Power/Signal Diagram
Power/Signal Action
1. Power from the wall socket goes through the plug and cord, through the fuse,
through the on/off switch, and into the drive board.
2. Wall power goes from the drive board to the transformer, where it is broken down
into smaller voltages for various circuits. At this point, power is still VAC.
3. The drive board converts this power into VDC for use by other components, such
as the display and resistance motor.
4. Power travels to the display through the data cable.
5. When the user presses a command key, the display main program IC emits a
signal that travels down the data cable to the drive board. The drive board puts out
or stops putting out power in response to display commands.
For wiring or voltage specifications, tur n to the following:
A. Wiring at the Fuse Holder: Page 2
B. Wiring at the On/Off Switch: Page 2
C. Drive Board Connectors, Voltage Specs, and LEDs: Page 3
D. Transformer Test: Page 3
E. Display Power Test: Page 4
F. Speed Sensor Test: Page 4
G. Resistance Operation and Troubleshooting: Page 5
Fuse
On/Off
Switch
Transfor mer
Drive Board
Magnet &
Reed Switch
Display Board
VR
Motor
Power cord & plug
Data
Cable
Key
Power:
Signal:
A
B
C
D
E
F
G
C51R/C51U Bike Troubleshooting Notes - April 20, 2004
Page 1
Cable Connectors
A. Incoming power wires: Black and white = 110-120 VAC.
B. Transformer wires: Red-red = 110-120 VAC;
yellow-yellow = 10 VAC; white-white = 9.8 VAC.
C. Optic sensor wires: black-black.
D. Resistance VR wires: blue, white, black.
Resistance motor wires: orange and brown.
E. Data cable to display.
LEDs
LED1: Power LED - Lights when power is turned on;
extinguishes when off.
LED2: Power LED - Lights when power is turned on;
extinguishes when off.
LED5: "Optic Sensor LED" - Lights when magnet and reed switch
make contact; extinguishes when there is no contact.
A
B
C
D
E
LED1
LED2
LED5
C. Drive Board Connectors, Voltage Specs, and LEDs
D. Testing the Transformer
Transformer testing works off this simple principle. If there's power
in, but no power out, the transformer is bad. Relace it.
With the unit power on, place voltmeter probes as follows:
Red-Red (primary=input): 110-120 VAC
Yellow-Yellow (secondary=output) : 10 VAC
White-White (secondary=output): 10 VAC
Page 2
C51R/C51U Bike Troubleshooting Notes - April 20, 2004
To ground
Screw
To On/Off
Switch
Black
Black
White
Green
L
L
N
Fuse
Power cord
connector
To On/Off
Switch
Back side of power cord connector and fuse holder
A. Wiring at the Fuse Holder
B. W iring at the On/Off Switch
Black
White
To drive board
Black
White
From fuse
Back side of On/Off switch
To drive board
From fuse
L
L
N
N
Page 3
C51R/C51U Bike Troubleshooting Notes - April 20, 2004
E. Display Power Test
The display does not have a power indicator LED. If the display LEDs don't
light, detect power to the display by placing probes on the capacitor near
the data cable. Normal reading: 5 VDC. If there is power here but the LEDs
don't light, replace the display board. If there is no voltage here, inspect
the data cable and drive board.
F. Speed Sensor Test
Operation
As the drive pulley rotates, a reed switch passes a magnet. Each time the
reed switch passes the magnet, the circuit is closed, creating a signal to
the display. The display main IC translates this signal into the speed and
distance readout.
a voltmeter to the audible continuity setting.
Symptom of Malfunction
A sign of a failing speed sensor circuit is no speed or distance on the
display. Resistance is not lost on this unit.
Troubleshooting
1. LED test: Rotate the drive pulley so the magnet and reed switch pass by
each other. Normal: LED5 on the drive board lights when the magnet and
reed switch pass by each other.
2. Voltmeter test: Put Place
probes on the two speed sensor wires. Rotate the drive pulley so the reed
switch passes by the magnet. Normal: The meter beeps, indicating
continuity, when the magnet and reed switch meet. This indicates that the
magnet/reed switch are OK.
3. Test the magnet by seeing if it attracts metal.
4. If the magnet or reed switch fail these tests, replace it.
Page 4
C51R/C51U Bike Troubleshooting Notes - April 20, 2004
G. Resistance Operation and Troubleshooting
Operation
1. When the user presses key commands, signals travel from the display
to the drive board.
2. The drive board puts out power to the motor; the motor operates.
3. As the motor operates, a variable resister (VR) moves. Movement
changes the VR output voltage.
4. The VR output signal travels through wires to the drive board, then up
the data cable to the display.
5. The display reads the VR signal, which indicates the position of the
motor. When the VR voltage reaches a target voltage (which equates to a
certain resistance level), the display sends a signal to shut off power to
the motor.
6. The drive board shuts off power to the motor. The motor stops moving.
Note: Resistance is increased or decreased through movement of
magnets in the flywheel. The closer the magnets are to the flywheel metal
surface, the stronger the attraction, thus the harder the resistance.
Resistance Motor Specifications
Orange and brown wires: up = + 5 VDX; down = -5 VDC.
VR Voltage Specifications (Approximately)
Wire colors: Black, white, blue
Level 1: Black & white = 4.68; white & blue = 0.35
Level 5: Black & white = 3.81; white & blue = 1.22
Level 10: Black & white = 2.70; white & blue = 2.33
Level 15: Black & white = 1.61; white & blue = 3.41
Level 20: Black & white = 0.48; white & blue = 4.55
Symptom of Malfunction
1. Resistance doesn't change when the user presses a resistance
command key or the resistance should change in a program.
Troubleshooting
Use the specs above to verity that the drive board is OK; It's putting out
power to the motor. If the VR is off, replace the VR/motor box. If the
problem is that the little lever that moves the magnets is jammed, try
taking out the VR/motor and working the mechanism by hand to loosen it.
Then reinstall the VR/motor box.
Page 5
C51R/C51U Bike Troubleshooting Notes - April 20, 2004
Fuse
On/Off
Switch
Transfor mer
Drive Board
Magnet &
Reed Switch
Display Board
VR
Motor
Power cord & plug
Data
Cable
Key
Power:
Signal:
Spor tsAr t Bike Power/Signal Flow Char t
506P/508P/C51U/C51R
Resistance
Speed Sensor
Spor tsAr t Bike Over view - April 20, 2004
Fuse
On/Off
Switch
Transfor mer
Drive Board
Display Board
Power cord & plug
Data
Cable
Key
Power:
Signal:
Spor tsAr t Bike Power/Signal Flow Char t
5002B/5005B
Speed Sensor
Resistance
Electro-
Magnet
Optic Sensor
Spor tsAr t Bike Over view - April 20, 2004
Generator
Drive Board
Display Board
Data
Cable
Key
Power:
Signal:
Spor tsAr t Bike Power/Signal Flow Char t
5100/5150/5200
Optic Sensor
Speed Sensor
Electro-
Magnet
Resistance
Note: The diagram for 5002/5005 would be similar except for two major
differences: 5002/5005 have a generator in the flywheel that produces
AC power, and they don't have an optic sensor. They use the wave
frequency instead of an optic sensor.
VDC
Batter y
Spor tsAr t Bike Over view - April 20, 2004
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