Shengyi CMT03P - User Manual

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CMT03P Technical Instruction
(English Version)
Product Name: Mid Motor Drive Unit
Product Model: CMT03P (Standard
Configuration)

Summary

Important Notice

Mid Motor Drive Unit

1.1 Material and waterproof grade

Details on shell materials, surface treatment, and protection grade.

1.2 Main technical parameters

Key technical specifications including power, voltage, torque, and efficiency.

Attachment

2.1 Instrument

Information about the TFT LCD instrument, its display and functions.

2.2 Speed sensor

Details on the speed sensor model, appearance, and specifications.

2.3 Dental tray

Appearance and basic parameters of the dental tray component.

2.4 Crank

Information on crank model, appearance, and basic parameters.

2.5 Other accessories

List and images of various other accessories included with the unit.

Assembly Method

3.1 System schematic diagram and wiring diagram

Overview of system components and their electrical connections.

3.2 Schematic diagram of loading

Step-by-step instructions for installing motor and related components.

Matters Needing Attention and Fault Analysis

4.1 Matters Needing Attention

Guidelines for proper storage, handling, and usage precautions.

4.2 General Fault Analysis

Common faults, possible causes, and debugging steps.

4.3 Other Fault Analysis and Error Codes

Detailed breakdown of error codes, LED flashing, and their meanings.

Packing List

Packaging Method

Overview

1. Mid Motor Drive Unit
   1. Material and Waterproof Grade
   2. Main Technical Parameters
2. Attachment
   1. Instrument
      1. Instrument Name
      2. Parameter Setting
   2. Speed Sensor
      1. Product Model
      2. Appearance
      3. Product Installation Drawing
      4. Specific Specifications
   3. Dental Tray
      1. Appearance of Dental Tray
      2. Tooth Plate Model
      3. Basic Parameters of Dental Tray
   4. Crank
      1. Appearance of Crank
      2. Crank Model
      3. Basic Parameters of Crank
   5. Other Accessories
3. Assembly Method
   1. System Schematic Diagram and Wiring Diagram
      1. System Schematic Diagram
      2. System Wiring Diagram
   2. Schematic Diagram of Loading
      1. Threading
      2. Install the Motor
      3. Install the Plastic Housing
      4. Install the Tooth Plate and Lock the Screw of the Tooth Plate
      5. Install Left and Right Cranks and Lock Crank Screws
      6. Install External Speed Sensor and Magnetic Steel
4. Matters Needing Attention and Fault Analysis
   1. Matters Needing Attention
   2. General Fault Analysis
   3. Other Fault Analysis and Error Codes
5. Packing List
6. Packaging Method

This document provides technical instructions for the CMT03P Mid Motor Drive Unit, a product of Suzhou Shengyi Motor Co.,ltd. It covers the motor's specifications, attachments, assembly methods, and fault analysis.

Mid Motor Drive Unit

The CMT03P is a mid-motor drive unit designed for electric bicycles. It features a modular design for easy installation and maintenance, and a half-package design that allows for customer customization. The unit incorporates double clutches and is controlled by torque with a built-in controller. It offers a large starting torque, which is beneficial for climbing, and boasts high efficiency, low power consumption, and a long cruising range.

Material and Waterproof Grade

The motor's internal aluminum shell is die-cast with an electrophoresis coating in matt black. The outer plastic shell is sprayed with matt black and silver paint. The unit has a protection grade of IP65, indicating it is dust-tight and protected against low-pressure water jets from any direction. It is designed to operate in temperatures ranging from -20°C to 55°C, at atmospheric pressures corresponding to altitudes up to 1000m, and with relative humidity of ≤90% at 25°C.

Main Technical Parameters

The CMT03P is available in two models: CMT03P36 and CMT03P48, differing primarily in their rated power and voltage.

Parameter	CMT03P36	CMT03P48
Rated power	350W@105RPM	450W@105RPM
Maximum input power	500W (T<7min); max: 640W	650W (T<7min); max: 860W
Rated voltage	36V	48V
Maximum current limit	18A	18A
Maximum torque	120Nm@25RPM	120Nm@25RPM
Maximum speed	115RPM	115RPM
Maximum efficiency	≥80%	≥80%

Attachment

The CMT03P system includes several attachments necessary for its operation and integration into an electric bicycle.

Instrument

The system utilizes a medium color TFT LCD instrument, model APT 850C, for displaying various operational parameters and user interface.

Instrument Name

The LCD display features indicators for:

• Braking reminder
• Failure reminder
• Battery level (in percentage)
• Headlight status
• Speed mode (AVG, MAX, SPEED)
• Speed display (MPH, Km/h)
• Gear indicator (L, M, H, ASSIST)
• Mileage mode (Trip, ODO, Time, Range, Power)
• Mileage indicator (Mile, Km, W)

The key functions on the instrument include "Up," "On/Off," and "Down" buttons for navigation and control.

Parameter Setting

For detailed parameter settings, refer to the 850C-ENS product specification -J-202106 billion.

Speed Sensor

Product Model

Model: SPL-10

Appearance

The speed sensor assembly includes:

• Speed sensor cable
• M5 PH screw
• Cover
• Induction magnet

Product Installation Drawing

The installation diagram illustrates the placement of the speed sensor and magnet on the bicycle frame, ensuring a 3-8mm gap between the sensor and the magnet. The M5 screw is used for mounting.

Specific Specifications

Parameter	Numerical value
Rated voltage	DC5V
Rated current	5mA
Pulse/cycle	One
Installation distance	3-10mm
Working temperature	-30~70°C
Waterproof grade	IPX7
Authentication	CE ROHS

Dental Tray

Appearance of Dental Tray

The dental tray is a circular component with a central spline for motor attachment and an outer ring for the chain.

Tooth Plate Model

Model: 42T unilateral chain cover

Basic Parameters of Dental Tray

• Number of teeth: 42 teeth
• Shape: Concave, with circular pattern
• Color: Black

Crank

Appearance of Crank

The cranks are black, elongated components designed to attach to the motor's central shaft.

Crank Model

Model: TS1-170AA

Basic Parameters of Crank

• Length: 170mm
• Material: 6061
• Color: Black

Note: The left and right cranks have different thread directions. The left crank is marked with "L," and the right crank is marked with "R."

Other Accessories

The system includes various fasteners and connection plates:

• Connection Plate
• Hex Torx sunk socket M6X65 screws (3 PCS)
• Hex Torx sunk screw M6X18 screws (3 PCS)
• Plastic shell (a set of 4)
• Hexagon socket pattern pan head screws M4X8 (6 PCS)
• Chain Wheel nut M26 (reverse tooth) (1 PC)
• Crank screw M8X20 (2 PCS)
• External speed sensor connection cable
• Front light connection cable
• Display connection cable
• Rear light connection cable
• Power connection cable

Assembly Method

System Schematic Diagram and Wiring Diagram

System Schematic Diagram

The schematic diagram illustrates the interconnections between the external speed sensor, front light, display, rear light, battery, and controller. It details the wiring for each component, including positive, negative, ground, signal, and communication lines (RX/TX).

System Wiring Diagram

This diagram provides a visual representation of the cable lengths and connection points for all components, including the battery, external speed sensor, front light, display, and rear light, to the central motor unit. It specifies the connector types (e.g., JL-F-Z309AM 13 core female, JL-F-L611AG 6 core thread male) and cable lengths (e.g., 130mm for display, 140mm for external speed sensor).

Schematic Diagram of Loading

Threading

1. Penetration: Route the external speed sensing adapter, headlight adapter, instrument adapter, rear light adapter, and power adapter cables through the bicycle frame according to the vehicle's requirements.
2. Connection: Insert these cables into the motor as per the 3.1.2 System Wiring Diagram.
3. Arrangement: Organize the cables to ensure appropriate length and position.

Install the Motor

1. Mounting Screws: Insert three M6X65 hexagon socket countersunk screws and three M6X18 hexagon socket countersunk screws into the corresponding holes of the frame connecting plate.
2. Tightening: Lock these screws with a torque of 8-10Nm.

Install the Plastic Housing

1. Attachment: Fix the plastic shell onto the motor.
2. Securing Screws: Lock six M4X8 hexagon socket head screws as shown in the figure, with a locking torque of <1Nm.

Install the Tooth Plate and Lock the Screw of the Tooth Plate

1. Assembly: Install the tooth disk assembly onto the motor, aligning it with the spline groove direction.
2. Tightening: Tighten the anti-tooth nut of the tooth plate in the reverse direction, with a locking torque of 20-24Nm.

Install Left and Right Cranks and Lock Crank Screws

1. Sleeve Cranks: Sleeve the left and right cranks onto the central shaft, ensuring an included angle of 180 degrees between them.
2. Tightening: Lock the crank screws as shown in the figure, with a locking torque of 30-35Nm.

Install External Speed Sensor and Magnetic Steel

Refer to the 2.2.3 Product Installation Diagram for specific installation requirements and positioning of the speed sensor and magnetic steel.

Matters Needing Attention and Fault Analysis

Matters Needing Attention

• Storage: The motor should be stored in a ventilated and dry warehouse, away from damp, acidic, or alkaline environments, and magnetic articles.
• Connections: Ensure all connectors are properly plugged in according to the arrows.
• LCD Protection: Protect the liquid crystal display from sharp objects.
• Overload: Avoid prolonged overloading of the product.
• Water Exposure: Prevent the product from wading or soaking in water.

General Fault Analysis

Serial Num	Fault Phenomenon	Possible Causes of Failure	Debugging
One	The motor cannot be mounted on the frame.	Welding deformation of frame connecting plate.	Reduce welding deformation of frame.
		Plug-in is not connected properly.	Check all plug-ins and connect.
Two	Meter no display	Use non-standard instruments.	Use our standard instrument.
		The battery runs out.	Charge as required.
Three	Meter kilometers are not displayed.	The external speed sensor plug-in is not connected properly.	Check plug-in and connect.
		Magnetic steel is not installed in place.	Check the position of magnetic steel and install it.
Four	Meter kilometer display is abnormal.	Unreasonable magnetic steel position distance.	Adjust the position distance of magnetic steel.
		There is strong environmental interference.	Change the environment.
Five	The front/rear lights are off.	The light control module is not installed.	Install the light control module.
		Plug-in is not connected properly.	Check all plug-ins and connect.
		The rated voltage of front/rear lamps does not match.	Replace the front/rear lights with the correct voltage.
Six	No response when the brake is cut off.	Plug-in is not connected properly.	Check all plug-ins and connect.

Note: When the motor operates without external force, it is normal for the crank to follow.

Other Fault Analysis and Error Codes

The system provides error codes and corresponding LED flashing patterns to diagnose issues.

NO	Error Code	Wrong Definition	LED Flashing	Describe
1	0x00	Normal	Flash once per second	--
2	0x10	Overtension	Flash once	Restorability
3	0x11	Undervoltage	Flash twice	Restorability
4	0x12	Motor speed feedback failure (such as motor stalling)	Flash 4 times	Restorability
5	0x13	Overtemperature	Flash 9 times	Restorability
6	0x14	Voltage fault	Flash 10 times	Beyond retrieve
7	0x15	Abnormal output	Flash 11 times	Beyond retrieve
8	0x16	MCU fault	Flash 12 times	Beyond retrieve
9	0x17	Flying car protection	Flash 13 times	Beyond retrieve
10	0x18	Pedal sensor failure	Flash 14 times	Beyond retrieve
11	0x19	Speed sensor failure	Flash 15 times	Beyond retrieve
12	0x30	Communication failure		The controller can't communicate with the instrument, and the instrument sends a fault code.
13	0x21	Overflowing	Flash 3 times	Restorability
		MOS tube failure	Flash 6 times	Beyond retrieve
14	0x22	Turn the voltage too high	Flash 8 times	Restorability
15	0x23	Phase line fault	Flash 7 times	Beyond retrieve
16	0x24	Hall fault	Flash 5 times	Restorability
17	0x25	Brake failure		Restorability

Note:

• Recoverable faults: After an alarm, the EPAC drive system will detect it in real time. Once the fault disappears, the alarm will be relieved, and normal operation will resume.
• Unrecoverable faults: If the EPAC drive system cannot work normally, turn off the power and troubleshoot.
• The display instrument can show error codes or error messages.

Packing List

The CMT03P package includes the following items:

1. Central drive unit (1 PC)
2. Instrument (1 PC)
3. Speed sensor set (including magnetic steel) (1 set)
4. Dental tray assembly (1 set)
5. Left crank (1 PC)
6. Right crank (1 PC)
7. Plastic shell set (1 set)
8. Tooth disk nut M26 (anti-tooth) (1 PC)
9. Crank screw M8X20 (used to install crank) (2 PCS)
10. Hexagon socket pattern pan head screw M4X8 (used to install plastic shell) (6 PCS)
11. Hexagon socket type countersunk head screw M6X65 (used to connect the motor and the frame connecting plate) (3 PCS)
12. Hexagon socket countersunk head screw M6X18 (used to connect motor and frame connecting plate) (3 PCS)
13. External speed sensing adapter (1 PC)
14. Headlamp adapter (1 PC)
15. Instrument adapter cable (1 PC)
16. Connector for rear light (1 PC)
17. Power adapter cable (1 PC)

Packaging Method

• The motors are wrapped in plastic film bags, with 3 sets packed into one box.
• Accessories are packaged separately from the motor. (Customers should pay attention to counting the quantity of accessories).
• The connecting frame is shipped separately in advance to facilitate welding the frame and streamline production arrangements.

Shengyi CMT03P Specifications

General

Brand	Shengyi
Model	CMT03P
Category	DC Drives
Language	English