SportsArt Fitness 5200 Repair manual

5100/5150/5200 Bicycle Troubleshooting Manual

Version 2; Date: 10-25-04

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

5100/5150/5200 Bicycle Troubleshooting Manual

This manual was designed as a troubleshooting guide for technicians in the field. If you have suggestions

or comments, please contact Bob Baumgartner at bob@sportsartamerica.com

. Thank you!

Version 1: June 11, 2002

Version 2: Oct. 25, 2004 – Updated to include 5150.

Note on Design Changes:

The 5100 and 5150 are very similar. The 5150 was a revision of the 5100. The revision was made in the

spring of 2002 mainly for aesthetic reasons. The 5100 had legs that extended in back from a round,

plastic case. These legs and the case, shown on page 1-1-1, were eliminated on 5150, and the drive

board and battery were placed under the main covers. The rear feet on the 5150 extend from a tube

like that shown on the 5200 on page 1-1-2. The 5100 and 5150 displays also differ in appearance.

Functions, except for minor program modifications, are the same.

In the summer of 2003, the 5150 and 5200 displays were changed. Models with the new displays

were called C5150 and C5200 to match the new C-series bikes. Program operation differs from

earlier models because the display key layout changed considerably.

0-0-0

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

Table of Contents

Chapter 1. Basic Configuration Diagrams

1-1-1 5100 Bicycle Electronic Component Placement Diagram

1-1-2 5200 Bicycle Electronic Component Placement Diagram

1-2-1 5100/5150/5200 Basic Configuration Diagram

1-3-1 5100/5150 Display Board Wiring Connection Diagram

1-4-1 5100/5150/5200 Drive Board Wiring Connection Diagram

1-5-1 5100/5200 Wire Hub Connection Diagram

Chapter 2. Operation Flow Charts

2-1-1 5100/5150/5200 Battery Switch Operation Chart, Cont. 2-1-2

2-2-1 5100/5150/5200 Generator Voltage Operation Chart, Cont. 2-2-2

2-3-1 5100/5150/5200 RPM Process Flow Chart, Cont. 2-3-2

2-4-1 5100/5150/5200 Resistance Operation Flow Chart, Cont. 2-4-2

2-5-1 5100/5150/5200 Display Keypad Function Flow Chart, Cont. 2-5-2

2-6-1 5100/5150/5200 POLAR Heart Rate Operation Flow Chart, Cont. 2-6-2

2-7-1 5100/5150/5200 HTR Operation Flow Chart

2-8-1 5100/5150 Remote Control Function Flow Chart, Cont. 2-8-2

0-0-1

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

Table of Contents

Chapter 3. Test Configurations

3-1-1 5100/5150/5200 Testing the Generator, Cont. 3-1-2

3-2-1 5100/5150/5200 Testing the Battery, Cont. 3-2-2

3-3-1 5100/5150/5200 Testing the Electro-Magnet, Cont. 3-3-2

3-4-1 5100/5150/5200 Testing Resistance Voltage at the Drive Board, Cont. 3-4-2

3-5-1 5100/5150/5200 Testing the Infrared Optic Sensor, Cont. 3-5-2

3-6-1 5100/5150/5200 Testing the POLAR Heart Rate, Cont. 3-6-2

3-7-1 5100/5150/5200 Testing the HTR Board, Cont. 3-7-2

3-8-1 5100/5150/5200 Testing the Remote Receiver, Cont. 3-8-2

3-9-1 5100/5150/5200 Testing the Display Board VCC Voltage, Cont. 3-9-2

3-10-1 5100/5150/5200 Testing the Drive Board VCC Voltage, Cont. 3-10-2

3-11-1 5100/5150/5200 Testing the Drive Board Power Transistor, Cont. 3-11-2

0-0-2

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

Chapter 1. Basic Configuration Diagrams

1-0-0

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

5100 Bicycle Electronic Component Placement Diagram

1-1-1

Display Panel

HTR

Handlebar

Drive Board

Flywheel and

Magnet

Optic

Sensor

Battery

Remote

Receiver

Remote

Transmitter

Generator

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

5200 Bicycle Electronic Component Placement Diagram

1-1-2

Display Panel

HTR

Handlebar

Drive Board

Flywheel and Magnet

Optic Sensor

Battery

Generator

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

5100/5150/5200 Basic Configuration Diagram

Display Board

Drive Board

Generator

Optic Sensor

Magnet

Battery

16 PIN

CBALE

WHITE-BLACK

2 PIN

CABLE

BLUE-BLUE

RED-YELLOW-

BLACK

Remote

Control/

Transmitter

Heart Rate

Board

3 PIN CABLE 3 PIN CABLE

1-2-1

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

5100/5150 Display Board Wiring Connection Diagram

J2

J4

J5

POLAR Heart

Rate Board

3 pin cable

Drive Board

16 PIN CABLE

Soft Keys

CNT3

CNT2

1-3-1

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

5200 Display Board Wiring Connection Diagram

J2

J4

J5

HTR Board

& HTR

Handlebar

POLAR Hear

t

Rate Board

3 pin cable

3 pin

Drive Board

16 PIN CBALE

Soft Keys

CNT3

CNT2

1-3-2

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

5100/5150/5200 Drive Board Wiring Connection Diagram

CN3

CN2CN1

Display BoardBatteryGenerator Magnet

Infrared

Optical

Sensor

BALCK

WHITE

YELLOW

RED

BLUE

BLACK

WHITE

16 PIN CBALE

F1

F2

1-4-1

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

5100/5150 Wire Hub Connection Diagram

CN1

CN2

TO CONTROL

TO DRIVER

CN4

CN3

HTR Board

Remote

Receiver

Drive Board

16 PIN

To Display Board

16 PIN

HTR HANDLE

BAR

1-5-1

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

Chapter 2. Operation Flow Charts

2-0-0

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

5100/5150/5200 Battery Switch Operation Chart

1. Configuration

Display Board

Drive Board

Battery

2 pin

V

Soft Keys

VCC

16 pin

ON

2. Operation

Order

Item Operation

1 Battery 1. When the bicycle isn’t being ridden, drive board temporary power supply

allows the display board to light up.

2. Riding for 20 minutes recharges the battery.

2 Soft keys 1. When the unit is off, pressing the display board “ON” key sends a message

prompting the drive board to start unit operation.

3 Display board 1. The soft key “ON” signal is sent to the drive board.

4 Drive board 1. The “ON” signal sends the battery voltage to the drive board.

2. After stabilizing the battery voltage, the drive board provides power to the

display board, starting up the display.

5 Display board 1. After getting power, the display board beeps;

2. The display windows light and numbers appear.

2-1-1

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

3. Operational Steps

Steps Operation

1 Display panel is inactive, dark.

2 Press the ON key.

3

1. Display panel beeps once. Main display shows “MAN’L”

2. Windows show “0”.

2-1-2

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

5100/5150/5200 Generator Voltage Operation Chart

1. Configuration

Display Board

Drive BoardGenerator

2 pin

V

Battery

2 pin

VCC

Recharge

16 pin cable

2. Operation

Order

Item Operation

1 Generator 1. When the bike is ridden, the generator makes power.

2 Drive

Board

1. The generator provides voltage to the drive board.

3 Display

Board

1. The drive board VCC circuit provides power to the display board.

2. The display lights.

4 Battery 1. The drive board provides processed power from the generator to recharge the

battery.

2-2-1

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

2. Operational Steps

Steps Operation

1 Display panel is inactive, dark.

2 Start riding the bike.

3 The display panel beeps once. The main display shows “MAN’L”. Other windows

show “0”.

2-2-2

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

5100/5150/5200 RPM Process Flow Chart

1. Configuration

Display

Drive Board

Infrared Optic

Sensor

16 pin cable

3 pin cable

Flywheel/

Reflective

Sticker

CLOCK

CLK

CLOCK

2. Operation

Item Operation

Flywheel 1.When the bike is ridden, the reflector sticker on the flywheel rotates.

Infrared Optic

Sensor

1.The optic sensor emits a signal to the sticker and detects the sticker teeth

rotation.

Drive Board

1. Once the infrared optic sensor signal information is processed, the drive

board CLK indicator lights.

2. The drive board CLK indicator flashes or remains lit.

Display Board

1. The program processes the infrared optic sensor information, calculating

the RPM value.

2. The RPM value shows on the RPM window.

2-3-1

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

3. Operational Steps

Step Operation

1 Start riding the bike; the display beeps and starts operating.

2 Start riding the bike; the flywheel rotates (the reflective sticker

rotates).

3 The RPM window shows the RPM value.

4 If the flywheel rotates once every second, the RPM window shows

“60”.

Note：RPM= revolutions per minute

2-3-2

SportsArt 5100/5150/5200 Bicycle Troubleshooting Manual

5100/5150/5200 Resistance Operation Flow Chart

1. Configuration

Display Board

Drive Board

Infrared

Optic Sensor

Magnet

Generator

3 pin

2 pin

2

p

i

n

PWM

Vload

Clock

V

16 PIN

Clock

Flywheel

2. Operation

Order

Item Operation

1 Generator 1. The generator produces power when the bicycle is ridden.

2. The generator supplies the drive board with power.

3. And the load resistance receives the power it needs.

2 Infrared Optic

Sensor

1. The optic sensor emits a signal to the flywheel reflective sticker.

2. The sensor determines the reflective sticker tooth count.

2-4-1

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