GE eBike III basic Series, eBike III comfort Series Service Manual

GE Healthcare

eBike III basic

eBike III comfort

with and without NIBP

Service Manual

2018111-336 Revision B

Manual InforMatIon

• GE Medical Systems Information Technologies GmbH considers itself responsible for the eects on safety,reliability, and
performance of the equipment, only if:

- assembly operations, extensions, readjustments, modications, or repairs are carried out by ergoline GmbH or by
persons authorized by GE Medical Systems Information Technologies GmbH,

- the electrical installation of the relevant room complies with the applicable national and local requirements,

- and the instrument is used in accordance with the intended use and the instructions for use.

• This manual contains service information; operating instructions are provided in the operator’s manual of the
instrument.

• This manual is in conformity with the instrument at printing date.

• The Service Manual eBike III is valid for the following devices:

2017911-301 EBIKE III BASIC
2017911-303 EBIKE III BASIC WITH NIBP
2017911-305 EBIKE III COMFORT
2017911-307 EBIKE III COMFORT WITH NIBP

Software Version GF 1.x and optional with Module “NIBP“ and Supply and Service Items.

Manufacturer: Distributor:

ergoline GmbH GE Medical Systems Information Technologies, Inc
Lindenstraße 5 8200 West Tower Avenue
D-72475 Bitz Milwaukee, WI 53223 USA
Germany Tel. [phone] 437 1171 (US only)
Tel.: [phone] - 0 1 800 668 0732 (Canada only)
Fax: [phone] - 128 Fax [phone]
e-mail: [e-mail]
internet: http://www.ergoline.com

©Copyright 2016 General Electric Company. All rights reserved.

2018111-336 Rev. B eBike III basic / comfort - 3 -

revIsIon HIstory

This manual is subject to the GE Medical Systems Information Technologies change order service.
The revision code, a letter that follows the document part number, changes with every update of the manual.
The initial version of the manual has the letter B.

Part No. Revision Code Date Comment

2018111-336 Rev A 2016-03 Engineering Release

2018111-336 Rev B 2016-04 Initial Release

- 4 - eBike III basic / comfort 2018111-336 Rev. B

Contents

Manual Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Leakage currents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Technical Safety Inspections and Inspections of the Measuring Systems . . . . . . . . . . . . . .7

eBike III basic / comfort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Very important service note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Final checkout procedure / Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Checkout procedure after repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Test procedure “RPM / Load“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Test procedure “Blood pressure (NIBP)“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Electronic modules / Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Description of electronics and cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

abbreviations (Electronic modules / PCBs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Electronic carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Dismounting of the electronic assembly group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Block diagrams bike ergometer electronics eBike III . . . . . . . . . . . . . . . . . . . . . . . 21

Wiring diagrams bike ergometer eBike III . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

DTU - Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

DTU - Patient display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

DTU - Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Load regulation and interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

LIU - Load regulation and interface board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

NIBP blood pressure unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Placement of pressure tubes (schematic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Block diagram of cabling of the bloodpressure unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

BPU - Blood pressure board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Miscellaneous modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

SMU - saddle height motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Mechanical assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Mounting the Handlebar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Handlebar - Adjust xture (inclination) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Handlebar - Dismounting / mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Remove Ergometer Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Plastic screw seals (caps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Dismounting the Handlebar pole housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Dismount pedal cranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Remove housing of the eBike III basic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Remove housing of the eBike III comfort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

2018111-336 Rev. B eBike III basic / comfort - 5 -

Saddle pillar exchange (eBike III basic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Saddle motor (eBike III comfort) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Strain gauge module exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

RPM module exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Load unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Load unit replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Power switch replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Power supply unit replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Remove Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Software Control terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Turning the System On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Settings Control Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

ECG Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

NIBP Beep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

NIBP mmHg / kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Dynamic Load Cal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Software Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Baudrate 8N2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Saddle Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Manual Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

System Cong. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

NIBP Test / NIBP Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Analog Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Alignment / Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Dynamic Load Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Calibration of Blood pressure unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

NIBP Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

NIBP Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Software update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Connectivity and installation eBike III to GE ECG devices . . . . . . . . . . . . . 81

eBike III to CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

eBike III to CARDIOSOFT / CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

USB interface / driver installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

eBike III to MAC 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

eBike III to MAC 5500 (MAC 5000 ST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Installation of ther COM - Interface extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Addendum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Errorcodes Software eBike III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Error code bits DTU (Control terminal PCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Error code bits LIU (Load regulation and interface PCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Error code bits SMU (Saddle-Motor PCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Error code bits BPU (Blood pressure module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Error code bits COM (External Analog interface module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Technical Specications eBike III basic / comfort . . . . . . . . . . . . . . . . . . . . . . . 121

Technical Specications eBike III Blood pressure module . . . . . . . . . . . . . . . . . . . 123

- 6 - eBike III basic / comfort 2018111-336 Rev. B

eleCtrICal safety

leakage Currents

MeasurIng equIpMent

The measuring equipment used for the electrical safety
tests must be inspected and calibrated at regular intervals
(refer to manufacturer of measuring equipment).
The measurement results must be documented.

eBIke III BasIC / CoMfort

The eBike III basic/comfort ergometers are protection
class II equipment (no connection to protective ground).
The necessary electrical safety tests for these devices
together with the limit values are listed in the
chapter titled “eBike III basic/comfort - Preventive

maintenance“.

teCHnICal safety InspeCtIons and

nspeCtIons of tHe MeasurIng systeMs

I

The load unit is recommended to be inspected to the
approved regional standards at intervals of 2 years by a
GE Medical Systems Information Technologies authorized
service technician, and calibrated or repaired if necessary.

Calibration instructions for the NIBP module can be found
in this Service manual. Follow these instructions to display
the BP values with the test setup according to
EN 1060-1 and EN1060-3 or appropriate regional standard.

Warning

• Equipment Damage •

• The regulations about handling ESD sensitive components
must be observed.

Warning

• Patient Hazard, Equipment Damage

• EN 62353 and/or IEC 60601-1 requirements must be
satised during repair, modications and inspections of
medical electrical equipment.

• To ensure that equipment functions faultlessly and
without presenting any hazard after service interventions,
it must be subjected to the test procedures stipulated for
the dierent device categories.

• A device is considered to be unsafe, when:

- it cannot be repaired

- the user does not wish to have the device repaired.
In this case, the operator must be informed in
writing of the hazard presented by the device.
The same remark must be annotated on the
service report and on the service invoice..

The measurement results must be documented.

Warning

• Patient Hazard, Equipment Damage

• Use original spare parts only.

• For information about product changes, refer to the
manufacturer’s original documentation only.

• Observe the fuses’ original ratings, characteristics and
Ampere interrupting capacity.

• Parts of the device that ensure its safe operation must be
neither damaged nor obviously unsuitable. This applies to
insulation and insulating components in particular.

• Power cords must be visually inspected for signs of
damage before connecting them to the power line.

2018111-336 Rev. B eBike III basic / comfort - 7 -

eBIke III BasIC / CoMfort

very IMportant servICe note

Warning

• Hazard, Equipment Damage

• When work at the bottom of the eBike III is required (e.g. access to electronic moduls, exchange

of load unit or installation of COM module) the eBike III should be carefully placed on one side

by grabbing it at the handlebar and the saddle.

• DO NOT tilt the eBike III forward to stand on the handlebar - this is an unsecure and instable

position!

preventIve MaIntenanCe

Note

• eBike III basic / comfort is a protection class II device (no connection to protective ground).

• Preventive maintenance is recommended to be performed every 2 years.

fInal CHeCkout proCedure / funCtIonal test

1. Check the setup for stability, adjust with leveling device if required.

Expected result: No instability Pass/Fail

2. Visually inspect the device:

- inspect cables / power cord

Expected result: No damage or wear detected Pass/Fail

- 8 - eBike III basic / comfort 2018111-336 Rev. B

3. Check cranks and pedals:

- pedals have no signs for damage / wear

- pedals securely xed on cranks

- crank screws securely xed (torque 40 Nm ± 2 Nm) on axis

Expected result: Cranks and pedals OK Pass/Fail

eBike III basic

- Check bellow on saddle for damage / wear / cracks

- Check handlebar adjustment (angle)

- Check saddle height adjustment

- Check that the clamping levers (saddle [height] and handlebar [angle] adjustment) are tight.
Grease the thread of the saddle clamping lever.
(Use of an universal high-performance lubricant such as OKS 470 is recommended.)

eBike III comfort

- Check handlebar adjustment (angle)

- Check that the clamping lever is tight.

- Check electrical saddle adjustment: adjust minimum and maximum saddle height;
then return saddle to mid-level

- Check correct indication of saddle height display

- Check that the clamping lever for handlebar adjustment (angle) is tight

Expected result: Adjustments work and levers are tight, thread properly greased Pass/Fail

4. Using the power cord, connect the device to the mains power line and place the power switch in the ON position
Wait for self test to end:

- check LCD for error messages (refer to „Turning the System On“ on page 60)

- check the software version in the service menu for correct version GF 1.x
(refer to „Software update“ on page 78)

- check the “error log le“ in service menu (refer to „Error log“ on page 67)

Expected result: Device powers on without errors, FW is correct version, no errors logged Pass/Fail

5. Check speed indication (rpm) is displayed on LCD and the additional speed indication on the patient display.
Check noise level of idling drive unit (for example, for grinding noises or noise from the bearing)

Expected result: Speed displayed on both displays and no noticeable noise Pass/Fail

6. Units with NIBP module:

- Check cu tubing and tubing connections, microphone connectors

- Check blood pressure measurement on test subject at rest (refer to the „eBike III operators manual“)

- Check blood pressure readings are displayed on LCD

Expected result: BP values are displayed and in proper range Pass/Fail

7. Set manual load (see „Manual Load“ on page 66), change load (for example, 50 W, 100 W)

- Check load level and load indication

Expected result: Load is set and changes as expected Pass/Fail

8. If ergometer is remote controlled from ECG recorder or PC-ECG system:

- Check connecting cable

- Check load control via ECG recorder or PC ECG system

- Check remote start if applicable

Expected result: Ergometer can be controlled by external unit Pass/Fail

2018111-336 Rev. B eBike III basic / comfort - 9 -

eleCtrICal safety

Perform electrical safety checks when indicated - current leakage test results meet requirements.
All indicated electrical safety checks require a pass/fail indication for steps performed.
Record the measurement values in your debrief.

Step Condition

(1)

UUT - ON

(2)

Result Leakage

Current limits

Earth Leakage Current

1. Forward Polarity N/A

2. Neutral open, Forward Polarity N/A

3. Neutral open, Reverse Polarity N/A

4. Reverse Polarity N/A

Enclosure Leakage Current

1. Forward Polarity NC __________ μA Pass/Fail 100 μA

2. Neutral open, Forward Polarity SFC __________ μA Pass/Fail 500 μA

3. Ground open, Forward Polarity N/A

4. Ground open, Reverse Polarity N/A

5. Neutral open, Reverse Polarity SFC __________ μA Pass/Fail 500 μA

6. Reverse Polarity NC __________ μA Pass/Fail 100 μA

Patient Leakage Current to Ground (3)

1. Forward Polarity NC __________ μA Pass/Fail 100 μA

2. Neutral open, Forward Polarity SFC __________ μA Pass/Fail 5000 μA

3. Ground open, Forward Polarity N/A

4. Ground open, Reverse Polarity N/A

5. Neutral open, Reverse Polarity SFC __________ μA Pass/Fail 5000 μA

6. Reverse Polarity NC __________ μA Pass/Fail 100 μA

Ground Continuity Resistance

1. AC mains power cord ground prong to
exposed metal surface (ground lug)

(1) NC = Normal Condition
SFC = Single Fault Condition
N/A = Not Applicable
(2) UUT = Unit Under Test
(3) Test applies for eBike III with blood pressure unit only - measuring point is the microphone connector

N/A

- 10 - eBike III basic / comfort 2018111-336 Rev. B

CHeCkout proCedure after repaIr

After replacing a FRU or performing certain tasks, it is necessary to also inspect the unit and perform a series of checks to
ensure the unit is functioning properly. The following tables identify the inspections and checkout procedures to perform.

To use the tables, locate the relevant FRU or task in the rst column and note the required checkout procedure(s) for the
item(s). Then locate the corresponding instructions in the sections following the tables.

fru repaIrs (exCHange)

FRU P/N Functional Checkout Procedure

Plastic cover parts 2018111-300

Details

1,2,3,5,6,24 42

Electrical

safety checks

2018111-303

2018111-304

2018111-326

2018111-327

2018111-328

Saddle 2018111-022 1,11,12,15,16

Saddle clamp lever 2018111-148 1,11,12,15,16

Saddle tube 2018111-144

1,2,3,5,6,11,12,1718,19,20 42

2018111-310

Saddle guidance tube 2018111-332 1,2,3,5,6,12,17,18,19,20,24,40 42

Saddle motor 2018111-337 1,2,3,5,6,8,10,12,1718,19,20,24,40 42

Leg leveler(s) 2018111-021 1,23,24

Wheel set(s) 2018111-311 1,7,23,24

Pedal(s) / crank(s) 2018111-301

1,28,41

2018111-302

Handle bar 2018111-324 1,13,14

Handle bar clamp lever 2018111-322 1,13,14

Drive unit 2018111-306

1,2,3,8,9,10,21,22, 24,27,28,29,41 42

2018111-307

Strain gauge module 2018111-308 1,2,3,8,9,10,21,22, 24,27,28,29,39,41 42

RPM sensor 2018111-309 1,2,3,8,9,10,21,22, 24,27,28,29,39,41 42

Power supply 2018111-152 1,2,3,5,6,8,10,22, 24,27,28,29 42

2018111-336 Rev. B eBike III basic / comfort - 11 -

FRU P/N Functional Checkout Procedure

Details

Electrical

safety checks

Power switch 2018111-305

1,2,3,5,6,8,10, 24,27,28,29 42

2018111-339

LIU (PCB) 2018111-312 1,2,3,8,9,10,21,22,

24,25,26,27,28,29,35,39

SMU (PCB) 2018111-314 1,2,3,8,9,10,21,22,

24,25,26,27,28,29,35,40

Blood pressure

components

2018111-313

2018111-315

1,2,3,8,9,10,21,22, 24,26,30,31,32,33,
34,35,36,37,38

42

42

42

2018111-316

2018111-317

2018111-318

Terminal cuff connector 2018111-323 1,2,3,4,8,10, 24,26,32,33,34,36,37,38 42

Control terminal w/o NIBP 2018111-321 1,4,8,21,22, 24,25,26,27,29,35 42

Control terminal with NIBP 2018111-320 1,4,8,21,22, 24,25,26,27,29,30,31,32,

33,34,35,36,37,38

42

non fru repaIrs

Repair Functional Checkout Procedure

Details

Software update 4,21,22, 24,26,27,30,32,33,34

Load calibration (recommended every 2 years) 1,2,3,21,22, 24,26,27,39

Electrical safety checkout (recommended every 2 years) 1,2,3,4,5,6,21,22,24,26 42

Electrical

safety checks

- 12 - eBike III basic / comfort 2018111-336 Rev. B

funCtIonal CHeCkout proCedure detaIls

Visual / functional checks

1. External surfaces passed inspection? pass/fail

2. Plastic cover screws complete and xed? pass/fail

3. Plastic caps on housing screws complete? pass/fail

4. Terminal foil, LCD and LED passed inspection? pass/fail

5. AC Power cord passed inspection? pass/fail

6. AC power cord strain relief mounted and cable secured pass/fail

7. Casters passed inspection? pass/fail

8. All board connectors and cable connectors connected and secured? pass/fail

9. All PCBs xed with screws on electronic carrier? pass/fail

10. All harnesses‘ and internal wiring has been secured? pass/fail

11. Bellow on saddle passed inspection? pass/fail

12. Saddle xture on saddle tube passed inspection? pass/fail

13. Handlebar adjustment (angle) passed inspection?

(refer to „Handlebar - Adjust xture (inclination)“ on page 37) pass/fail

14. Clamping lever handlebar angle adjustment passed inspection? pass/fail

15. eBike III basic only: Mechanical saddle height adjustment passed inspection? pass/fail

16. eBike III basic only:Clamping lever saddle height passed inspection

(tight; thread of lever is greased)? pass/fail

17. eBike III comfort only: Saddle motor keys at terminal functional? pass/fail

18. eBike III comfort only: Electrical saddle adjustment passed inspection? pass/fail

19. eBike III comfort only: Check correct indication of saddle height display pass/fail

20. eBike III comfort only: Check if saddle tube moves tightly and without any mechanical wobble

in saddle tube guidance. pass/fail

21. Check software (rmware) is at correct version GF 1.x

(refer to „Software update“ on page 78) pass/fail

22. Check and clear the “error log le“ in service menu

(refer to „Error log“ on page 67) pass/fail

23. Check stable position on oor, check leveler adjustment pass/fail

Operational Checks

24. Power-up self-test passed (no error messages on LCD)? pass/fail

25. LCD contrast ok?

(refer to „Contrast“ on page 62) pass/fail

26. eBike successfully communicates with ECG device?

(refer to „Connectivity and installation eBike III to GE ECG devices“ on page 81) pass/fail

27. Check load level and load indication on LCD pass/fail

28. Set manual load (see „Manual Load“ on page 66),
change load (for example, 50 W, 100 W)
Check noise level of idling drive unit (for example, for grinding noises or noise from the bearing) pass/fail

29. Check speed indication (rpm) displayed on LCD and the additional speed indication
on the patient display. pass/fail

30. Blood pressure measurement successfully initiated by ECG device? pass/fail

31. Blood pressure values successfully communicated to ECG device pass/fail

32. Check cu tubing and tubing connections, microphone connectors pass/fail

33. Check blood pressure measurement on test subject at rest pass/fail

34. Check blood pressure readings on LCD pass/fail

Tests and Calibration Checks

35. System conguration and settings correct?
(refer to „System Cong.“ on page 66) pass/fail

36. NIBP test successfully passed?
(refer to „NIBP Test“ on page 76) pass/fail

37. NIBP calibration successfully performed?
(refer to „NIBP Calibration“ on page 77) pass/fail

2018111-336 Rev. B eBike III basic / comfort - 13 -

38. Check and clear the “NIBP error log le“ in service menu

(refer to „Error log“ on page 67) pass/fail

39. Dynamic load calibration with test bench successfully performed?

(refer to „Dynamic Load Calibration“ on page 72) pass/fail

40. Electrical saddle adjustment: adjust minimum and maximum saddle height

(refer to „Saddle Calibration“ on page 64) pass/fail

41. Check torque values for screws pass/fail

Electrical Safety Checks

42. Current leakage and ground continuity test results meet requirements?
Perform electrical safety checks when indicated (refer to „Electrical Safety“ on page 10).
All indicated electrical safetychecks require a pass/fail indication for steps performed.
Record the measurement values. pass/fail

- 14 - eBike III basic / comfort 2018111-336 Rev. B

test proCedure “rpM / load“

Note

• Unless regulatory requirements of the country dene a dierent test procedure or test intervall, it is recommended to perform the
test “RPM / load“ at least every 2 years.

Note

• An external calibration device for dynamic load testing is needed to perfom the following test procedures
(“ergoline ergotest 550“ - order direct from Ergoline P/N 705890) or equivalent device.

• Please refer to the operator manual of the used calibration device.

test preparatIon

1. Dismount BOTH (!) pedal cranks of the eBike III - see “Dismount pedal cranks“ under section „Dismount pedal cranks“
on page 41.

2. Follow the operator manual from the manufacture of calibration device being used to connect the calibration device
with the axis of the eBike III.

3. If supported by the calibration device, connect the eBike III interface (RS-232 or USB) with the calibration device.

4. Connect the calibration device to the PC / notebook setup containing the software and conguration to work with the
device.“

5. Start the test software of the calibration device.

rpM test protoCol

1. Apply a load of 100 W to the eBike III
(-either by command of the test software or manually on the eBike III (see „Manual Load“ on page 66).

2. Perform the following RPM tests step by step. Note the results in the table or use the printed protocol of the
calibration device to document the test.

Step Target RPM Actual RPM Deviation max. Pass / Fail

#1 30 ± 1 rpm

#2 40 ± 1 rpm

#3 50 ± 1 rpm

#4 100 ± 1 rpm

#5 120 ± 1 rpm

2018111-336 Rev. B eBike III basic / comfort - 15 -

load test protoCol

1. Perform the load test (RPM is set by the calibration device / load of the eBike III is set either by command of the test
software or manually on the eBike III -see „Manual Load“ on page 66) step by step.

2. The actual load is measured and displayed by the calibration device software. Note the results in the table or use the
printed protocol of the calibration device to document the test.

Step RPM set Target Load Actual Load Deviation max. Pass / Fail

#1 40 25 ± 3 Watt

#2 40 50 ± 3 Watt

#3 40 100 ± 5 Watt

#4 70 200 ± 10 Watt

#5 90 300 ± 15 Watt

#6 100 500 ± 25 Watt

- 16 - eBike III basic / comfort 2018111-336 Rev. B

test proCedure “Blood pressure (nIBp)“

Note

• Unless regulatory requirements of the country dene a dierent test procedure or test interval, it is recommended to perform the
test “Blood pressure (NIBP)“ at least every 2 years.

Note

• A calibrated NIBP measure instrument set is needed to perfom the following test procedures.

• Please refer to the operator manual of the used device.

test preparatIon

1. Power eBike III on and enter service menu / NIBP test (-see „Calibration of Blood pressure unit“ on page 75).

2. Connect the calibration equipment with the eBike III cu connector.

leak-tIgHtness test

1. Use the connected test equipment to apply the target pressure (see table below) to the eBike III cu connector, wait
until the pressure in the system has stabilized (approx. 5 sec).

2. After 1 min check the actual pressure and note the pressure drop in the table

Step Target Pressure Actual pressure drop Pressure drop max. Pass / Fail

#1 50 mmHg mmHg / min < 6 mmHg / min

#2 300 mmHg mmHg / min < 6 mmHg / min

aCCuraCy test

1. Use the connected test equipment to apply the target pressure (see table below) to the eBike III cu connector, wait
until the pressure in the system has stabilized (approx. 5 sec).

2. Check the actual pressure displayed on the eBike III display and note the value in the table.

Step Target pressure Displayed pressure (eBike III) Deviation max. Pass / Fail

#1 0 ± 3 mmHg

#2 50 ± 3 mmHg

#3 100 ± 3 mmHg

#4 150 ± 3 mmHg

#5 200 ± 3 mmHg

#6 250 ± 3 mmHg

#7 300 ± 3 mmHg

2018111-336 Rev. B eBike III basic / comfort - 17 -

tools

The following tools (metric) are recommended to disassemble the eBike III devices:

Flat bladed screwdrivers: Allan keys:

1 pc. 1.0 x 0.18 mm 1 pc. 2.5 mm straight and elbow
1 pc. 4.5 x 0.8 mm 1 pc. 3 mm straight and elbow
1 pc. 4 mm straight and elbow

Philips screwdrivers: 1 pc. 5 mm straight and elbow

1 pc. PH 2
1 pc. PH 3 1 pc. 8 mm straight and elbow
1 pc. extension for Allen key 8 mm (drive unit exchange)

1 pc. 6 mm straight and elbow

Fork wrenches: Socket wrenches:

1 pc. 10 mm 1 pc. 10 mm
1 pc. 13 mm 1 pc. 13 mm
1 pc. 14 mm 1 pc. 14 mm
1 pc. 17 mm 1 pc TORX T30
1 pc. 19 mm

Pliers

1 pc. side cutter
1 pc. flat nose pliers

Special tools

1 pc. crank extractor (P/N 2005737-001)
1 pc. round pin, max. 3 mm, minimum length 15 mm
1 pc torque wrench (10 - 100 Nm)
1 pc. calibrated NIBP measurement instrument set
1 pc. external calibration device for dynamic load testing
(“ergoline ergotest 550“ - order direct from Ergoline P/N 705890) or equivalent device

- 18 - eBike III basic / comfort 2018111-336 Rev. B

eleCtronIC Modules / asseMBly

overvIew

desCrIptIon of eleCtronICs and CaBlIng

The electronics of the eBike III are based on a modular
concept.
Each module has its own processor with appropriate
software.

To communicate between dierent modules, the CAN bus
is used, which is a stable and standardized protocol that is
used in the automotive industry.

The connection between dierent modules is made by
direct adaptation of the dierent PCBs or by use of
standard shielded CAT-5 patch cables.

The direct connectors and cables carry the power lines
(24 volt) and the CAN bus signal lines.

pcb direct connector SyStem

aBBrevIatIons (eleCtronIC Modules / pCBs)

DTU Display terminal unit
LIU Load regulation and interface unit
BPU Bloodpressure unit
SMU Saddle motor unit
(also used as handlebar motor unit))

DMS Torque sensor
LCD Display Standard connecting cablel (cat-5 patch cable, Shielded)

2018111-336 Rev. B eBike III basic / comfort - 19 -

eleCtronIC CarrIer

desCrIptIon

All electronic boards are mounted on a special metal sheet
integrated in the bottom plate of the eBike III ergometers.

This metal sheet contains a grid of holes to mount all
possible combinations of electronic boards (e.g. LIU, SMU,
BPU).

metal Sheet carrier with mounting holeS (grid)

pcb direct connector SyStem

dIsMountIng of tHe eleCtronIC asseMBly group

1. Grab the eBike at handlebar and saddle and carefully
lay it sideways on one side.

2. Remove six screws (see picture) and ip the carrier
plate carefully aside.

3. Remove the connecting cables from the corresponding
boards.

4. The PCBs are mounted on spacers, screwed from
outside of the metal sheet carrier.

5. After removing these screws, the PCBs can be
removed.

metal Sheet carrier, aSSembled (bpu, Smu, liu)

6. After replacing a board, installation is performed by
following the steps in reverse order.

- 20 - eBike III basic / comfort 2018111-336 Rev. B

BloCk dIagraMs BIke ergoMeter eleCtronICs eBIke III

power cable

power

supply unit

Power supply

switch

24 V

RJ-45 Patchcable

PCB connector (direct)

Microfone cable

Connecting tube (cu)

rpm sensor

module

strain gauge

Brake unit + interface

brake

eddy current

Control unit

USB

RS-232

LIU

DTU

LCD

NIBP key

ebike iii baSic

keys for

saddlemotor,

service menu

patient rpm

2018111-336 Rev. B eBike III basic / comfort - 21 -

cu connector

pressure

microphone

connector

patient rpm

service menu

NIBP key

LCD

saddlemotor,

keys for

Control unit

DTU

eddy current

brake

BPU

valves etc.

PCB connector (direct)

Microfone cable

Connecting tube (cu)

Bloodpressure module

pump

RJ-45 Patchcable

USB

LIU

RS-232

24 V

supply unit

module

switch

power

Brake unit + interface

strain gauge

rpm sensor

Power supply

power cable

ebike iii baSic with bloodpreSSure unit

- 22 - eBike III basic / comfort 2018111-336 Rev. B

Power supply

power cable

power

supply unit

switch

24 V

RJ-45 Patchcable

PCB connector (direct)

Microfone cable

Connecting tube (cu)

rpm sensor

module

strain gauge

Brake unit + interface

brake

eddy current

Control unit

USB

RS-232

LIU

motor

Motor saddle height

sensor

position

saddle height

SMU

DTU

LCD

NIBP key

ebike iii comfort

keys for

saddlemotor,

service menu

patient rpm

2018111-336 Rev. B eBike III basic / comfort - 23 -

cu connector

pressure

microphone

connector

patient rpm

service menu

NIBP key

LCD

saddlemotor,

keys for

Control unit

DTU

eddy current

brake

BPU

valves etc.

Microfone cable

Connecting tube (cu)

Bloodpressure module

pump

RJ-45 Patchcable

PCB connector (direct)

position

sensor

SMU

saddle height

motor

Motor saddle height

USB

LIU

RS-232

24 V

supply unit

module

switch

power

Brake unit + interface

strain gauge

rpm sensor

Power supply

power cable

ebike iii comfort with bloodpreSSure unit

- 24 - eBike III basic / comfort 2018111-336 Rev. B

wIrIng dIagraMs BIke ergoMeter eBIke III

Power supply

white

black

Main switch

white

brown

rpm module

X 2

RS 232

USB

Torque module

Eddy current brake

Brake unit

X 19 X 11X 14 X 13

red

blue

LIU PCB

Load regulation / interface

X 8

Patch cable

RJ-45

Control unit

ebike iii baSic

2018111-336 Rev. B eBike III basic / comfort - 25 -

Microphone cable

Control unit

RJ-45

Patch cable

pump + valve

J4 to pump

J6 to valve

J 9

Bloodpressure module

X 8

Load regulation / interface

Brake unit

Eddy current brake

BPU PCB

LIU PCB

Direct PCB connector

blue

red

Torque module

X 19 X 11X 14 X 13

USB

RS 232

rpm module

X 2

white

brown

Main switch

white

black

Power supply

ebike iii baSic with bloodpreSSure unit

- 26 - eBike III basic / comfort 2018111-336 Rev. B

Power supply

Main switch

rpm module

Torque module

white

white

black

brown

X 19 X 11X 14 X 13

X 2

RS 232

USB

Eddy current brake

Brake unit

Control unit

red

blue

RJ-45

LIU PCB

Load regulation / interface

X 8

Patch cable

Direct PCB connector

SMU PCB

Saddle motor

X 5 (2 pol) to motor

X10 (3 pol) to sensor

ebike iii comfort

2018111-336 Rev. B eBike III basic / comfort - 27 -

Microphone cable

J 9

Control unit

pump + valve

J4 to pump

J6 to valve

X 5 (2 pol) to motor

X10 (3 pol) to sensor

Bloodpressure module

BPU PCB

Direct PCB connector

Saddle motor

SMU PCB

Direct PCB connector

Patch cable

Patch cable

X 8

RJ-45

Load regulation / interface

LIU PCB

blue

red

X 19 X 11X 14 X 13

Brake unit

Eddy current brake

Torque module

USB

RS 232

rpm module

X 2

white

brown

Main switch

white

black

Power supply

ebike iii comfort with bloodpreSSure unit

- 28 - eBike III basic / comfort 2018111-336 Rev. B

Control unIts

dtu - Control unIt

The DTU board of the control unit is the “mainboard“ of
the eBike III electronics.

The DTU together with the LCD is mounted inside the
housing of the control unit.

Note

• The housing of the control unit CANNOT be opened!

• For repairs / upgrades the complete control unit has to be
replaced.

control unit

dtu board (top view) with patient rpm diSplay

dtu with lcd

2018111-336 Rev. B eBike III basic / comfort - 29 -

dtu - patIent dIsplay

The patient display for rpm and the push buttons for
service menu control are internally connected by a at
cable and screwed into the housing.

dtu - ConneCtors

1 2 3

dtu patient diSplay / buttonS for Saddle height

1 LED for rpm zones
2 Display for rpm
3 Push buttons for saddle height (eBike III comfort) and

service menu control

1

dtu

1 RJ-45 connector (patch cable to LIU)

- 30 - eBike III basic / comfort 2018111-336 Rev. B