work properly and brake cables are in good condition. — Suspensions are not blocked. Forks are not damaged and can retract and extend properly.— Tires have the right pressure (see the side of the tire for the right values).— Tires run smoothly. — Tires have enough tread depth.— Seat has the right height for the rider.— Pedals turn smoothly.— Display works and shows all information. — Battery is installed properly.— Battery is fully charged, when you intend to make a long trip.

T R E F E C TA O W N E R S M A N U A L Q U I C K S TA R T G U I D E

Q U I C K S TA R T G U I D E

B E F O R E T H E F I R S T R I D E , P L E A S E F O L L O W T H E S E I N S T R U C T I O N S :

— To make yourself familiar with all functionalities of your Trefecta e-bike, read carefully all safety notes and all instructions in this user manual.— Adjust the seat height. Your optimal seat position can be adjusted by the handle below the seat and pulling the seat higher or pushing it lower. You have the perfect position when you sit comfortably on the Trefecta e-bike with your feet able to lightly reach the ground.— Make sure the battery pack of your Trefecta e-bike is fully charged.— Make a test ride. Electro motors have a fast acceleration in the first few meters. Make yourself familiar with the suspension and the brakes. Be careful when using the throttle for the first time, as acceleration might be much faster than expected!

15

S TA R T I N G T H E T R E F E C TA

To start the Trefecta e-bike, follow these steps:

— Squeeze the brakes.— Press the on-off button on the left hand remote.— You will see that the display lightens up.— Release the brakes.— Move the throttle slowly or start pedalling to make the Trefecta move. — Release the throttle, stop pedalling and/or squeeze the brakes to slow down.

D R I V I N G T H E T R E F E C TA

While driving the Trefecta e-bike:

— Take care of the battery life. Make sure you have enough range left to reach your final destination. — Be careful with braking, because disk brakes can be very sensitive. Try brakes a few times on a safe spot. This might come in handy when making an emergency stop. New brakes require a certain amount of usage before they will gain optimal functionality.

A F T E R E A C H D R I V E

After each drive, please follow these steps:

— Clean your Trefecta e-bike from dirt, sand and dust.— Recharge the battery to be prepared for your next drive.

T R E F E C TA O W N E R S M A N U A L Q U I C K S TA R T G U I D E

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G E N E R A L D E S C R I P T I O N

Four types of the Trefecta e-bike are available, each one tailored to the individual needs of the rider.

Pedelec

Speed-pedelec

L1e

Off-road

E - B I K E S P E C I F I C S E T U P P E R C AT E G O R Y

V E R S I O N S P E E D R E Q U I R E SP E D A L L I N G

S P E E D C O N T R O LC R A N K

T U R B O S U P P O R T

I N S TA L L E D M O T O RP O W E R

N L L I C E N S E P L AT E

H E L M E TO B L I G AT O R Y

< 25 km/hr

< 45 km/hr

< 45 km/hr

< 45 km/hr

Yes Yes

No No

Yes Yes Yes Yes

Yes Yes No No

250 W

500 W – 1 kW

4 kW

> 4 kW

Blue

Yellow

Yellow

N/A

No

Yes

Yes

N/A

S P E E D C O N T R O LT H R O T T L E

Limited Limited Full Full

P r o d u c t d e s c r i p t i o n a n d s p e c i f i c a t i o n s

T R E F E C TA O W N E R S M A N U A L G E N E R A L D E S C R I P T I O N P R O D U C T D E S C R I P T I O N A N D S P E C I F I C AT I O N S

17

E - B I K E C H A R A C T E R I S T I C S P E R C AT E G O R Y

Common denominator

Drive

Top speed

Cruising speed

Speed Uphill Low gear High gear

Range

Bike Weight

Battery Weight

Number of Charges

Charging Time

Continuous Motor Power

Peak Motor Power

V E R S I O N S P E E DS P E E D S P E E DS P E E D

E-fiets, Snorfiets

Human power with electric power assist

25 km/h

20 km/h

??

120 km

250 W ?

E-fiets, Snorfiets


45 km/h

35 km/h

15 km/h (15%)35 km/h (5%)

120 km

0.4 – 1 kW ?

E-Brommer


45 km/h

40 km/h

25 km/h (20%)45 km/h (5%)

100 km

2.5 kW

4 kW (2 min.)

E-Motor


70 km/h

55 km/h

25 km/h (30%)55 km/h (5%)

55 km

2.5 kW 4 kW (2 min.)

36 kg (excluding battery pack)

9 kg

500 cycles (capacity > 80%)

4 hours (450 standard charger) / 2 hours (1.5 kW fast charger)


18

1000 mm

1150

mm

The Trefecta e-bike is designed in such a way that it folds into relatively small sizes. The folded bike can be packaged in a case. This case can be used for transportation but also for storage of the Trefecta e-bike.

F O L D E D D I M E N S I O N S O F T H E E - B I K E

L E N G T H W I D T H H E I G H T

DRT 18”

DRT 20”

URB 18”

URB 20”

1000 mm 1000 mm

1150 mm

1175 mm

590 mm 450 mm

510 mm 475 mm

1150 mm 1150 mm 1125 mm 1125 mm

F R A M E

F O L D E D D I M E N S I O N S O F T H E T R E F E C TA D R T 2 0 ”


19

1. Remove the wheels from the bike using the quick release clasps.

2. Fold the powertrain below the frame.

3. Adjust the seat mast and front fork to their lowest positions. Mudguards or fenders are removed.

2. Place into the folded e-bike transportation case.

H O W T O F O L D Y O U R T R E F E C TA


20

O p e r a t i o n

R E Q U I R E M E N T S F O R I N I T I A L O P E R AT I O N

The Trefecta e-bike system can only be activated when the following requirements are met:

— A sufficiently charged battery pack is inserted (see chapter Battery pack)— An iPod is properly inserted in the battery pack lid (see chapter Frame)

S W I T C H I N G T H E E - B I K E S Y S T E M O N / O F

Press the on-off button on the left hand remote to activate the e-bike (see chapter Handlebar). The powertrain is activated as soon as you step on the pedals. The motor output depends on the chosen mode of operation on the control display unit (CDU) (see chapter Powertrain).

I O S A P P O V E R V I E W

After pairing with the e-bike by means of Wi-Fi, the dedicated Trefecta iOS App can be used to display data and to setup e-bike settings. The App runs on iPod and iPhone devices. The App shows following data.

T H E T R E F E C TA I O S A P P

T R E F E C TA O W N E R S M A N U A L G E N E R A L D E S C R I P T I O N O P E R AT I O N

21

Motor RPM

Motor power (Watts)

Pedal RPM

Pedal power (Watts)

R I D E R A N D M O T O R R P M A N D P O W E R

Motor temperature (°C)

Electronics temperature (°C)

Battery temperature (°C)

Electronics temperature (°C)

O P E R AT I N G T E M P E R AT U R E

T R E F E C TA O W N E R S M A N U A L G E N E R A L D E S C R I P T I O N O P E R AT I O N

22

E-bike battery

Battery power (Amps)

Battery power (Watts)

Battery life remaining (Mins)

Increase front fork tension

Increase rear fork tension

Decrease rear fork tension

Decrease front fork tension

R I D E R A N D M O T O R R P M A N D P O W E R T R A I LT R O N I C F R O N T A N D R E A R S U S P E N S I O N

T R E F E C TA O W N E R S M A N U A L Q U I C K S TA R T G U I D E O P E R AT I O N

23

P E D E L E C S U P P O R T L E V E L I N C U S T O M M O D E

A N G L E O F W H E E L I E M O D E

Increase throttle power

Decrease throttle power

Wheelie mode reset button

Wheelie degree of Angle

T R E F E C TA O W N E R S M A N U A L Q U I C K S TA R T G U I D E O P E R AT I O N

24

F R A M E

The Trefecta e-bike frame is designed to the highest standards. It adheres the demanding norms of aerospace engineering. Premium materials, together with the fully integrated cables and components, make it a tough e-vehicle and ensure protection from all elements. Its foldability also guarantees easy transportation and broad application for professional needs.

F R A M E S I Z E S

Two frame sizes are available: an 18” (medium) version and a 20” (large) version. Interfaces of the medium and large frame to the powertrain and the front fork, as well as the seat mast assembly, are all the same.

U S A B I L I T Y

The frame geometry fits both urban (URB) and off-road (DRT) use. All aluminium frame components are anodized for corrosion protection. The frame assembly itself is not designed to be water, sand and dust proof, but the (electrical) subsystems inside the battery compartment and the battery lid are.

M A X I M U M L O A D

The maximum load on frame amounts 160 kg (120 kg rider + 40 kg cargo rack).


T R E F E C TA O W N E R S M A N U A L F R A M E P R O D U C T D E S C R I P T I O N A N D S P E C I F I C AT I O N S

25

B AT T E R Y C O M PA R T M E N T

The upper side of the frame is open to enable placement of subsystems, such as battery pack and vehicle electronics. It is closed with a shockproof hingeable battery pack lid.

B AT T E R Y PA C K L I D

The battery pack lid contains an integrated smartphone (iPod touch 5G or iPhone 5 or 5S) for using the dedicated Trefecta iOS App, for route planning or for other applications. Connection is made through a 0.5 m lightning-USB cable to the USB outlet on the battery pack.

B O D Y C O N T R O L L E R M O D U L E

The body controller module (BCM), as part of the battery pack, is the central computer on the E-bike. All sensors and electronic components are being controlled by the BCM, including the motor gear actuator and the driver gear actuator. The BCM is equipped with WLAN for wireless communication with the integrated smartphone.

Q U I C K R E L E A S E W H E E L S

The quick release system allows easy mounting/dismounting of the front and rear wheel. The wheel nut has a safety clamp to prevent the nut from coming off the axle during use. The system is designed such that it front and rear wheel are fully interchangeable. The front axle has the same interface as the rear axle to the wheels. The wheels (front and rear are the same) are mounted on the front or rear axle with a quick release nut and clip.

A s s e m b l y

T R E F E C TA O W N E R S M A N U A L F R A M E A S S E M B LY

26

P O W E R T R A I N

A top-of-the-line pedelec system makes optimal use of human power at low speeds. The battery capacity and motor power are utilized fully due to a conversion efficiency of electrical to mechanical power of more than 90%. Efficiency is enhanced by an innovative brake-energy recuperation system, extending the range of the vehicle significantly. When starting pedalling, sufficient torque shall immediately kick in to start forward movement of the Trefecta e-bike.

S P E E D

For speed characteristics, see the table in chapter General description.

M A I N T E N A N C E

The powertrain is designed to be maintenance-free for 10.000 km or 2 years.


The powertrain consists out of 5 main components:

— Brushless DC (BLDC) Motor— Power electronics (PE), installed on top of the motor and controlled via CAN.— Smesh motor gearbox that is specifically developed for the Trefecta e-bike. The smesh motor gearbox is actuated with an electrical/hydraulical actuator.— Rohloff 14 speed speed hub as the pedal gearbox with an electrical actuator.— Bottom bracket with integrated torque/rpm sensor to enable electrical pedal assistance.

The powertrain construction is an enclosed box structure with a single sided (left) axle design. It is made of aluminium 7075 T651, which is the same as the frame. The metal structure functions as a heat sink, enabling the flow down of heat from electrical and mechanical components via the construction to the outside.

A s s e m b l y

T R E F E C TA O W N E R S M A N U A L P O W E R T R A I N P R O D U C T D E S C R I P T I O N A N D S P E C I F I C AT I O N S & A S S E M B LY

27T R E F E C TA O W N E R S M A N U A L P O W E R T R A I N O P E R AT I O N

M O D E S O F O P E R AT I O N

On the control display unit (CDU) (see chapter Handlebar) the rider can choose a mode of operation:

Power mode Maximum performance (power and torque)Eco mode Maximum efficiency and rangeNormal mode Uniform assistance, for touring with long cruising rangeCustom mode System settings are tuned by the user for his/her specific tasteExtreme mode A special power mode that also includes self-balancing behaviour

In case of a low battery state (10% to 3%), ‘limp home’-mode is activated: pedalling with minimum power assist, only to overcome the powertrain mechanical resistance (see chapter Battery pack).

O p e r a t i o n

G E A R S E L E C T I O N

Human gear selection is made by the rider on the handlebar with remote buttons (see chapter Handlebar). Motor gear selection is either high gear or low gear. The selection is made by the rider, but it can also automatically be selected based on vehicle operational status.The auto mode still has to be implemented

E L E C T R I C A L P O W E R A S S I S T

The electrical power assist is provided by the electric motor. Based on pedal input, measured by the bottom bracket sensor (torque, direction, and pedalling speed) the electric motor will provide power, additional to the power from the rider.

R E C U P E R AT I N G

On a downhill slope and when braking, the surplus of available electrical power is used to recuperate the battery, increasing battery power availability and thus range.

28 T R E F E C TA O W N E R S M A N U A L S U S P E N S I O N P R O D U C T D E S C R I P T I O N A N D S P E C I F I C AT I O N S & O P E R AT I O N

The suspension system is equipped with Trailtronic functionality. Trailtronic actively adjusts the firmness of the front and rear suspension in response to actual road conditions. The adjustment is linear including complete lock-out front and rear if required. Trailtronic settings are set up via a dedicated developed iOS App.


S U S P E N S I O N

U S I N G T H E R I G H T H A N D L E B A R

The right handlebar remote allows switching between auto, open, and closed mode of front and rear suspension. In auto mode the Trailtronic system adjusts itself automatically (see chapter Handlebar).

Based on the input from the front and rear fork speed/accelerometer sensors, and the ride mode setting determined by the rider via handlebar controls, the desired suspension control is determined such as to reduce the vehicle body movement. This enables reduction of extreme vehicle response to sudden hard braking (squat) or hard acceleration (wheelie). The suspension can also be locked or put in open position manually from the handlebar, for vehicle use on flat surfaces.

S U S P E N S I O N S Y S T E M ( T R A I LT R O N I C D A M P I N G S Y S T E M )

The suspension system is equipped with Trailtronic functionality. Trailtronic actively adjusts the firmness of the front and rear suspension in response to the road conditions. The adjustment is linear including complete lock-out front and rear if required. Trailtronic settings are set up via the dedicated developed iOS App.

O p e r a t i o n

29

The right handlebar remote allows switching between auto, open, closed mode of front and rear suspension. In auto mode the Trailtronic system adjusts itself automatically.

A speed acceleration sensor is installed on the un-suspended part of the front fork. This sensor provides the accelerations in all directions (x, y and z direction), as well as vehicle speed to the BCM, which in turn controls the suspension servo-actuators as part of the Trailtronic system. This system controls frame movement within certain limitations to provide the rider with a smooth ride.

Based on the input from the front and rear fork speed/accelerometer sensors, and the ride mode setting determined by the rider (via handlebar controls), the desired suspension control is determined such to reduce the vehicle body movement.

This enables reduction of large vehicle response to sudden hard braking (squat) or hard acceleration (wheelie). The suspension can also be locked or put in open position manually from the handlebar, for vehicle use on flat surfaces.

T r a i l t r o n i c S e t u p i n i O S A p p

Trailtronic setup in Trefecta iOS App

T R E F E C TA O W N E R S M A N U A L S U S P E N S I O N T R A I LT R O N I C S E T U P I N I O S A P P

30 T R E F E C TA O W N E R S M A N U A L S U S P E N S I O N F O R K S U S P E N S I O N

The front fork suspension is a new developed suspension for the Trefecta e-Bike. Two types of forks, DRT (off-road) and URB (city), and matching rear suspension are available on the Trefecta vehicle.

The DRT and URB front fork have a similar interface with the frame via an off-the-shelf headset of Cane Creek. This modularity allows interchangeability of the two types of forks. Customers can decide to change to another fork and keep the rest of the vehicle if they would wish.

The differences in in length between the DRT fork and the URB fork are used to optimize the overall vehicle geometry, see Annex1?? for details on geometry, for either off-road or city use.

F o r k S u s p e n s i o n

URB front forkDRT front fork

31

The DRT 0-series vehicle will be equipped with a custom designed Upside Down fork with double crowns and 180 mm travel from German Answer. It is an air spring system, based on the three chamber concept to enable linear suspension behavior.

The fork legs have an oval shape to optimize stiffness/weight properties. These oval shapes are patented by the supplier.

The USD has an interface prepared for mounting the front speed/acceleration sensor.

The scope of supply for USD forks for the 0-series is described in r4.4.

Front USD fork with 180 mm travel for 0-series DRT series

A D J U S T I N G T H E F O R K A I R P R E S S U R E

The air pressure system in the DRT fork requires 9 bar pressure for 60 kg rider, every 20 kg more requires additional 1,8 bar. After pressurizing the fork, push both buttons to the end stop. The valve between the positive and the negative air chamber opens for a pressure equalization.

Check pressure again and repeat the steps until the desired pressure is reached.

T R E F E C TA O W N E R S M A N U A L S U S P E N S I O N D R T U S D F O R K

D R T U S D F o r k

32

A D J U S T T O L O N G T R AV E L M O D E

When the big button is pushed the small button gets out and the fork works in normal mode again.

T R A N S P O R T M O D E A N D H E I G H T A D J U S T M E N T

When the big button is pushed the small button gets out and the fork works in normal mode again.


33

A D J U S T T O S H O R T T R AV E L M O D E

When the small button is pushed the big button gets out.

When pushing down the fork with this setting, the fork stays in a defined position.

The point of short travel can be adjusted with the wheel inside the big button. Rotating the wheel clockwise the brings the travel point down. Rotating the wheel counter clock-wise brings the travel point up. The fork gets back in the long travel position when the big button is pushed.


34

The URB variant series vehicle will be equipped with a custom designed one-sided fork, on the left side, same as the drivetrain, with 120mm travel, also from German-Answer. The URB fork features active trail compensation. This function keeps the distance between the front and rear wheel nearly constant during suspension.

The shock used in the URB fork is similar to the rear shock. The URB front fork requires 5 bar pressure for 60kg rider, every 20 kg more requires additional 1 bar.

T R E F E C TA O W N E R S M A N U A L S U S P E N S I O N U R B S I N G L E L E G F O R K

U R B S i n g l e L e g F o r k

URB front fork – side viewURB front fork – front view

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Frame (or rear) suspension is based on a German-A Titan shock. It is mounted between the frame and the drivetrain and damps movement the rider experiences with respect to vehicle movement. In the DRT variant the rear travel is 180mm, in the URB variant a rear shock with 120mm travel is installed. The rear shock has a Quick Release interface with the drivetrain to allow easy folding of the vehicle. The rear shock has on the DRT has 320mm length, on the URB this is 310mm.

Both rear shocks have a trailtronic actuator integrated for electronic control of the rear suspension. The rear shock requires 15 bar pressure for 60kg rider, every 20 kg more requires additional 2 bar.

T R E F E C TA O W N E R S M A N U A L S U S P E N S I O N F R A M E S U S P E N S I O N F O R K

F r a m e S u s p e n s i o n F o r k

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T E C H N I C A L D ATA Motor power BLDC motors Operational temperature range Vibration and shock

Electrical/EMC signature

O N - B O A R D E L E C T R O N I C S & V E H I C L E S TAT E S


Scalable up to 4 kW

48 V to 60 V DC

-10 ºC to +50 ºC

Shockproof up to vibration levels of a small (off-road) motorbike Integrated electronics withstand a drop of 3 m free-fall

In compliance with UNECE norms

T R E F E C TA O W N E R S M A N U A L O N - B O A R D E L E C T R O N I C S & V E H I C L E S TAT E S P R O D U C T D E S C R I P T I O N A N D S P E C I F I C AT I O N S

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H A R D WA R E

The following electronic hardware is used in the vehicle:

— Body controller module (BCM)— Power electronics (PE)— Battery management system (BMS)— Control display unit (CDU)— Speed/acceleration sensor— Remotes (left and right)

C O N T R O L L E R A R E A N E T W O R K ( C A N )

The e-bike is equipped with a controller area network (CAN) to enable direct communication between the electronic hardware components.

W I R E L E S S C O M M U N I C AT I O N

Three types of wireless communication are foreseen:

— Wi-Fi for communication with smartphone— Low energy (LE) Bluetooth connection

A s s e m b l y

V E H I C L E S TAT E S A N D M O D E S

To power-up the vehicle, press the on/off button located on the handlebar or the on/off button on the battery. The table on page 32 presents the states of the BMS as a reaction on vehicle input.

O p e r a t i o n

T R E F E C TA O W N E R S M A N U A L O N - B O A R D E L E C T R O N I C S & V E H I C L E S TAT E S A S S E M B LY & O P E R AT I O N

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Deep- sleep

Init

Standby

Active

Error

Critical Error

Flash- update

E - B I K E S P E C I F I C S E T U P P E R C AT E G O R Y

S TAT E F U N C T I O N W H E N D O E S T H E B M S E N T E R T H I S S TAT E ?

S TAT E O F H I G H C U R R E N TO U T P U T

S TAT E O F 1 0 / 1 2 V S U P P LY

Reduce standby current to a minimum. Controller is not working, output is disabled, cells are not monitored/protected

Load parameters from flash and start the controller

Wait for activation request via long-press on pushbutton or external request via CAN or ENA-EXT-CTRL

Output of the BMS is activated for charging / discharging

Protect the system

Disable the BMS and enter the deep-sleep to save current and/or give extraordinary errors a chance to disappear

Update the SW of the BMS

— On timeout in standby state (typically 2 min)— On Idle-timeout in active state (current flow below threshold, typically 10min below 200mA). Threshold can be adjusted with USB tool

On wake-up from deep-sleep. This happens when the user pushes the button for at least 250ms

— After init-state— Each time when returning/leaving from and active state to non-active state

— On button long-press— External request (ENAEXT- CTRL or CANBus)

If any error occurs, e.g. cellovervoltage, undervoltage, over-temp, undertemp, communication-error, etc. If errors exist that cannot be reset and do not disappear after 5 retries If the BMS is in deep-sleep and the USB-cable is attached

Disabled Disabled

Disabled

Enabled

Disabled

Disabled

Disabled

Disabled

Enabled

Enabled

Enabled

Enabled

Disabled

Disabled

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A U T O M AT I C E R R O R R E S E T

Errors can occur during special situations, like a short term cell-undervoltage. If so, errors are automatically reset by the BMS. The BMS is intelligent and tries to restore the power on its outlet as long as the user does not command the bike into deep sleep and a maximum number of retries is reached.

C R I T I C A L E R R O R S

If errors cannot be reset, because either something is really damaged, or the battery is in bad condition, the BMS will shut down and fall into deep-sleep.

T R E F E C TA O W N E R S M A N U A L O N - B O A R D E L E C T R O N I C S & V E H I C L E S TAT E S

C R I T I C A L B AT T E R Y C O N D I T I O N

If the battery condition is critical, the BMS falls to deep-sleep within 5 sec after power-up. This can be either caused by a mechanical damage inside the battery or by extreme cell undervoltage.

O P E R AT I O N

40

T E C H N I C A L D ATA

Electrical output power Nominal Capacity Nominal Energy Weight

Target lifetime

Nominal Voltage

Outlets

B AT T E R Y PA C K

C O N S T R U C T I O N

The following illustration represents a side view of the battery pack. 4kW continuous (6kW peak)

29Ah

1461 Wh 9 kg (complete battery pack)

500 cycles (> 80% capacity) or > 2 years

50.4 V

High voltage and 12 VDC (2A continuous to 6A peak)


T R E F E C TA O W N E R S M A N U A L B AT T E R Y PA C K P R O D U C T D E S C R I P T I O N A N D S P E C I F I C AT I O N S

Battery cells

Battery management system

Powerstage

41

B AT T E R Y S TAT U S

In the battery pack several sensors are placed to determine the battery status and provide vehicle protection when possible. Safety features include:

— Battery pack temperature protection:— Battery overtemperature protection— Battery cell overtemperature— Battery power-stage overtemperature— Battery status monitoring:— Over-voltage, under-voltage and overcurrent protection— Battery discharge voltage and current— Battery charge voltage and current (in case of recuperative braking or charging)

I N T E R FA C E S

Mechanical interfaces:

— Space envelope and installation into the frame hull

Electrical interfaces:

— Battery management and powerstage connected to the powertrain wiring harness, which is connected to the frame wiring harness— Software interface via CAN and control via the BMS

B AT T E R Y C H A R G E R S

Two types of battery charger by Industry Electronik Brilon are available:— Standard charger (Filon Futur S, 450W)— Fast charger (Filon Futur M, 1500W)

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I N S E R T I N G A N D R E M O V I N G T H E B AT T E R Y PA C K

Use the handle to lock or unlock the battery inside the frame. Two Rosenberger magnetic connectors connect the battery pack with the wiring harness inside the vehicle.

A s s e m b l y

T R E F E C TA O W N E R S M A N U A L B AT T E R Y PA C K A S S E M B LY

Handle

Rosenberger magnetic connectors

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T U R N I N G T H E B AT T E R Y PA C K O N A N D O F F

Press the on/off-button on top of the battery pack to wake-up the battery/bike. An LED shows the state-of-charge and availability of voltage on the high voltage and low voltage line.

N O R M A L O P E R AT I O N

Normal operation counts for battery ranges from 100% to 10%. You can choose between 5 modes of power assist: Power, Eco, Normal, Custom, and Wheelie.

L O W B AT T E R Y O P E R AT I O N

Low battery operation counts for battery ranges from 10% to 3%. In this state, ‘limp home’-mode is activated: pedalling with minimum power assist, only to overcome the powertrain mechanical resistance.

O p e r a t i o n

E M P T Y B AT T E R Y O P E R AT I O N

Empty battery operation counts for battery ranges from 3% to 0%: pedalling with no power assist at all. Rest power is only used to support electronic functions.

D E E P - S L E E P

The battery can also be in deep-sleep (see chapter On-board electronics and vehicle states).

U S E W I T H N O B AT T E R Y I N S TA L L E D

Without the battery installed, pedalling with no power assist and no electronic functions is possible. However, if a speed of approx. 7 km/h is reached, power electronics get activated. This can cause load torque which feels like a small additional braking torque. Using the e-bike in such condition should be prevented.

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H A N D L E B A R S

B R A K I N G S Y S T E M

The Trefecta e-bike is equipped with two independent hydraulic disc brakes. They operate independently from the electrical system and are always available. Brake levers are located on the handlebar. Braking front and rear is detected by means of two brake sensors when the brake levers are operated. Upon brake detection the rear motor power is cut-off and the brake light is activated. The braking system specifications are as follows:

— Enough capacity to enable a 120 kg rider + luggage to continuously brake on a descent of 2500 altimeters with 15% inclination.— Capable of - 4.9 m/s2 when operated by a 120 kg rider + luggage.— Maximum braking distance at a speed of 40 km/h in normal dry road conditions does not exceed 22 m (front brake only), 27 m (rear brake only) and 18 m (with combined brakes).— Maximum braking distance at a speed of 80 km/h in normal dry road conditions with both brakes does not exceed 50 m.


‘Fly by wire’ handlebar controls adjust throttle and suspension settings, gear selection, and various trip functions. The controls can be operated without taking your hands off the handlebars.

All relevant information appears consolidated on the backlit handlebar display indicating all essential riding statistics like speed, distance, rest range, mode, gear, battery life indicators, suspension and more, legible in all light and weather conditions.

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A s s e m b l y

O p e r a t i o n

On the handlebar a number of controls are located, each generating control signals to the vehicle following rider input.

C O N T R O L D I S P L AY U N I T ( C D U )

The control display unit (CDU) presents the status of the e-bike to the rider. All input signals from the handlebar are collected by the CDU, with the exception of the on/off signal. The CDU is placed central on the handlebar.

T R E F E C TA O W N E R S M A N U A L H A N D L E B A R S A S S E M B LY & O P E R AT I O N

Overview of handlebar controls

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The control display unit (CDU) presents the status of the e-bike to the rider. All input signals from the handlebar are collected by the CDU, with the exception of the on/off signal. The CDU is placed central on the handlebar.

C O N T R O L D I S P L AY U N I T O V E R V I E W

7.

1.

2.

3.

4.

5.

6.

8.

9.

10.

11.

1 . S P E E D I N D I C AT O R

Actual / Average / Top speed (Miles or KM/h)

2 . R A N G E I N D I C AT O R

Restrange (Miles or KM/h)

3 . P O W E R A S S I S T A N D W H E E L I E M O D E

Feedback on selected Power Assist level (adjustable 4 levels), icons for Power, Normal, Eco, Custom, and Wheelie Mode.

C O N T R O L D I S P L AY U N I T ( C D U )

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4 . G E A R I N D I C AT O R

Feedback on selected gear from Rohloff hub (1 – 14 gears)

Sliding scale,switch downfrom top

Selected gear

5 . R E G E N I N D I C AT O R

Feedback on regenerated energy through braking, arrow is flashing, when braking. Arrow is getting smaller with decreasing energy.

Full 3/4 1/2 1/4 >1/4

Flashing

6 . S O C I N D I C AT O R

SOC Batteries (%) sliding scale goes down from top.

Empty

Full

7. S O C I N D I C AT O R

Feedback on actual gear setting;2 gears (high and low)

8 . F O R K S U S P E N S I O N I N D I C AT O R

Feedback on selected suspension mode(automatic, manual, locked)

9 . F R A M E S U S P E N S I O N I N D I C AT O R

Feedback on selected suspension mode(automatic, manual, locked)

1 0 . L I G H T I C O N

Appears when light is switched on.

1 1 . O D O A N D T R I P I N D I C AT O R


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Two buttons are located below the CDU:

M E N U B U T T O N

This button enables viewing other screens on the CDU, providing more information about vehicle status.

L I G H T S W I T C H

This button switches the vehicle lighting on or off. An icon on the display indicates that vehicle lighting is activated.

I N D I C AT O R L E D S O N D I S P L AY

L O W B AT T E R Y I C O N

The LED turns on when the battery has only 10% capacity left.

R F I D L O C K I C O N

— LED on, when vehicle is locked— Flashing, when detecting RFID key— Off, when vehicle is switched off

E R R O R I C O N ( W H I T E )

White LED on, when there is a technical error in the vehicle system and vehicle is working.

E R R O R I C O N ( R E D )

Red LED on, when there is a technical error in the vehicle system and the vehicle is not working.

Menu Button

Light Switch


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The left hand remote contains five buttons:

1 . P E D A L G E A R U P S H I F T I N G B U T T O NPress this button to move the stepper motor one step further, resulting in a gear shift in the pedal gear box.

2 . P E D A L G E A R D O W N S H I F T I N G B U T T O NPress this button to move the stepper motor one step back, resulting in a gear shift in the pedal gear box.

3 . H O R N B U T T O NPress the horn button to sound a signal. Release the button to stop the signal.

4 . M E N U B U T T O NPress the menu button to activate the gear shifting screen on the CDU. By pressing the button again, the standard screen will be displayed.

5 . O N - O F F B U T T O NPress the on-off button to activate the e-bike.

L E F T H A N D R E M O T E

3.4.5.

2.

1.


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R I G H T H A N D R E M O T E

The right hand remote contains three buttons and a twist throttle:

1 . S M E S H G E A RPress the smesh gear button to switch to motor gear, to high or low gear, or to automatic gear selection depending on vehicle status.

2 . F O R K S U S P E N S I O N B U T T O NPress this button to open or lock the fork suspension, or to set it to a certain suspension resistance.

3 . F R A M E S U S P E N S I O N B U T T O NPress this button to open or lock the frame suspension, or to set it to a certain suspension resistance.

4 . T H U M B T H R O T T L ETwist the thumb throttle to activate power assist from the electrical engine.

2.

3.

4.

1.


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O T H E R C O N T R O L I N P U T

On the handlebar more rider control input collectors are located:

— Brake levers and sensors/switches, integrated in the left and right remotes to sense brake activation the bike is equipped with brake sensors. Brake activation sensing is required as release for recuperative braking.— Bluetooth low energy solution. The display-controller integrates a Bluetooth low energy solution in case of proximity of a activation device (e.g. key-fob, iPhone). In addition, this Bluetooth device enables connection with other devices such as a heart rate sensor.

G R I P S

Several grips are available on the Trefecta e-bike, with Ergon GS1 or G1 grips as standard.

P R O X I M I T Y D E T E C T I O N

The CDU is equipped with Bluetooth low energy (BLE) hardware, allowing proximity detection of BLE devices like an iPhone. This proximity detection may be used as an e-lock. The e-bike wakes up when a bonded key comes in Bluetooth range. When the e-bike is bonded/paired to the key, the system is unlocked.

T H R O T T L E A N D B R A K E S E T U P

Before using the e-bike, the brakes and analogue throttle need to be setup properly once. The procedure to do that is as follows:

1. Press the menu button until ‘ENTER SETUP’ is displayed2. Hold the menu button for approx. 5 to 6 seconds3. ‘THROTTLE ADC’ will be displayed4. Turn the throttle all the way for 2 or 3 times (the digits on the display count up and down)5. Press the menu button6. Check the throttle position in percentage7. Press the menu button8. Repeat step 4 to 7 for the ‘LEFT BRAKE ADC’ and the ‘RIGHT BRAKE ADC’9. Leave setup with a long press on the menu button.

NB This procedure might need to be repeated when recup braking does not function properly anymore.

PA I R I N G M O B I L E P H O N E S ( E - L O C K )

The procedure for bonding/pairing an iPhone (or other BLE device) is based on a PIN code. For every device this only has to be done once.


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T I R E S F O R U R B A N U S E

The following tyres are approved for urban use on the Trefecta e-bike:— Schwalbe Big Ben (HS-439) 26” x 2.35— Schwalbe Crazy Bob (HS-356) 26” x 2.35

T I R E S F O R O F F - R O A D U S E

The following tyres are approved for off-road use on the Trefecta e-bike:— Schwalbe Magic Mary 26” x 2.6— Schwalbe Wicked Will 26” x 2.5— Continental Baron 26” x 2.5

H U B S

Custom hubs are used in the carbon wheels and spoked wheels. These hubs are designed such that front and rear wheels are interchangeable.

P E D A L S

The Ergon PC2 pedals for the urban vehicle are equipped with reflectors. The off-road variant has Hope F20 flat pedals without reflectors.

F I N I S H I N G

F R O N T L I G H T A N D R E A R L I G H T

The Trefecta e-bike is equipped with an urban or off-road lights that fit the legal requirements.

R E F L E C T O R S

For clear visibility, reflectors are installed beside the pedal reflectors:• Red rear reflector (Jute R003/B or PS50-R, or Busch & Müller 313/1 or 313/3Z)• Amber side reflectors, one on each side (Jute R003/A, or Busch & Müller self-adhesive, 563)

H O R N

The HYF-307 (12V horn) from Yarton is mounted inside/below the lower crown of the urban e-bike front fork.

R E A R V I E W M I R R O R

A rear view mirror on the left hand side (or optional on the right hand side) of the handlebar increases rider situational awareness. The L1e version of the Trefecta e-bike is equipped with appropriate mirrors.

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V I N N U M B E R

Each vehicle is marked with a unique vehicle identification number (VIN). The VIN is marked on the statutory plate, as well as on the chassis, frame or a similar structure of the vehicle when the vehicle leaves the production line. The first three characters uniquely identify the manufacturer of the vehicle using the world manufacturer identifier (WMI). The 4th to 8th positions are the vehicle descriptor section (VDS).

This is used to identify the vehicle type, and may include information on the platform used, the model, and the body style. The 10th to 17th positions are used as the vehicle identifier section (VIS). This is used by the manufacturer to identify the individual vehicle in question.

B I K E S TA N D

The bike stand automatically retracts when the vehicle is put in riding position.

L I C E N S E P L AT E

A license place is installed on the street legal variant. The license plate holder is integrated with the rear fender on the urban e-bike.

S TAT U T O R Y P L AT E

The statutory plate is located at the bottom of the frame.


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E N - 1 4 7 6 6 L A B E L

After successful passing the EN-14766 tests, a label is affixed to the Trefecta e-bike that states that the vehicle has passed the EN-14766 tests.

C E M A R K I N G

The CE marking is the manufacturer’s declaration that the product meets the requirements of the applicable EC directives. Trefecta, as the manufacturer, affixes the CE marking to the Trefecta vehicles.

D E C A L S

All aluminium are (hard) anodized for corrosion protection. The paint on the vehicle consists of two layers: colour paint + clear coat. The decals are fixed onto the colour paint and covered with the clear coat.

A N T I -TA M P E R I N G L A B E L

A sticker with the information as shown in the illustration is glued in a durable manner inside the frame in the battery compartment.


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C A R G O R A C K

An optional cargo rack is mounted to the seatmast.

S A D D L E

For the off-road e-bike an Ergon SM3-L Pro and for the urban variant the SMC3 with alcantara sides is used. Other saddles can be installed.

S E AT M A S T

For the off-road e-bike a standard HAVOC aluminium 31.6 mm diameter seatmast from Easton is used. A lever operated Dropzone dropper with 75 mm, 100 mm or 125 mm of Kind Shocks is available as an upgrade option.

F E N D E R

The custom made carbon mudguards and fenders are mounted by means of quick release.


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M A I N T E N A N C E A N D S E R V I C E

T O O L S F O R M A I N T E N A N C E

All bolts that may require adjustment by the user are titanium or stainless steel bolts with a M5 (size 4) ‘allen’ interface. All other bolts are stainless steel bolts with a ‘torx’ interface.

The following tools are required by the user:

— Trefecta chain tensioner tool— Trefecta wheel nut spanner (for easy removal of the wheels)— M5 (size 4) allen key

A F T E R - S A L E S S E R V I C E A N D A P P L I C AT I O N S E R V I C E

In case of questions concerning the e-bike system and its components, please refer to an authorised Trefecta e-bike dealer. For contact data, please refer to www.trefectamobility.com.

M A I N T E N A N C E A N D C L E A N I N G

Keep all components of your e-bike clean, especially the battery pack contacts and corresponding holder contacts. Clean them carefully with a soft, damp cloth. All components including the drivetrain may not be immersed in water or cleaned with a high-pressure cleaner. The user may change tires of enhance the chain tension himself. For other service or repairs on the e-bike, please refer to an authorised dealer.

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D I S P O S A L

The drive unit, on-board computer including operating unit, battery pack, speed sensor, accessories and packaging should be disposed of in an environmentally correct manner. Do not dispose of e-bikes and their components into household waste.

O N LY F O R E C C O U N T R I E S

According to the European Guideline 2012/19/EU, electrical devices/tools that are no longer usable, and according to the European Guideline 2006/66/EC, defective or used battery packs/batteries, must be collected separately and disposed of in an environmentally correct manner. The integrated battery pack in the on-board computer may only be removed for disposal. Opening the housing shell can destroy the on-board computer. Please return battery packs and on-board computers that are no longer usable to an authorised dealer.

Subject to change without notice. When applicable, an updated Manual can be downloaded via the website www.trefectamobility.com.

T R A N S P O R T

The battery packs are subject to the dangerous goods legislation requirements. Private users can transport undamaged battery packs by road without further requirements. When being transported by commercial users or third parties (e.g. air transport or forwarding agency), special requirements on packaging and labelling must be observed (e.g. ADR regulations). If necessary, an expert for hazardous materials can be consulted when preparing the item for shipping.

Dispatch battery packs only when the housing is undamaged. Tape or mask off open contacts and pack up the battery pack in such a manner that it cannot move around in the packaging. Inform your parcel service that the package contains dangerous goods. Please also observe the possibility of more detailed national regulations.

In case of questions concerning transport of the battery packs, please refer to an authorised Trefecta e-bike dealer. The Trefecta e-bike dealers can also provide suitable transport packaging.

T R E F E C TA O W N E R S M A N U A L M A I N T E N A N C E A N D S E R V I C E

A H Y B R I D O F P O W E R F U N C T I O N A N D D E S I G N T H E U LT I M AT E H I G H P E R F O R M A N C E E - B I K E

For any questions regarding your Trefecta bike please do not hesitate to contact us at [email protected]+31 88-7333282

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150430 Trefecta Owner's Manual.indd

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Transcript of 150430 Trefecta Owner's Manual.indd