Heinzmann CargoPower Technical Information

Electric drives, drives for light electric vehicles

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10034

HEINZMANN

Electric drives

Drives for light electric vehicles

Drive system

CargoPower

Technical information on

installation and operation

(translated version)

Revision - 01

This publication may not be reproduced or passed on to third parties.

Heinzmann GmbH & Co. KG

Electric drives

Am Haselbach 1

D-79677 Schönau

Phone+49 (0)

Fax+49

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info@heinzmann.com

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www.heinzmann-electric-motors.com

USt-IdNr.:DE145551926

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Document F 22 003-e / 09-23

76738208-0

76738208-188

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Page 1 Technical information on installation and operation (translated version) Revision - 01 Copyright 2023 by Heinzmann GmbH & Co KG. All rights reserved. This publication may not be reproduced or passed on to third parties. 10034 Document F 22 003-e / 09-23...
Page 2 All instructions concerning the installation and safety must be followed. Failure to follow the instruction may result in personal injury and/or damage to property. HEINZMANN accepts no liability for damage caused by failure to follow instructions. Independent testing and verification is of particular importance in all applications where malfunction may result in personal injury or property damage.
Page 3 Version index Revision Date Name Comments Translated version of document F_22_003_d_03_23_ 27-06-2023 WaJ/HaF “CargoPower_Info_Einbau_Betrieb_10034.pdf” HEINZMANN reserves the right to make changes in the course of technical development.
Page 4: Table Of Contents
2.2 Driving licence, registration, insurance ......................2 2.3 General safety ..............................3 2.4 Requirements for the installation of the CargoPower drive system ............... 4 2.5 Transport and handling of the motor ......................5 3 Installation of the drive set ..........................7 3.1 Installation of the controller box........................
Page 5 7 Maintenance, repair and cleaning ........................61 7.1 Oil filling ..............................61 7.2 Repairs and service ............................62 7.3 Cleaning ............................... 63 8 Spoking the CargoPower motor RN 111 ......................64 8.1 Rims................................64 8.2 Spoke diameter ............................64 8.3 Spoke lengths............................... 64 8.4 Spoke pattern and spoke tensions ........................
Page 6 Content Downloads and links: • Electric drive system for bicycles, cargo bikes and light vehicles https://www.heinzmann-electric-motors.com/produkte/fahrrad- radnabenmotoren/cargopower https://www.heinzmann-electric-motors.com/downloads CargoPower installation and operation, revision - 01...
Page 7: Safety Instructions And Symbols Used For Them
This symbol does not indicate safety instructions, but provides important information for a better understanding of the functions. These should be observed and adhered to without fail CargoPower installation and operation, revision - 01...
Page 8: Warnings And Safety
2.1 Intended use The CargoPower drive system is used as a wheel hub drive for equipping electro motor- assisted wheels in accordance with DIN EN 15194:2018-11 and DIN EN 79010:2020 such as EPAC ("electrically power assisted cycle").
Page 9: General Safety
Due to unforeseen events or unauthorized use, the vehicle may start moving unexpectedly! This may result in personal injury or damage to property! ˃ Always switch off the drive system when parking and leaving the vehicle CargoPower installation and operation, revision - 01...
Page 10: Requirements For The Installation Of The Cargopower Drive System
˃ Practice using an electric motor-assisted vehicle sufficiently outside of public transport. 2.4 Requirements for the installation of the CargoPower drive system Risk of breakage Installation of the drive system in vehicles that are not sufficiently stable...
Page 11: Transport And Handling Of The Motor
This oil film does not restrict the functionality of the plug. Always transport and store motors upright. Correct Incorrect Torque support with axle stub or transport lock must be fitted. Right, Right, Incorrect with torque support With transport lock and stub axle CargoPower installation and operation, revision - 01...
Page 12 However, this only applies to motors with M8×0.75 thread for brake disks assembly! For motors with thread M6×0.5, the threaded holes do not have to be closed. Correct, Correct, Incorrect with setscrews with brake disk CargoPower installation and operation, revision - 01...
Page 13: Installation Of The Drive Set
Each controller box has two screw lugs on its housing for mounting. Only these screw lugs may be used for mounting controller boxes (see fig.). Screw recommended by HEINZMANN:  Cylinder screw DIN-EN-ISO14580-M5x12-8.8 galZn with Precote 30-8 coating Fig. 5.1 Dimensions of the controller box CargoPower installation and operation, revision - 01...
Page 14: Installation Location And Position Of The Controller Box, Cable Routing
If possible, do not lead cables coming out of the controller box upwards, but downwards, so that any water flowing along the cables does not flow to the controller box. CargoPower installation and operation, revision - 01...
Page 15: Installation Of The Motor
Installation of the drive system in vehicles that are not sufficiently stable can cause load-bearing parts to break during operation! This may result in a fall! ˃ Install CargoPower motor RN 111 only in forks and frames, which can withstand use with electric auxiliary drive up to at least 113 Nm!
Page 16: Torque Support
The torque support (marked red in the following picture) must be attached to the vehicle without play. It must not be loose in any direction. The fastening to the vehicle frame must always be sufficiently dimensioned to be able to transmit the forces that occur. CargoPower installation and operation, revision - 01...
Page 17: Motor Cable Routing
The motor cable must be positioned on the frame of the vehicle in such a way that chafing is excluded and securely fasten the cable in this position with cable ties or adhesive tape. CargoPower installation and operation, revision - 01...
Page 18: Brake Disks
Dirty brake disks lead to reduced braking power or complete failure of the brakes! This can result in a fall! ˃ Always keep brake disks free of oil or lubricants Suitable for the CargoPower motor RN111 motor are brake disks with the following technical data: Brake disk diameter: at least Ø160 mm or larger...
Page 19: Brake Disk Initial Assembly And Change
Without it, there is a risk of damaging the pin holes during disassembly. An impact extractor is available from HEINZMANN. Item no.: 880-80-303-00 View of the motor, stub axle and torque arm disassembled. CargoPower installation and operation, revision - 01...
Page 20 The threads can be damaged by residual threadlocker when fitting new brake disk bolts. View of the motor with repositioned brake disk. CargoPower installation and operation, revision - 01...
Page 21 8.5 (+1.2) Nm Item no: 001-01-030-21 If other bolts are to be used to mount the stub axle, the following specification applies: Screw thread: M6×0,5 Screw-in depth: 7.3 mm Strength: 10.9 Threadlocker is essential CargoPower installation and operation, revision - 01...
Page 22: Sprocket Assembly
3 Installation of the drive set 3.2.5 Sprocket assembly Mounting a sprocket on the CargoPower motor RN 111 motor instead of a brake disk does not correspond to the intended use and is not permitted without approval by HEINZMANN! It is essential that such an application is checked in advance by HEINZMANN and that suitable fixing screws are specified for it.
Page 23: Peripherals
4 Peripherals Peripheral devices are all additional attachments that are compatible with the CargoPower drive system but are not manufactured by HEINZMANN itself. The CargoPower drive system can be operated in the following desired modes depending on the application: •...
Page 24: Pedal Sensors
Remove any existing chain guard • Dismantle chain and crankset • Screw bottom bracket out of bottom bracket tube with suitable bottom bracket key. • Remove any chain guards that may be present CargoPower installation and operation, revision - 01...
Page 25: Torque Sensor
Torque sensors measure the speed and the torque generated at the crank by pedaling. They are not attached to the bottom bracket but are part of the bottom bracket. Torque sensors are available with measurement on one or both sides. HEINZMANN recommends the use of sensors that measure on both sides.
Page 26 In addition to the systems with speed or torque sensors, there is also the FREE DRIVE  system , which HEINZMANN is developing in cooperation with Schaeffler AG. This system works without chains for mechanical power transmission via and is based on a ...
Page 27: Hmi And Display
Light on/off, Light on/off button, Automatic Display LED strip, multicoloured For a description of the functions of the HMI and its use on the FREE DRIVE  system see chapter: 5.3 Using the HMI CargoPower installation and operation, revision - 01...
Page 28 For more information, see the following links: https://sigmasport-ebike.com/integrated#rubrik-ebike-2 https://www.sigmasport.com/de/haendler/downloads For safety, the starting aid is not activated via the Cargo Remote HMI, but with a separate button. See chapter 4.4 "Buttons for further functions". CargoPower installation and operation, revision - 01...
Page 29: Throttle Grip And Thumb Throttle
4.4 - Buttons for further functions. More detailed information on the products can be found under the following links: Catalogue https://www.star-union.net/products-catalog/ Thumb https://www.star-union.net/e-bike-130x-product/ Throttle https://www.star-union.net/e-bike-192xht375-product/ grip Thumb throttle Throttle grip CargoPower installation and operation, revision - 01...
Page 30: Buttons For Further Functions
• With reverse button and throttle grip/thumb throttle: Press the button for reverse and at the same time twist the grip throttle respectively press the thumb throttle. This will activate the reverse drive. CargoPower installation and operation, revision - 01...
Page 31: Batteries
4 Peripherals 4.5 Batteries It is possible to use the CargoPower drive system with a single as well as with several batteries. Batteries are not part of the HEINZMANN delivery scope. The following list provides an overview of the Batteries from other manufacturers that can be used: F 20 001 - d-e "List of suitable Batteries for the operation of...
Page 32: Batteries With Can Communication
Additional shielding or modified routing solves the problems in most cases. • In order to improve EMC, it has proven useful to choose an installation location for the controller box that is as low as possible on the vehicle. CargoPower installation and operation, revision - 01...
Page 33: Cargopower System
4 Peripherals 4.6.2 CargoPower System CargoPower System CargoPower installation and operation, revision - 01...
Page 34: Cargotwinpower System
4 Peripherals 4.6.3 CargoTwinPower System CargoTwinPower System CargoPower installation and operation, revision - 01...
Page 35: Cargotwinpower System With One Battery
4 Peripherals 4.6.4 CargoTwinPower system with one battery CargoTwinPower System (with one battery) CargoPower installation and operation, revision - 01...
Page 36: System Free Drive
5 System FREE DRIVE  The FREE DRIVE system was developed in cooperation between the companies Heinzmann GmbH & Co KG and Schaeffler AG. An elementary feature of the system is that it no longer has a mechanical chain. Instead of a conventional chain transmission, a generator is installed.
Page 37: Cargopower Free Drive  System
5 System FREE DRIVE  5.1.1 CargoPower FREE DRIVE System  CargoPower FREE DRIVE System CargoPower installation and operation, revision - 01...
Page 38: Cargotwinpower Free Drive  System
5 System FREE DRIVE  5.1.2 CargoTwinPower FREE DRIVE System  CargoTwinPower FREE DRIVE System CargoPower installation and operation, revision - 01...
Page 39: Installation Of The Free Drive  Alternator
Instead of a normal bottom bracket, a corresponding receptacle with dimensions suitable for the generator must have been integrated into the vehicle frame. A technical drawing with all necessary dimensions of this mount is available from HEINZMANN. The alternator is inserted into the mount and fastened with the corresponding mounting screws.
Page 40: Using The Hmi Cargo Remote
Shift: Manual gearbox/CVT EOX Remote 500 LED Illuminated display bar HMI Cargo Remote Power button On/Off Power button Light button • Short press: switch on / off • Long press: automatic mode Light button CargoPower installation and operation, revision - 01...
Page 41: System Start
5 - "ULTRA 5.3.4 Battery charge level indicator The charging status of the battery is shown on the display bar with the lower LEDs. Number LEDs 100 % 80 % 40 % 20 % CargoPower installation and operation, revision - 01...
Page 42: Gear Selection And Transmission Ratio
˃ If no gear ratio = 0 has been set, it is imperative that the driver is informed that the vehicle can start even if the gear ratio = 0 has been set. CargoPower installation and operation, revision - 01...
Page 43: Change Between Cvt And Manual Transmission
The adjustable target cadence is adjusted in steps of 5 rpm each. Each of the nine LEDs in the display bar corresponds to such a step. Setting range of the target cadence: 40 ... 80 rpm Number Cadence LEDs CargoPower installation and operation, revision - 01...
Page 44: System Settings And Service Software
6 System settings and service software 6 System settings and service software Before a CargoPower drive system can be used in driving operation for the first time, it must be fundamentally parameterised and set. This is done with the help of the HEINZMANN service software.
Page 45: Starting And Setting Up The Configuration Suite
6.1.3 Starting and setting up the Configuration Suite With the help of the HEINZMANN Configuration Suite, dashboards can be opened. In the dashboard, current data of the CargoPower system can be read out and certain parameters can be adjusted. The dashboard file is created customer-specific by HEINZMANN and sent to the customer.
Page 46 6 System settings and service software • Then start Dashboard by double-clicking on the corresponding icon CargoPower installation and operation, revision - 01...
Page 47 1.12, for example, the software of version 1.10 can be used. However, dashboard files are not upward compatible. With a version 1.10 dashboard, for example, the version 1.12 software cannot be used. Always use the latest Dashboard version! CargoPower installation and operation, revision - 01...
Page 48: Establish Communication
• Connect computer and control unit via a USB cable or the separate CAN interface (see Technical Customer Information F23 001). • Select the correct connection type in the menu ribbon (serial or CAN). • Click on "Start" in the meu bar CargoPower installation and operation, revision - 01...
Page 49 CAN connection HEINZMANN recommends the connection via CAN described below as this has advantages compared to a serial connection. The access is located between the splitter 1 and the HMI interface, which is located in the cockpit or on the handlebars of the vehicle.
Page 50 There is an RS 232 connection on the CAN-Y cable to which a CAN interface for USB is connected: Source of supply e.g.: https://www.peak-system.com/PCAN-USB.199.0.html (recommended is: PCAN-USB opto-decoupled) PEAK CAN to USB converter CargoPower installation and operation, revision - 01...
Page 51 - the CAN connection is less susceptible to interference and usually easier to install - several controllers can be accessed with this connection Via the serial connection, only the currently connected control unit can be accessed. CargoPower installation and operation, revision - 01...
Page 52: Structure Of The Development Dashboard
Status bar For service calls, there is a dashboard with restricted functions to prevent manipulation by the service partner. This looks like this: All further descriptions in this manual refer to the development dashboard. CargoPower installation and operation, revision - 01...
Page 53 With this symbol, a firmware can be transferred to the control unit. To do this, navigate to the corresponding "dwn file". (See chapter 6.1.6 , section "Transferring the firmware to the control unit") CargoPower installation and operation, revision - 01...
Page 54 Settings This symbol leads to the settings. The language can be selected here Info This icon opens a window with information about the service software. CargoPower installation and operation, revision - 01...
Page 55 Display of any errors that may have occurred Tooltips The service software offers a so-called tooltip function. If the mouse pointer is moved to a corresponding position, a corresponding tooltip appears and provides information on the function and setting options. CargoPower installation and operation, revision - 01...
Page 56: Functions Of The Configuration Suite
However, some batteries switch off the power supply if there is no communication with the controller. As a result, the update fails. Information on how to avoid this can be found in the instructions provided by the battery manufacturer. CargoPower installation and operation, revision - 01...
Page 57 (see menu bar [H]) Alternatively, the "Reset control unit" symbol can be clicked immediately. You will then be asked whether the parameter values should be saved in the control unit. Confirm this with "OK". CargoPower installation and operation, revision - 01...
Page 58 Click on the "Transfer data to control unit" icon (see menu bar [G]) This transfers all changes made to the control unit. • Click on the "Reset control unit" symbol (see menu bar [H]) This resets the system. CargoPower installation and operation, revision - 01...
Page 59 ˃ Prescribed tightening torques of the wheel nuts must be observed further information, please refer technical information "F_21_004_e_07_21_ED_CPS_ExperienceCalibration". • Select "Perform calibration". The motor will now start to rotate! • Wait for the motor to stop CargoPower installation and operation, revision - 01...
Page 60 • reduced drive power As already mentioned in chapter 2 "Warnings and safety", the sole responsibility for compliance with applicable laws or directives when using electrically assisted vehicles lies with the operator. CargoPower installation and operation, revision - 01...
Page 61 Select the bottom bracket sensor installed in the system at "Torque/Speed Sensor Type". • In addition, the upper and lower reference voltage of the installed throttle grip can be adjusted and the current voltage can be read out. CargoPower installation and operation, revision - 01...
Page 62 According to the DIN EN 15194 standard, the values for the limitations are: − Torque/speed sensor: max.25 km/h − Starting aid: max.6 km/h − Reversing: max.6 km/h If a value above this limit is entered, the control unit automatically goes into error mode. CargoPower installation and operation, revision - 01...
Page 63 This value must not be changed arbitrarily! • Pushing aid: If this function is activated, the assistance from the throttle grip only starts after the system registers a forward movement of the motor. CargoPower installation and operation, revision - 01...
Page 64 In addition, the vehicle's odometer can be set to a new value. This function is used when replacing a controller on a vehicle already in operation. CargoPower installation and operation, revision - 01...
Page 65 Among other things, the error number and the time of occurrence are stored. • Open the error memory with the "error memory" function The error memory can be operated using buttons on the right edge of the screen. CargoPower installation and operation, revision - 01...
Page 66: Braking And Recuperation
6 System settings and service software 6.2 Braking and recuperation The CargoPower drive system offers additional electric braking aids. However, these can in no way replace mechanical braking systems on an electrically assisted vehicle! • Braking via brake contact For this function, at least one brake lever with brake contact must be installed on the vehicle.
Page 67: Maintenance, Repair And Cleaning
7 Maintenance, repair and cleaning 7 Maintenance, repair and cleaning CargoPower motors RN 111 are basically maintenance-free. The gearboxes are designed for the product's service life, as is the oil filling. Oil does not need to be replaced or topped up.
Page 68: Repairs And Service
Private users report a defect to the manufacturer or dealer of the vehicle or contact a service partner: https://www.heinzmann-electric-motors.com/kontakt/servicepartner Vehicle manufacturers who use the CargoPower drive system use the following service and complaint or complaints use the following service form: https://www.heinzmann-electric-motors.com/kontakt/kundenservice...
Page 69: Cleaning
The penetration of water into the control housing, the motor or the electrical plug connections can destroy the units. One exception to this is the alternator of Schaeffler AG is an exception. This may be cleaned wet with a water jet. CargoPower installation and operation, revision - 01...
Page 70: Spoking The Cargopower Motor Rn 111
8 Spoking the CargoPower motor RN 111 8 Spoking the CargoPower motor RN 111 Risk of breakage An incorrectly or improperly stored rim can lead to wheel failure and thus accidents. ˃ Spoking the motor into a rim may only be carried out by expert personnel! 8.1 Rims...
Page 71: Spoke Pattern And Spoke Tensions
• 8.4.1 Spoking symmetrical wheels The CargoPower motor RN 111 are spoked symmetrically. plane of the rim center = plane of the axle center The plane of the axle center does not correspond to the center plane between the motor flanges.
Page 72: Spoking Non-Symmetrical Wheels
8.4.2 Spoking non-symmetrical wheels If sufficient installation space is available CargoPower motors RN 111, which are intended for single-sided suspended drive wheels or for two-track vehicles, can also be asymmetrically spoked. In such cases, it is recommended that the spokes are:...
Page 73: Spoke Pattern For Rear Wheel, Rim 26" Or Rim 28", 1× Crossed
8 Spoking the CargoPower motor RN 111 8.4.3 Spoke pattern for rear wheel, rim 26" or rim 28", 1× crossed When spoking in CargoPower motors RN 111 applies as rear wheel drive in rims 26" or 28": - all spokes are guided through both flanges from the B-side (= side of the brake disk).
Page 74: Spoke Pattern For Front Wheel, Rim 26" Or 28", 1× Crossed
Fig. 4.2 Spoke pattern front wheel, rim 20" or 24", without crossing 8.4.6 Spoke pattern for rear wheel, rim 20" or 24", without crossing When spoking in motors CargoPower RN 111 as rear wheel drive in rims 20" or 24" applies: - all spokes are guided through both flanges from the B-side (= side of the brake disk).
Page 75: Index
........58 DIN EN 15194 ......17, 18, 26 parameter direction of rotation ......... 58 save ............. 52 display ............. 22 setting ..........52 display bar ..........34 transfer ..........51 peripherals ..........17 CargoPower installation and operation, revision - 01...
Page 76 ......... 66 splitter ............43 symmetrical ......... 66 spoke ............64 wheel nuts ......3, 4, 9, 53, 62 bore diameter ........64 torque ............ 9 length ........... 64 tension ..........66 CargoPower installation and operation, revision - 01...

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