Harmony™ OEM Installation

Version 1.4

July 2014

READ ME FIRST – Sprocket & Chain Compatibility

NuVinci Harmony is compatible with the following size steel sprockets that are flat on at least one side:

• 16 Tooth

• 17 Tooth

• 18 Tooth

• 19 Tooth

• 20 Tooth

NuVinci Harmony is compatible with 3/32” (2.3mm) chains and sprockets only.

• Do not use 1/8” (3.2mm) single speed chains or sprockets

READ ME FIRST – Compatibility

NuVinci Harmony is incompatible with belt drive systems due to clearance at the rear wheel

The Harmony Hub Interface is incompatible with all derailleur hangars

X

READ ME FIRST – Minimum Sprocket Ratios

Bosch GEN2 Frame Motor E-Bikes

READ ME FIRST – Encoder, Programming, Calibrating

The color-matched Harmony Encoder must be installed on the N360 CVP for Harmony to function

• Sample units may be pre-installed

A Harmony Programming tool is provided to customize Harmony to the bicycle being produced – if this is not used, settings may be inappropriate for the bicycle

Every installation on a bicycle requires an initial calibration – skipping this calibration will result in poor ride performance and consistency

Harmony Advanced System

HARMONY HUB

ENCODER (COLOR

MATCHED TO CVP)

HARMONY

HUB INTERFACE MAIN (Y) WIRE

HARNESS

ADVANCED

CONTROLLER

POWER HARNESS

(ORDER

SEPARATELY)

OWNER

MANUAL

Harmony Base System

HARMONY

HUB INTERFACE MAIN (Y) WIRE

HARNESS

BASE CONTROLLER

& MOUNTING H/W

OWNER

MANUAL

HARMONY HUB

ENCODER (COLOR

MATCHED TO CVP)

POWER HARNESS

(ORDER

SEPARATELY)

N360 Bulk CVP & Hardware

N360 CVP

AXLE NUTS (2)

RH NUT

SPROCKET

SPACER

SPROCKET

SNAP RING

NO-TURN

WASHERS (2)

NOTE: 16 – 20 tooth sprocket is not included, OEM must purchase

separately or as additional order item through Fallbrook Technologies, Inc.

Wheel Building

Install the Harmony Hub Encoder

The Harmony system comes with a color-matched Hub Encoder

• Six magnets in the Hub Encoder provide bicycle speed

Harmony Hub Encoder must be installed before sprocket installation

• Sample units may come with Harmony Hub Encoder pre-installed

Align the Hub Encoder

• Locate the key on the N360 CVP RH Shield

• Align the keyway on the Hub Encoder with the RH Shield

Install the Harmony Hub Encoder (continued)

Installing the Hub Encoder

• With the key and keyway aligned, start at that location and press the Hub Encoder onto the RH Shield

• “Walk” the snap-fit around to the opposite side with continuous pressure

• The Hub Encoder should be tight and secure, with the Hub Encoder ending flush to the CVP

Sprocket Requirements

REMINDER:

NuVinci Harmony is compatible with the following steel sprockets that are flat on at least one side:

• 16 Tooth

• 17 Tooth

• 18 Tooth

• 19 Tooth

• 20 Tooth

Minimum Sprocket Ratio as shown in tables earlier in this presentation

NuVinci Harmony is incompatible with belt drive system

Installing the Sprocket

Hub Interface Orientation and Installation Angle

0°

20°

• Orient the Harmony hub

interface roughly parallel to

the chainstay

• Move the hub interface along

the dropout to ensure

clearance at different axle

positions.

The Harmony hub interface

has integrated sensors at the

inboard location shown (4).

• Ensure that the sensor

location (4) is within the chain

perimeter and will not contact

the chain

• When installing hub interface,

be sure not to catch the chain

on the sensor (4)

2.4

2.5

2.6 2.6

Installing the Hub Interface

The 2012 Model N360 has two

splines, the Shift Driver (3) and the

Spline Nut (2). For Harmony

installation, Shift Driver location is

unimportant (the Harmony system

determines the shift position during

the initial calibration).

Installing the Hub Interface

When the installation angle is

aligned, seat the hub interface fully

onto the shift driver and the spline

nut until it is flush with the spline

nut, as shown

• N360 cable shift hub interface

shown, but Harmony Hub

Interface installation is identical

NOTE:

N360 cable shift hub interface shown here for reference only, but the Harmony Hub Interface installation process is identical

RH Nut serrations must face outward:

Fitting the Rear Wheel

Mount the Base Controller either on the left or right-hand side

Use the appropriate size O-ring and spacer for your handlebar size / location

Guide the cable and Base Controller connector to the bottom bracket location of the bicycle

• Be sure to provide excess cable for turning of the handlebars

Base Controller Installation

Advanced Controller Installation

E-Bike Electrical Integration

18-44V

Y-Harness – Harmony Hub Interface to Bottom Bracket (BB) area

Power Harness – Battery / e-Bike system power to BB area

Rider Controller Cable – Handlebar to BB area

Connection to e-Bike power (OEM to provide)

Harmony connections (provided)

Inspect all cables prior to installation - do not install if damaged.

OEM / assembler is responsible for routing cables in a way that will avoid damage with use.

Inspect all cables prior to installation - do not install if damaged

• OEM / assembler is responsible for routing cables in a way that will avoid damage with use

OEM must connect Harmony system to 18 - 44V (nominal) power source

• Maximum voltage the Harmony system can withstand is 50V peak

– Please check your battery chemistry to determine if the maximum voltage when fully charged is higher than 50V

– Higher voltage battery systems can be used, but must regulate voltage to the Harmony system to less than 50V peak

• When Harmony is powered by a source that cannot be switched on/off, Harmony can be configured to enter an ultra-low power “sleep mode”

– Panasonic System Example

▪ Spade-style connectors under battery connector are accessible

▪ Power source cannot be switched on/off when battery is installed

• When Harmony is powered by a source that is switched on/off with use, Harmony will automatically function

– Bosch System Example

▪ Bosch / Harmony wire harness is purchased from Bosch

▪ Power source automatically turns off

Once all wires are routed, connect them and apply power to the e-Bike & Harmony system

• Regardless of any indications, the Harmony system must be calibrated prior to use (see following pages)

E-Bike Electrical Integration (continued)

Calibration (REQUIRED prior to operation!)

Pedal the bicycle lightly and quickly through entire calibration procedure (preferably on a stand with rear wheel off the ground)

Initiate the Calibration Routine:

Continue pedaling lightly and quickly while the system shifts from “low” to “high” ratio multiple times and completes calibration

• Advanced Controller: Hold down the ‘Mode” Button until the rear hub begins shifting (5-7 seconds typically), then release the button

• Base Controller: Press and hold the Top and Bottom buttons simultaneously until the rear hub begins shifting (5-7 seconds typically), then release the buttons

Confirm Calibration & System Operation

Check system calibration

• Pedal the bicycle lightly and quickly while shifting through the ratio range (manual mode) and cadence range (automatic mode)

• Ensure the system is able to shift through the full range of the display without issue

• If operation is inconsistent while pedaling on a stand or riding, recalibrate the system

Reminders:

• Calibration:

– Without pedaling, Harmony will not calibrate correctly and function will be compromised

– Pedaling will get harder and easier during calibration as the Harmony system determines the shift range for the N360 CVP

– Pedal by hand lightly and quickly until the system stops shifting (less than 10 seconds)

• System Operation:

– The Harmony system will not shift if there is no pedal or wheel movement on the bicycle

– The ability to shift the N360 CVP is affected by input torque, and shifting can be delayed under high pedal torque and e-Bike assist levels

NuVinci® Desktop™ PC Application Instructions

V2.0.7

(Includes NuVinci Harmony™ Firmware Update Instructions)

Supplied to OEMs and Bicycle Dealers

• Web download through secure site: http://harmony.fallbrooktech.net/

• Required to update Harmony firmware

• Required to program cadence and bicycle settings

Operates via standard USB to mini-USB cable (not supplied)

• Compatible with Windows XP, Vista, and 7, 32 and 64 bit operating systems

• Mini-USB sealed connector at underside of Harmony Hub Interface

NuVinci Desktop (Harmony Programming) Software

Disconnect Harmony Main Connector

• Pull in direction shown

“Click to Connect” Page

• Run program

• Initial “Click to Connect” page with NuVinci Desktop Software Version

• Attach USB Cable between computer and Harmony Hub Interface and Click to Connect

“Communication Established” Page

• Harmony Firmware Version displayed

• Options to

– Proceed to Harmony Setup

– Load setup from File

– Update Firmware

Harmony Programming Software

Update Firmware

Select “Update Firmware” from initial screen

Select Firmware File from the directory automatically opened

Firmware update will start

Firmware success message

Clicking “OK” will take you back to the initial connection screen

• If firmware update fails, unplug the USB cable and re-start the NuVinci Desktop software. Attempt the firmware update again.

Select “Harmony Setup” from initial screen

Bicycle Configuration

• Front & rear sprocket sizes

Advanced Controller Setup

• High Cadence Limit

• Low Cadence Limit

• Display Brightness

Base Controller Setup

• High Cadence Setting

• Medium Cadence Setting

• Low Cadence Setting

Simulate selected number of “gears” with smooth transitions

Time to Sleep

• Number of minutes before ultra-low power mode is started

Select “Send Settings to Harmony”

Verification Message

Harmony Setup Page

Harmony Setup – Save Setup to File

Choose Harmony setup values that you would like to save for future access or programming

Select “Save Setup to File” from Harmony Setup page

Choose file name, location, and save

This file can now be used for programming units quickly and easily from the Connection page

NOTE: A setup file should only be created on the

same computer that will be used to program the

Harmony systems. Using a setup file that was created

on a different computer may cause issues due to

different Windows Region Settings numbering formats.

Harmony Setup – Edit Setup from File

If you would like to review settings from a saved file

Select “Edit Setup from File” from Harmony Setup page

Choose previously saved file

Settings are imported and shown on Harmony Setup page

Modify settings if necessary, then select “Send Settings to Harmony” to program the Harmony system

Verification Message

NOTE: A setup file should only be created on the

same computer that will be used to program the

Harmony systems. Using a setup file that was created

on a different computer may cause issues due to

different Windows Region Settings numbering formats.

Load Setup From File (OEM assembler programming)

Select “Load Setup From File” from initial screen

Select Setup File (previously saved)

Harmony System will be automatically programmed with the Setup

Clicking “OK” will take you back to the initial connection screen

Subsequent programming will automatically use same file without needing selection

• Speeds up OEM process

NOTE: A setup file should only be created on the

same computer that will be used to program the

Harmony systems. Using a setup file that was created

on a different computer may cause issues due to

different Windows Region Settings numbering formats.

After Firmware Update and Programming

If connected, disconnect USB Cable and reset rubber seal

Install the Main Harmony Connector (align arrows and press together)

Turn e-Bike system power on

Calibrate Harmony system (REQUIRED, see next page)

Calibration (REQUIRED prior to operation!)

Pedal the bicycle lightly and quickly through entire calibration procedure (preferably on a stand with rear wheel off the ground)

Initiate the Calibration Routine:

Continue pedaling lightly and quickly while the system shifts from “low” to “high” ratio multiple times and completes calibration

• Advanced Controller: Hold down the ‘Mode” Button until the rear hub begins shifting (5-7 seconds typically), then release the button

• Base Controller: Press and hold the Top and Bottom buttons simultaneously until the rear hub begins shifting (5-7 seconds typically), then release the buttons

Confirm Calibration & System Operation

Check system calibration

• Pedal the bicycle lightly and quickly while shifting through the ratio range (manual mode) and cadence range (automatic mode)

• Ensure the system is able to shift through the full range of the display without issue

• If operation is inconsistent while pedaling on a stand or riding, recalibrate the system

Reminders:

• Calibration:

– Without pedaling, Harmony will not calibrate correctly and function will be compromised

– Pedaling will get harder and easier during calibration as the Harmony system determines the shift range for the N360 CVP

– Pedal by hand lightly and quickly until the system stops shifting (less than 10 seconds)

• System Operation:

– The Harmony system will not shift if there is no pedal or wheel movement on the bicycle

– The ability to shift the N360 CVP is affected by input torque, and shifting can be delayed under high pedal torque and e-Bike assist levels

"Insert" Date via Date & Time

Appendix files

Low Cadence

• Very low cadence settings may have the following disadvantages:

– Very low cadence typically means high torque from the rider, which may compromise e-Bike battery range

– Very low cadence will shift through the ratio range of the N360 CVP more quickly, meaning cadence will increase once CVP is in full overdrive

High Cadence

• Very high cadence settings may have the following disadvantages:

– Some riders may not be able to pedal at very high cadences, and drivetrain will feel as if it “never shifts” because they don’t reach the cadence set point

– Some e-Bikes do not assist at higher cadence settings, so riders may be frustrated at a lack of assist from their e-Bike at higher cadence settings

Harmony Programming Tips

Cadence range

• Recommended to have at least 20 RPM difference between High and Low Cadence Settings

– Riders want to feel a cadence change, and less sensitive riders may not feel enough variation if the range is less than 20 RPM

– The smaller the cadence range, the more likely a rider will not be able to choose a comfortable cadence

Base Controller Recommended Settings

• High Cadence Setting: 70 RPM*

• Medium Cadence Setting: 55 RPM

• Low Cadence Setting: 40 RPM

Advanced Controller Recommended Settings

• High Cadence Limit: 85 RPM*

• Low Cadence Limit: 40 RPM

Harmony Programming Tips

* Some e-Bike systems do

not assist above 65 RPM -

plan High Cadence Setting

appropriately

Dimensions – Harmony Hub Interface

Dimensions – Harmony Advanced Rider Controller

Dimensions – Harmony Basic Rider Controller