TQ HPR50 HPR Range Extender V01 160 Wh User Manual

: June 3, 2024
: TQ

Table of Contents

TQ HPR50 HPR Range Extender V01 160 Wh
Safety
Technical data
Operation
Transport
Storage
Cleaning
Maintenance and Service
Environmentally friendly disposal
References
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TQ HPR50 HPR Range Extender V01 160 Wh

TQ HPR50 HPR Range Extender V01 160 Wh product

Safety

These instruction contains information that you must observe for your personal safety and to prevent personal injury and damage to property. They are highlighted by warning triangles and shown below according to the degree of danger.

Read the instructions completely before start-up and use. This will help you to avoid hazards and errors.
Keep the manual for future reference. This user manual is an integral part of the product and must be handed over to third parties in case of resale.

NOTE
Also observe the additional documentation for the other components of the HPR50 drive system as well as the documentation enclosed with the e-bike.

Hazard classiﬁcation

HAZARD
The signal word indicates a hazard with a high degree of risk which will result in death or serious injury if not avoided.
WARNING
The signal word indicates a hazard with a medium level of risk which will result in death or serious injury if not avoided.
CAUTION
The signal word indicates a hazard with a low level of risk which could result in a minor or moderate injury if not avoided.
NOTE
A note in the sense of this instruction is important information about the product or the respective part of the instruction to which special attention is to be drawn.

Intended Use

The HPR Range Extender is intended exclusively for supplying power to the HPR50 drive system and must not be used for any other purpose. Any other use or use that goes beyond this is considered improper and will result in the loss of the warranty. In case of non-intended use, TQ-Systems GmbH assumes no liability for any damage that may occur and no warranty for proper and functional operation of the product. Intended use also includes observing these instructions and all the information contained therein as well as the information on intended use in the supplementary documents enclosed with the e-bike. Faultless and safe operation of the product requires proper transport, storage, installation and operation.

Safety instructions for the HPR Range Extender

The installation of the HPR Range Extender may only be carried out by authorised dealers. The persons must be qualiﬁed accordingly, e. g. by training as a two-wheel mechatronics technician. They must be able to recognize possible dangers during installation. Otherwise, there is a risk that the Range Extender or other lithium-ion batteries on the e-bike will be damaged or that the Range Extender comes off during the ride due to incorrect mounting.
Explosion and ﬁre hazard with damaged Range Extender housing
If the Range Extender housing is damaged, make sure to have it replaced by a TQ authorised bicycle dealer, even if the Range Extender is still functional.
Do not make any repair attempts under any circumstances.
Explosion and ﬁre hazard when short-circuiting the Range Extender terminals Keep the Range Extender away from metallic objects as there is a risk of short circuits. Do not allow nails, screws or other small, sharp and/or metallic objects to come into contact with the Range Extender (charging/discharging socket).
Risk of explosion and ﬁre in case of high heat, ﬁre or contact with water
Protect the battery from ﬁre, high heat and also from extended direct exposure to sunlight.
Never immerse the battery in water.
Danger of poisoning by gases from a smoking or burning Range Extender in case of damaged Range Extender or improper use.
Be careful not to breathe in the highly toxic gases from a smoking or burning Range Extender.
Ensure good ventilation and consult a doctor if you notice any unde-sirable effects on the respiratory organs. The vapors may irritate the respiratory organs.
Liquid may leak from the battery if used improperly. Avoid any contact with this liquid. Wash it off with water if you do come into contact with the liquid. Also seek medical attention if the liquid has come into contact with your eyes. Liquid leaking from the Range Extender can cause irritation or burns.
Never subject the Range Extender to mechanical shocks to prevent damage to the Range Extender.
Only adults are allowed to handle the Range Extender. Keep the battery away from children.
Never open the Range Extender case or attempt to disassemble the Range Extender.
Never break or puncture the Range Extender.
Only charge the Range Extender in well ventilated rooms.
Only use the intended TQ charger to charge the Range Extender.— Use only original HPR Range Extenders to supply power to the drive system.

Technical data

Nominal voltage 50.4 V
Nominal capacity 2.8 Ah
Nominal energy 160 Wh
Discharge logic When operating the e-bike, the Range Extender is discharged ﬁrst afterwards the battery.
Dimensions 76 mm, length 185 mm / ∅ 3”, length 7.3”
Protection class IP66
Charging temperature 0 °C bis 40 °C / 32 °F bis 104 °F
Operating temperature -10 °C bis 60 °C / 14 °F bis 140 °F
Storage temperature 10 °C bis 20 °C / 50 °F bis 68 °F
Weight approx. 950 g / 2.1 lbs
(without frame fastening like FIDLOCK®)

Tab. 1: Technical data – HPR Range Extender

Operation

Installing the Range Extender on the e-bike

The design of the mounting system for the Range Extender on the e-bike depends on the manufacturer. This section shows how to mount the Range Extender on the down tube of the e-bike using the FIDLOCK® system. Make sure especially in case of retroﬁt that no components of the e-bike such as the battery or wiring harness are damaged when installing the Range Extender.
Pay special attention to the following points:

The assembly of the HPR Range Extender may only be carried out by authorised dealers. The personnel must be appropriately qualiﬁed, e.g. through training as a two-wheel mechatronics technician. They must be able to recognize possible dangers during assembly. Otherwise, there is a risk that the Range Extender or other lithium-ion batteries on the e-bike will be damaged or that the Range Extender comes loose during the ride due to insufﬁcient fastening.
Selection of the correct screw heads and screw lengths.
Selection of the positions recommended by the bicycle manufacturer for the attachment.

Fitting the FIDLOCK® Bike Base to the e-bike
WARNING
Fire hazard due to damage to the battery inside the e-bike frame caused by using screws that are too long.

Only use the screws provided by the bicycle manufacturer or the ISO 7380–1 M5 × 10 A2 button head screws included in the scope of delivery to attach the FIDLOCK® Bike Base.

Using screws that are too long can damage the battery inside the e-bike frame.
CAUTION
Risk of accident due to release of the Range Extender from the locking mechanism

Only use the screws provided by the bicycle manufacturer or the ISO 7380–1 M5 × 10 A2 button head screws included in the scope of delivery to attach the FIDLOCK® Bike Base.

Screws with a higher head mean that the FIDLOCK® Force Connector on the Range Extender is not ﬁrmly connected to the FIDLOCK® Bike Base and will come loose while riding.

Fasten the FIDLOCK® Bike Base Fasten the FIDLOCK® Bike Base to the e-bike
with the two button head screws (Pos. 2 in Fig. 1) in the threads provided for this purpose (Pos. 3 in Fig. 1, follow the speciﬁcations of the bicycle manufacturer) inside the e-bike frame.
Tighten the two button head bolts with a torque of 2 Nm or to the max. torque values speciﬁed by the bicycle manufacturer.

NOTE

Observe the inscription engraved “upside>>” when mounting on the FIDLOCK® Bike Base .Orientation of FIDLOCK® Bike Base and FIDLOCK® Force Connector
The upper edge of the FIDLOCK® logo (Pos. 2 in Fig. 2) on the FIDLOCK® Force Connector must point in the direction of the arrow from “upside >>”.

Fasten FIDLOCK® Force Connector to Range Extender
WARNING
Fire hazard due to damage to the Range Extender by using screws that are too long

Only use the screws provided by the bicycle manufacturer or the ISO 4762 M4 × 16 A2 cylinder screws included in the scope of delivery to fasten the FIDLOCK® Force Connector.

Using screws that are too long can damage the battery in the Range Extender.

Fasten the FIDLOCK® Force Connector (Pos. 1 in Fig. 3) in the threads Fasten FIDLOCK® Force Connector to Range Extender
in the Range Extender using the four M4 × 16 cylinder screws supplied (Pos. 2 in Fig. 3).
Tighten the four cylinder screws with a torque of 1.0 Nm.

Insert and lock the Range Extender on the FIDLOCK® Bike Base

Place the Range Extender Insert Range Extender
with the fastened FIDLOCK® Force Connector (Pos. 2 in Fig. 4) diagonally onto the FIDLOCK® Bike Base (Pos. 3 in Fig. 4). The pin (Pos. 4 in Fig. 4) on the FIDLOCK® Bike Base must slide into the corresponding socket in the FIDLOCK® Force Connector when it is put on. The magnets support the attachment and the Range Extender should automatically lock into place with an audible click.

Locking the Range Extender into the FIDLOCK® Bike Base
The FIDLOCK® system is still unlocked after inserting the Range Extender. This condition is indicated by the red ﬁeld TQ HPR50 HPR Range Extender V01 160
Wh 06 FIDLOCK® system unlocked
on the locking tab.

Push the locking tab in as far as it will go FIDLOCK® system locked
, to ﬁx the Range Extender ﬁrmly in place.

CAUTION
Risk of accident due to unlocked Range Extender

Always lock the Range Extender with the locking tab in the FIDLOCK® system before go riding.

Otherwise there is a risk that the Range Extender will come loose while riding, which can lead to a crash.
NOTE

Check the FIDLOCK® Bike Base and the FIDLOCK® Force Connector for dirt and damage before every ride.

For more information on the FIDLOCK® TWIST system and compatible accessories, please visit http://www.ﬁdlock-bike.com/TQ.

Connect the connection cable to the Range Extender

Connect the plugFasten the connection cable to the Range Extender
of the connection cable to the socket (Pos. 2 in Fig. 7) in the Range Extender.
Fasten the connector to the Range Extender with the M3 × 8 socket head screw (Pos. 3 in Fig. 7) included in the scope of delivery of the cable, with a torque of 1 Nm. Never use a longer screw. Other-wise there is a risk of damaging the electronics in the Range Extender.

NOTE
Connecting cables are available in various versions with different cable lengths and connector orientations to meet the requirements of the respec-tive installation situation.
Enquire at the e-bike manufacturer about the connection cable you need.
Connect the connection cable to the charging port of the e-bike

Unfold the cover Connect the connection cable to the charging port
of the charging port (Pos. 2 in Fig. 8) on the e-bike frame.
Check that the terminals in the charging port are free of dirt and clean them if necessary.
Align the connector (Pos. 3 in Fig. 8) of the connection cable so that the connector coding of the plug and charging port match.
Insert the plug into the charging port and secure the plug with the cover (Pos. 1 in Fig. 8).

CAUTION
Risk of accident due to free hanging connection cable on the Range Ex- tender

Always connect the Range Extender to the charging port of the battery in the bicycle frame when you have installed the Range Extender on the bicycle.
Otherwise there is a risk that the free hanging connection cable on the Range Extender will get caught in the pedals while riding and so leads to crash.

Range Extender charging

WARNING
Fire or electric shock hazard due to damage to battery, Range Extender, charger, cable and plug.

Never charge the Range Extender if you notice any damage to the battery, Range Extender, charger, cables or connectors.
Only perform the charging process in a place where there are no ﬂam-mable materials in surrounding.
Never leave the charging process unattended.

NOTE

The drive system detects whether the Range Extender is connected to the charging port of the battery in the bicycle frame. In this case the drive system is deactivated during the charging process for safety reasons.
The charging system detects whether the Range Extender is connected to the charging port of the battery in the bicycle frame. In this case both are charged, ﬁrst the battery and afterwards the Range Extender.

CAUTION
Risk of accident due to activated drive system during the charging process

Always connect the Range Extender to the charging port of the battery in the bicycle frame when you have installed the Range Extender on the bicycle.

This is the only way to ensure that the drive system is deactivated during charging. Otherwise there is a risk that you can start the drive system during charging and that the plugged-in charging cable will cause damage or leads to a crash.

Connect the charger to the power supply.
Unfold the cover Range Extender charging
on the charging port of the Range Extender.
Check that the terminals in the charging port (Pos. 2 in Fig. 9) are free of dirt and clean them if necessary.
Insert the charging plug (Pos. 3 in Fig. 9) of the charger into the charging port of the Range Extender.
Connect the charger to the power supply.
Unfold the cover (Pos. 1 in Fig. 9) on the charging port of the Range Extender.
Check that the terminals in the charging port (Pos. 2 in Fig. 9) are free of dirt and clean them if necessary.
Insert the charging plug (Pos. 3 in Fig. 9) of the charger into the charging port of the Range Extender.
Pull the charger plug of the Fig. 9: charger out of the charging port of the Range Extender when charging is complete.
Close the cover on the charging port when charging is complete.
Disconnect the charger from the power supply.

Notes on Charging

NOTE
The temperature of the Range Extender must be within the permissible charging temperature range (0 °C to 40 °C / 32 °F to 104 °F). Otherwise the charging process will not start.

The Range Extender can be charged directly on the e-bike or separately.— The drive system is deactivated during charging when the Range Extender is connected to the battery charging port in the bicycle frame.
The charging status of the Range Extender can be read on the display and on the 5 LEDs on the side of the Range Extender. Brieﬂy cover the light sensor to the left of the LEDs with a ﬁnger to activate this display.
New Range Extenders have a state of charge of 20% to 30% due to trans- port regulations and must be recharged within less than 6 months after manufacturing.
The Range Extender should be recharged immediately after it has been completely discharged (state of charge <5 %).
1 charge cycle can consist of a full charge of the Range Extender capacity (0% to 100%) or several partial charges that add up to 100% of the charge capacity.
The Range Extender capacity should be at least 60 % after 500 charging cycles.

Transport

The transport of lithium batteries is subject to country-speciﬁc laws and regulations. Inform yourself about the respective regional regulations and observe them during transport.
For transport observe the special requirements for packaging and labeling that apply in your country.
Contact a TQ authorised bicycle dealer for information on transporting the Range Extender and suitable transport packaging. For transport outside the bicycle frame, we recommend a certiﬁed transport box.

Storage

Store the Range Extender at room temperature (approx. 10 °C to 20 °C / 50 °F to 68 °F) and do not expose it to direct sunlight.
Do not store the Range Extender near heat sources or other easily ﬂam- mable materials.
Store the Range Extender in dry rooms (humidity below 70 %) and protect it from rain and moisture.
Store the Range Extender only in rooms equipped with smoke detectors.
Charge the Range Extender to approx. 30 % to 60 % before storage.
Check the Range Extender every 6 months and recharge it to approx. 30 % to 60 %.
Fully charge the Range Extender before use.
Do not store the Range Extender with the charger plugged in.

Cleaning

Never immerse the Range Extender in water to clean it.
Never clean the Range Extender with a water jet.
Only clean the Range Extender with a soft, damp cloth.
Please contact a TQ authorised bicycle dealer, if the Range Extender is no longer functional.

Maintenance and Service

All service, repair or maintenance work performed by a TQ authorized bicycle dealer. Your bicycle dealer can also help you with questions about bicycle use, service, repair or maintenance.

Environmentally friendly disposal

The components of the drive system and the batteries must not be disposed of in the residual waste garbage can.

Dispose of metal and plastic components in accordance with country-speciﬁc regulations.
Dispose of electrical components in accordance with country-speciﬁc regulations. In EU countries, for example, observe the national implementations of the Waste Electrical and Electronic Equipment Directive 2012/19/EU (WEEE).
Dispose of batteries and rechargeable batteries in accordance with the country-speciﬁc regulations. In EU countries, for example, observe the national implementations of the Waste Battery Directive 2006/66/EC in conjunction with Directives 2008/68/EC and (EU) 2020/1833.
Observe additionally the regulations and laws of your country for disposal.

In addition you can return components of the drive system that are no longer required to a bicycle dealer authorized by TQ.
NOTE
For more information and TQ product manuals in various language, please visit www.tq-ebike.com/en/support/manuals or scan this QR-Code. TQ HPR50 HPR Range
Extender V01 160 Wh 11 We have checked the contents of this publication for conformity with the product described. However, deviations cannot be ruled out so that we cannot accept any liability for complete conformity and correctness. The information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. All trademarks mentioned in this manual are the property of their respective owners.
Copyright © TQ-Systems GmbH