The HEINZMANN CargoPower drive system is an electric drive solution designed for bicycles, cargo bikes, and light electric vehicles (EPACs), adhering to DIN EN 15194:2018-11 and DIN EN 79010:2020 standards. It functions primarily as a wheel hub drive, providing electric assistance during riding. The system can operate in two main modes: eBike mode, where it assists pedaling, and External Control mode, where it receives torque setpoint values via CAN bus from a higher-level system.
Function Description:
The CargoPower system integrates a motor, controller, and various peripheral devices to provide electric propulsion. It supports both single and dual motor configurations (CargoPower and CargoTwinPower systems). A key innovation is the FREE DRIVE® system, developed in cooperation with Schaeffler AG, which eliminates the mechanical chain. Instead, a generator simulates pedaling feedback and converts mechanical energy from pedpedaling into electrical energy for the drive system, effectively replacing a torque sensor. This system requires batteries with a Battery Management System (BMS) and a permanent 12 VDC power supply.
Important Technical Specifications:
- Permissible Ambient Temperature: -15 to +40 °C.
- Motor Type: RN 111 wheel hub motor.
- Controller Box: Dimensions are 128 ±0.1 mm x 104 ±0.3 mm x 38.5 ±0.5 mm. It features two screw lugs for mounting. Recommended screw: DIN-EN-ISO14580-M5x12-8.8 galZn with Precote® 30-8 coating.
- Motor Installation Requirements:
- Fork and frame must comply with DIN EN 15194:2018-11 or DIN EN 79010:2020 and not be warped.
- Dropouts must be sufficient for secure motor axle and torque arm attachment.
- Required installation widths: Front wheel (VR) 100 mm, Rear wheel (HR) 135 mm.
- Permissible axle loads: Front wheel 880-00-181-XX (max. 150 kg), Rear wheel 880-00-180-XX (max. 125 kg), Single-sided suspension 880-00-182-XX (max. 100 kg).
- Stub axle fastening screws (art. no. 001-01-030-21, TORX®) tightening torque: 8.5 Nm +1.2 Nm.
- Wheel nuts tightening torque: 45 Nm ± 5 Nm (for M10×1).
- Brake Disks:
- Diameter: at least Ø160 mm or larger.
- Recording: 4-hole Rohloff, Ø65 mm bolt circle.
- Fastening: M6×0.5 (HEINZMANN special screw).
- Brake disk bolts tightening torque: 10 (+0.5) Nm. New bolts must be coated with Precote®.
- Speed Limit:
- Torque/speed sensor: max. 25 km/h.
- Starting aid: max. 6 km/h.
- Reversing: max. 6 km/h.
- Continuous Power Limitation: Total system max. 250W. In a primary/secondary system, each motor is limited to 125W.
- Torque/Rotation Sensor Gradients:
- Gradient of rise: max. 1000 Nm/s.
- Return gradient: 500 Nm/s to 2000 Nm/s.
- Oil Filling: Addinol CKT 68, 50 ±1 ml. Pan-head screw DIN7985-Torx-M5 and O-ring 5x1 FPM-80 (HZM article no.: 001-01-118-13 and 001-12-364-00) tightening torque: 5 ± 0.2 Nm.
- Spoking: RN 111 motors are spoked symmetrically. Rims with 36 spoke holes are required. Spoke tension checks are recommended after 200 km, 500 km, 2,000 km, and 5,000 km, then every 5,000 km.
Usage Features:
- Transport and Storage: Motors must always be transported and stored upright, in their installation position, to prevent oil leakage due to pressure equalization. The axle stub and torque support or transport lock must be fitted during transport.
- Controller Box Installation: Should be mounted in positions protected from rain/splash water. Cables exiting the box should point downwards or sideways to prevent water ingress.
- Motor Cable Routing: Cable must be mounted upwards or horizontally to prevent oil collection in the connector. It must be secured to prevent chafing against brake disks or other components.
- HMI Cargo Remote (Human-Machine Interface):
- Key Assignment: Buttons for increasing/decreasing support levels, shifting gears (manual) or changing cadence (CVT mode), and switching display.
- System Start: Press and hold power button for ≥ 4 seconds.
- Support Levels: Five levels (ZERO, ECO, NORMAL, HIGH, POWER, ULTRA) indicated by upper LEDs.
- Battery Charge Indicator: Lower LEDs show charge status (5 LEDs = 100%, 1 LED = 20%).
- Gear Selection/Transmission Ratio: Max 10 gears. Button A shifts up, Button C shifts down. After power-on, system defaults to Gear 0, Support Level "Zero".
- CVT/Manual Transmission: Press and hold Button C for ≥ 4 seconds to switch. In CVT mode, starting cadence is 50 rpm. Target cadence adjustable from 40-80 rpm in 5 rpm steps.
- Starting Aid: Supports up to 6 km/h without pedaling. Activated by pressing the starting aid button and throttle/thumb throttle simultaneously, or by pulling the brake handle, pressing throttle, then releasing brake.
- Reverse Function: Activated by pressing the reverse button and throttle/thumb throttle simultaneously.
- Braking and Recuperation:
- Brake Contact: Activates generator mode, braking the vehicle and recuperating energy to the battery. Requires brake levers with electrical contacts.
- Recuperation: When not pedaling, the system switches to generator mode at a set speed, braking the vehicle and charging the battery.
- Backpedal Brake (FREE DRIVE® only): Activated by momentarily stopping pedaling, then pedaling backwards by a defined angle. The Schaeffler alternator generates counter-torque, simulating a back-pedaling brake.
Maintenance Features:
- General: CargoPower motors RN 111 are largely maintenance-free. Oil filling is designed for the product's service life.
- Safety Inspection: A safety inspection is required after every 1000 km of mileage, checking the electrical system, cable/part fastenings, and battery operating safety.
- Oil Filling: In case of a leak, the motor can be refilled. The motor must be positioned with the drain hole downwards to empty completely (approx. 1 hour), then with the drain hole upwards for refilling. New screws and O-rings must be used.
- Repairs and Service: Repairs should generally not be carried out by the user. HEINZMANN must be contacted for blockages, malfunctions, or damage.
- Cleaning: Components can be cleaned with a soft cloth and soapy water. Steam jets, high-pressure cleaners, or water jets are not permitted, except for the Schaeffler AG alternator, which can be cleaned wet. The battery must be removed before cleaning, and contacts kept free of cleaning agents.
- Motor Calibration: Each controller must be calibrated once to its respective motor. This is necessary if a motor or control unit is exchanged.
- Wheel Circumference Setting: The circumference of the driven tire must be set in mm for correct operating values and limitations. Incorrect settings can lead to excessive speed, reduced braking, or reduced drive power.
- Configuration Suite (Service Software): Used for parameterization and settings.
- Installation: Install "setup.exe".
- Communication: Connect computer to control unit via USB or CAN interface (CAN is recommended for better interference resistance and multi-controller access).
- Firmware Transfer: Transfer ".dwn" files to update firmware. Power supply must be ensured during updates.
- Parameter Transfer/Save: Transfer saved ".hzc" parameter files to the control unit or save current settings to a file.
- Reset Control Unit: Resets the system.
- Error Logging: View current and past errors, including error number and time of occurrence.
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