Q? Falco Quick Start Guide

Quick Start Guide for Installing a Falco eBike Drive System (For Bottle Battery Configuration) PDF

Step 1: Flip the bicycle upside down and install the small torque arm as shown below using an M6 bolt.

Flip the bike and install the torque arm.
Flip the bike and install the torque arm.

Step 2: Before sliding the wheel into the frame, make sure that the rear derailleur is in the lowest gear. Pull back the idler/shifter and slide the spoked Falco wheel into the frame as shown below. Red mark on the axle on the drive side should be pointed to the back of the bicycle.

Before sliding the wheel into the frame, make sure that the rear derailleur is in the lowest gear. Pull back the idler/shifter and slide the spoked Falco wheel into the frame as shown below. Red mark on the axle on the drive side should be pointed to the back of the bicycle.
Before sliding the wheel into the frame, make sure that the rear derailleur is in the lowest gear. Pull back the idler/shifter and slide the spoked Falco wheel into the frame as shown below. Red mark on the axle on the drive side should be pointed to the back of the bicycle.

Step 3: Tighten the wheel into the frame as shown below. Recommended torque for the M12 hex nut is in the range of 30 to 45Nm. Please refer to your frame manufacturer’s recommendation to make sure that the frame care guidelines are followed.

Follow the specific torque tightening requirements.
Follow the specific torque tightening requirements.

Caution: The axle flats are machined to 10mm to allow for a tight fit into the drop-outs. Caution should be taken to ensure that the drop-out is deep enough (> 14mm) to accommodate the Falco wheel securely and properly.

Caution: M12 hex nut should be tightened from 30 to 45Nm. Be sure to follow your bike manufacturer’s frame care guidelines.

Caution: M6 and M5 bolts should be tightened to 3 and 6 Nm respectively.

Step 4: Install the battery as shown below. Install the holder and thereafter insert the battery and lock it.

Falco Battery Installation

Caution:M5 bolts should be tightened between 3 to 6 Nm. Please be sure to follow the bicycle manufacturer’s frame care guidelines.

Step 5: Install the Console and the PLUS-MINU button as shown below.

Installing the Console and the Plus Minus

Step 6: Install the throttle as shown below. Procedure is similar for the thumb throttle.

Installing the Throttle

Step 7: Route the wires (this step does require some planning and thoughtfulness)

Routing the Wires

Caution:
While using zip ties, make sure the zip ties are not too tight as they can dig into the cables and damage the cables.
Routing the Wires

The optimum position of the wireless module and connectors is shown above. Some models have longer cables for the wireless module. In that case wireless module should be re-positioned.

Step 8: Make the connections. Make sure battery is OFF before making the connections.

Making the connections.

While using a NON-FALCO battery, caution must be taken not to reverse the connection to the motor. A reverse polarity will damage the motor controller permanently and will void the warranty.

Step 9: Adjust the torque sensor parameters.

Adjusting the Torque Sensor Parameters

We strongly recommend that the torque sensor be calibrated and adjusted for your frame before your first ride. Use the Falco Interface and Falco USB stick to connect to the motor wirelessly through your PC or a windows laptop (Currently Mac version is under development). Also, be sure to understand how does the Falco torque sensor work by reading this document.

Additional Resources:

  1. Falco You Tube channel – https://www.youtube.com/user/falcoemotors
  2. Falco Site – http://www.falcoemotors.com/
  3. Call us toll free (US and Canada): +1 877 278 6323
  4. Download PDF.
  5. Falco Open Propulsion Systems.
  6. Falco Lithium Batteries.
  7. Falco Five Phase Motors.
  8. Falco Components.
  9. Email
Q? Upgraded and Simplified Console for Falco’s US Customers

The console has been upgraded and simplified as follows:

  1. Internal Battery Charge Indication: The bars on the top left hand side show charge of the internal battery at ZERO speed. Six bars indicate full charge. When charge is less than full and the console is hooked upto a USB charger, the bars will increment and decrement indicating that the cell inside is being charged.
  2. ODO is shown at all times. Clock has been permanently removed.
  3. MPH is permanently set for the US models.
  4. Upper segments show battery voltage when console is paired with a motor.
  5. SLEEP time has been increased from 20 seconds to 300 seconds.
  6. BACKLIGHT time at ZERO speed has been increased from 20 seconds to 300 seconds.
  7. HRT function for pairing a heart rate monitor has been eliminated from the console for US models.
  8. Charging the Console: Please charge the console when not in use either using your computer USB port or any other USB charger.
  9. Storing the Console: While storing the console, please be sure to TURN OFF the console from the back of the console.

Additional Resources:

  1. Falco You Tube channel – https://www.youtube.com/user/falcoemotors
  2. Falco Site – http://www.falcoemotors.com/
  3. Call us toll free (US and Canada): +1 877 278 6323
  4. Download PDF.
  5. Falco Open Propulsion Systems.
  6. Falco Lithium Batteries.
  7. Falco Five Phase Motors.
  8. Falco Components.
  9. Email
Q? Training Documents for Falco Dealers and Customers
Spoking Information:

For Spoking Hx 2.0 500W Motors, review the following documents:
500W Front Wheel Installation with 100 mm Spacing:
http://falcoemotors.com/dealers/500W%20Front%20Wheel%20Installation.jpg

500W Rear Wheel Installation with 135mm Spacing:
http://falcoemotors.com/dealers/500W%20Rear%20Wheel%20Installation.jpg
For Spoking Hx 3.0 750W Motors, review the following documents:
750W Front Wheel Installation with 100 mm Spacing:
http://falcoemotors.com/dealers/750W%20Front%20Wheel%20Installation.jpg

750W Rear Wheel Installation with 135mm Spacing:
http://falcoemotors.com/dealers/750W%20Rear%20Wheel%20Installation.jpg
For Spoking Hx 4.0 1000W Motors, review the following documents:
1000W Front Wheel Installation with 100 mm Spacing:
http://falcoemotors.com/dealers/1000W%20Front%20Wheel%20Installation.jpg

1000W Rear Wheel Installation with 135mm Spacing:
http://falcoemotors.com/dealers/1000W%20Rear%20Wheel%20Installation.jpg
Troubleshooting the motor:
In a rare instance where motor is not working with throttle or torque sensor or crank sensor, the following things should be checked:

  1. Is motor receiving power? How do you check that? Check voltages on the 6-pin and 4-pin motor connectors. 6-pin connector voltages are documented here. 4-pin connector voltages are documented here. Also, make sure the battery connector is installed as per this document. Check to make sure battery fuse is not blown and the battery connector is outputting correct voltage. Motor will not work beyond 55V as an internal safety mechanism.
  2. Is motor locked? If the wheel is stiff to rotate, the motor is most likely locked. It should be unlocked using the console or the Falco Interface. If motor is locked, some versions of Falco Interface (1.4.2 or lower) will show the Hall Code (Err) as 255.
  3. Is motor in mode 0. If the connected console or the Falco interface is in mode 0, motor is automatically in non-assist mode.

Hx Motor Wiring Diagram can be downloaded here. (Note: A number of brake sensors can be interfaced with the Hx motor. The 6-pin connector has the default provision to connect to a brake sensor (for OEM applications). Also, crank sensor connection can be reprogrammed to act as a brake sensor or reverse function).
Falco Interface :
Falco interface serves two main purposes: one to adjust the torque sensor settings and secondly to diagnose any issues with the motor and the console. The third and least used purpose is to be used as a way to connect to an ANT+ heart rate sensor while using the bike as an indoor exercise machine.

Falco Interface 1.4.3 version can be downloaded here. How to use Falco Interface? The YouTube videos can be seen here: Part 1 and Part 2. You can also review this video published by Court Rye of Electric Bike Review.
How does Falco Torque Sensor work?
Review this document.
Falco Quick Start Installation Guide
Falco Quick Start Guide can be found here.
Falco’s Simplified Console for US Customers
Learn about Falco’s simplified console here.
Other Dealer Training Documents
http://falcoemotors.com/dealers/dealer_training_documents.zip
Images for Your Website
http://falcoemotors.com/dealers/Dealer_Photos.rar
http://www.falcoemotors.com/?page_id=43
Falco Press Images

Q? Cable Handling Guidelines

While routing cables on an electric bike frame, cables can be quite easily mishandled. One of the most looked over fact is that cable-ties should not be used or used with extreme caution. They can cause severe damage to the cable because of uncontrolled force exerted on the cables when a cable tie is used.

Falco recommends using Velcro cable ties (Falco Part Number VELCRO-8):

Recommended Cable Ties for Motor and Battery Cables

Recommended Cable Ties for Motor and Battery Cables

 

Recommended Cable ties are 8" long and 1/2" wide.

Recommended Cable ties are 8″ long and 1/2″ wide.

Q? Falco Torque Sensor Operation Video Transcript

Falco torque sensor operation is characterized by 12 parameters.  The 12 parameters are:

  1. Torque Sensor Raw Value
  1. Torque Sensor Rectified Value
  1. Torque Sensor Peak Value
  1. Actual Torque Sensor Value
  1. Turn On Speed
  1. Turn On Delay
  1. Base Active Current
  1. Turn Off Delay
  1. Flip Torque Sensor Command
  1. Max TS Value
  1. TS Turn On Value
  1. TS Offset Value

How do you get the most out of your torque sensor?  The first step is to calibrate your torque sensor. One way to calibrate your torque sensor is to use Falco interface v1.4.3 and  ANT+ micro USB.

So the first thing is that we want to focus on the following four parameters:

  1. Torque Sensor Raw Value
  1. Torque Sensor Rectified Value
  1. Torque Sensor Peak Value
  1. Actual Torque Sensor Value

 

These four parameters allow us to make sure that when you’re not pedaling, when the bike is at stand still, the torque sensor is correctly calibrated. So the first thing you want to do is look at the TS Row Value.  The TS Row Value will have an initial value between 300 to 500 at stand still.  After you have connected the Falco interface with your Falco system, you want to sit on the bike and see the variation in the TS Row Value.  If there’s no variation that’s great.  That means that the motor is very close to a calibrated value in the frame.  The second step is that you want to take the wheel off the ground and twist your throttle, and look at the Actual TS Value.  If this remains zero, then you’re all done.   You are looking for 2 counts:  One is the variation in Raw Value when you sit on the bike.  And the second is you want to look at the Actual TS Value.  So you get two offsets from this exercise.

We can call it one for sitting and then there’s the offset two known as throttle no load test. Once we have found out offset one and offset two, essentially these two offsets are added together and then we put that under motor control tab in the TS Offset Value.  That essentially completes the calibration of the Torque Sensor.

Torque Sensor Fine Tuning

Now what we want to do is some  fine tuning, so you have got the following parameters to do the fine tuning of the Torque Sensor.

  1. Turn On Speed
  1. Turn On Delay
  1. Base Active Current
  1. Turn Off Delay
  1. Flip Torque Sensor Command
  1. Max TS Value
  1. TS Turn On Value
  1. TS Offset Value

Now let’s understand the operation of the Torque Sensor.  Torque Sensor gives you infinite combinations to match human power to motor power.  So let’s talk about our 500 watt motor power. This is 500 watt motor power on the y-axis, and then on x-axis let’s us plot human power.

If you are a fit athlete and let’s say that you can produce 250 watt of power, and you want to essentially match 250 watt of power with the 500 watt of power, so I’m going to draw a box here and I’m going to draw a line here.    So when I produce 250 watt of power my motor should produce 500 watt of power so I’ve got a total of 750 watt of power which I want to use.   So how do you set that?

The second aspect is let’s say that you’re not a very fit and / or let’s say you have some sort of disability.  And your ability is to produce say 50 watt of power.    So I am going to draw a line here now and I’m going to say that  I want my 50 watt to be matched to 500 watt of human power.   So you see how these slopes are different.  Now when these slopes are controlled  there is no limit here.  You could essentially control these with a very wide range.  For example if you are a top athlete, then you say well  I can produce 2,000 watt of power, so I want my 2,000 watt of power to be matched with 500 watt of motor power.  That’s how the torque sensor works.

Now, how do you manipulate these slopes.  The parameter we use is called Max TS Value.  So here: Max TS Value could be as high as let’s say 50.  Default, Max TS Value is around 5 .  And in this case Max TX Value is around, let’s say, 1 or 2 when we can only produce 50 Watt of power.   Depending upon your ability to produce power you can perfectly match that with the motor.

Let us talk about the different power levels:  Level one.  Level two.  Level three.  Level four.  Level five.  And then a turbo mode.  These control the torque.  For a 500 watt motor Level 1 is about 8, then Levle 2 is about 12, Level 3 is about 16, Level 4 is about 20, and level 5 is about 24, and then you have Turbo at 26.  These are the different torque levels, not the power levels.

Let me quickly talk about the Turn On Speed, the Turn On Delay, Base Active Current, Turn Off Delay, Flip TS Command, and TS Turn On Value.

Turn On Speed is the speed at which the torque sensor comes on.   But however since the motor computes the speed very fast,  it is not a slow computation of the speed, it’s a fast computation of the speed, so if you set it high 150 rpm right, then the torque sensor is going to turn on when the motor thinks that it’s rotating at 150 rpm.

Turn On Delay – This is a delay in seconds. It is count. 1 count roughly equals 200ms.

Base Active Current – This provides boost at start up or zero speed. Higher this value, higher the boost.

Turn Off Delay – This compensates for lack of our ability to produce torque at higher speeds. As speed is increased, we lose ability to produce torque at the cranks. Turn off delay can be used to compensate for that lack of ability at higher speeds.

Flip TS Command – This allows rotation of the axle by 180 degrees and calibrate the torque sensor in the opposite direction. Mostly beneficial for cable routing.

TS Turn ON Value – Value at which the torque sensor becomes active. For example a value of 5 means, motor is looking for a 5 Nm torque before torque sensor can become active inside the motor.

Contact

North American Region:

Falco eMotors Inc.
100 Executive Dr.
Ste C
Dulles, VA 20166

Email:Contact_USOffice@falcoemotors.com

Phone:Toll Free USA +1 (877) 278-6323

Fax:Toll Free USA +1 (877) 278-6323 FREE

Asian Region:

Falco eMotors Pvt. Ltd.
A-105, H-Block, Pimpri MIDC
Pune – 411018
Maharashtra, India

Email:Contact_IndiaOffice@falcoemotors.com

Phone: +91-20 69332266, +91-20-69332255