SERVICE & MAINTENANCE MANUAL
REV. 1.0
The information contained in this manual is intended for QUALIFIED TECHNICIANS who have
completed a specific TECHNOGYM training course and are authorized to perform machine start-up
and adjustment procedures as well as extraordinary maintenance or repairs which require a thorough
knowledge of the machine, its operation, its safety devices and working procedures.
CAREFULLY READ THE INFORMATION CONTAINED IN
THIS MANUAL BEFORE PERFORMING ANY MAINTENANCE
PROCEDURES ON THE MACHINE
DANGEROUS VOLTAGES
PRESENT
NOTE
The information contained in this document is subject to change without notice.
Technogym does not guarantee this documentation in any way. Technogym shall not be held
responsible for any errors contained in this manual and declines all liability for accidents or
damages resulting from the supply, characteristics or use of this manual.
This document contains proprietary information that is protected by copyright. All rights reserved.
No part of this document may be photocopied, reproduced or translated into another language
without the prior written consent of Technogym.
The Technogym™ trademark is property of Technogym S.p.A.
The Bike Forma™ trademark is property of Technogym S.p.A.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page i
Contents
1. GENERAL NOTICES............................................................................................................................................1.1
1.1. INTRODUCTION .................................................................................................................................................1.1
1.2. RECOMMENDATIONS.........................................................................................................................................1.1
1.3. GENERAL RULES FOR REPAIR PROCEDURES....................................................................................................... 1.2
2. TECHNICAL CHARACTERISTICS ..................................................................................................................2.1
2.1. CHARACTERISTICS ............................................................................................................................................2.1
2.2. MECHANICAL CHARACTERISTICS ......................................................................................................................2.1
2.3. ELECTRICAL CHARACTERISTICS ........................................................................................................................2.1
2.4. AMBIENT SPECIFICATIONS.................................................................................................................................2.2
2.5. CONFORMITY TO REGULATIONS ........................................................................................................................2.2
2.6. PRODUCT CODES ...............................................................................................................................................2.3
2.7. WIRING DIAGRAM .............................................................................................................................................2.4
2.8. CABLES .............................................................................................................................................................2.5
3. PRINCIPLES OF OPERATION ..........................................................................................................................3.1
3.1. BLOCK DIAGRAM ..............................................................................................................................................3.1
3.1.1. Display board ....................................................................................................................................... 3.2
3.1.2. CSafe Board..........................................................................................................................................3.3
3.1.3. TGS/Smart Card Board ........................................................................................................................3.3
3.1.4. Cardio receiver.....................................................................................................................................3.3
3.1.5. Connectors panel..................................................................................................................................3.3
3.1.6. Brake board..........................................................................................................................................3.3
3.1.7. Brake 3.4
3.1.8. Speed sensor .........................................................................................................................................3.4
3.1.9. Power entry module..............................................................................................................................3.4
3.2. BRAKE CONTROL ..............................................................................................................................................3.6
3.2.1. Mechanics.............................................................................................................................................3.6
3.2.2. Control 3.6
3.2.3. The signals involved .............................................................................................................................3.7
4. ACCESSORIES ...................................................................................................................................................... 4.1
4.1. CARDIO THEATER CONNECTION ........................................................................................................................4.1
4.2. PC LINK FOR PROGRAMMING ............................................................................................................................4.1
5. INSTALLATION INSTRUCTIONS ....................................................................................................................5.1
5.1. SPECIFICATIONS AND REQUIREMENTS ...............................................................................................................5.1
5.2. INSTALLATION ..................................................................................................................................................5.1
5.3. FIRST POWER-ON...............................................................................................................................................5.2
6. TROUBLESHOOTING.........................................................................................................................................6.1
6.1. SERVICE TROUBLESHOOTING MENU ..................................................................................................................6.2
6.1.1. Automatic Test ......................................................................................................................................6.2
6.1.1.1. I2C Devices Test ....................................................................................................................................................... 6.3
6.1.1.2. LED Test ................................................................................................................................................................... 6.3
6.1.1.3. Serial Ports Test......................................................................................................................................................... 6.3
6.1.2. Manual Test..........................................................................................................................................6.3
6.1.2.1. Man. Keyboard Test .................................................................................................................................................. 6.3
6.2. THE DISPLAY FAILS TO ILLUMINATE ..................................................................................................................6.4
6.3. “THE EQUIPMENT IS BLOCKED” MESSAGE ON THE DISPLAY....................................................................6.7
6.4. ERROR DETECTED BY BRAKE BOARD ................................................................................................................6.8
6.4.1. Error 1 on brake board ........................................................................................................................6.8
6.4.2. Error 2 on brake board ........................................................................................................................6.8
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6.4.3. Error 4 on brake board ........................................................................................................................6.9
6.4.4. Error 8 on the brake board...................................................................................................................6.9
6.4.5. Error 16 or 32 on the brake board.......................................................................................................6.9
6.4.6. Error 128 on brake board ....................................................................................................................6.9
6.5. THERE IS NO RESISTANCE................................................................................................................................6.10
6.6. THE RESISTANCE IS INCORRECT ......................................................................................................................6.11
6.7. THE SPEED SIGNAL IS INCORRECT....................................................................................................................6.13
6.8. THE MACHINE DOES NOT READ THE TGS/SMART CARD....................................................................................6.14
6.9. THERE IS NO HEART RATE SIGNAL...................................................................................................................6.16
6.9.1. Ricevitore telemetrico HFU................................................................................................................6.16
6.10. THE TELEMETRIC HR SIGNAL IS INCORRECT.....................................................................................................6.17
7. DISASSEMBLY OF COMPONENTS .................................................................................................................7.1
7.1. DISASSEMBLING THE DISPLAY...........................................................................................................................7.1
7.2. DISASSEMBLING THE CIRCUIT BOARDS ON THE DISPLAY ...................................................................................7.2
7.3. DISASSEMBLING THE KEYBOARD ......................................................................................................................7.3
7.4. DISASSEMBLING THE CARDIO RECEIVER............................................................................................................7.4
7.5. DISASSEMBLING THE HANDLEBAR.....................................................................................................................7.5
7.6. DISASSEMBLING THE GUARDS ...........................................................................................................................7.6
7.7. DISASSEMBLING THE SEAT GROUP.....................................................................................................................7.7
7.8. DISASSEMBLING THE ADJUSTING KNOB .............................................................................................................7.9
7.9. DISASSEMBLING THE ELECTRICAL BOX ...........................................................................................................7.10
7.10. DISASSEMBLING THE BELT ..............................................................................................................................7.11
7.11. DISASSEMBLING THE PEDALS AND THE PEDAL CRANKS...................................................................................7.12
7.12. DISASSEMBLING THE PULLEY..........................................................................................................................7.13
7.13. DISASSEMBLING THE BRAKE WINDING ............................................................................................................7.14
7.14. DISASSEMBLING THE BRAKE GROUP ................................................................................................................7.15
7.15. DISASSEMBLING THE SPEED SENSOR ...............................................................................................................7.17
7.16. DISASSEMBLING THE PLATFORMS WITH CSAFE BOARD CONNECTORS AND POWER ENTRY MODULE................ 7.18
8. ADJUSTMENTS ....................................................................................................................................................8.1
8.1. BELT TENSION...................................................................................................................................................8.1
8.2. PLAY OF SADDLE STEM .....................................................................................................................................8.2
8.3. SPEED SENSOR POSITION ...................................................................................................................................8.3
8.4. BRAKE ASSEMBLY ............................................................................................................................................8.4
9. MACHINE CONFIGURATION...........................................................................................................................9.1
9.1. USER MENU CONFIGURATION............................................................................................................................ 9.1
9.1.1. Language..............................................................................................................................................9.1
9.1.2. Distance................................................................................................................................................ 9.2
9.1.3. Maximum excercise time.......................................................................................................................9.2
9.1.4. Pause time.............................................................................................................................................9.2
9.1.5. Default age ...........................................................................................................................................9.3
9.1.6. Default weight.......................................................................................................................................9.3
9.1.7. Default time ..........................................................................................................................................9.3
9.1.8. Default calories ....................................................................................................................................9.4
9.1.9. Default distance.................................................................................................................................... 9.4
9.1.10. Enable TGS...........................................................................................................................................9.4
9.1.11. Enable keyboard................................................................................................................................... 9.5
9.1.12. Modifiable target heart rate .................................................................................................................9.5
9.1.13. Enable custom messages.......................................................................................................................9.5
9.1.14. Resetting parameters to default values.................................................................................................9.6
9.1.15. Format P&P .........................................................................................................................................9.6
9.2. SERVICE MENU CONFIGURATION.......................................................................................................................9.7
9.2.1. Time and date .......................................................................................................................................9.7
9.2.1.1. Hour .......................................................................................................................................................................... 9.8
9.2.1.2. Minutes...................................................................................................................................................................... 9.8
9.2.1.3. Day............................................................................................................................................................................ 9.8
9.2.1.4. Month........................................................................................................................................................................ 9.8
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9.2.1.5. Year........................................................................................................................................................................... 9.8
9.2.1.6. Set Clock................................................................................................................................................................... 9.8
9.2.2. Low kit parameter.................................................................................................................................9.8
9.2.2.1. Read from low kit...................................................................................................................................................... 9.9
9.2.2.2. Write to low kit.......................................................................................................................................................... 9.9
9.2.2.3. Default Setting........................................................................................................................................................... 9.9
9.2.2.4. Configuration parameters table ............................................................................................................................... 9.10
9.2.3. Operating data....................................................................................................................................9.10
9.2.3.1. Read from low kit.................................................................................................................................................... 9.11
9.2.3.2. Write to low kit........................................................................................................................................................ 9.11
9.2.3.3. Machine usage data................................................................................................................................................. 9.11
9.2.4. Errors log ...........................................................................................................................................9.11
9.2.4.1. Read from low kit.................................................................................................................................................... 9.12
9.2.4.2. Reset Errors............................................................................................................................................................. 9.12
9.2.4.3. View Errors ............................................................................................................................................................. 9.12
9.2.5. Standard settings ................................................................................................................................9.13
9.2.6. Low kit menu.......................................................................................................................................9.13
9.2.6.1. Low kit version........................................................................................................................................................ 9.14
9.2.6.2. Low Kit fault code................................................................................................................................................... 9.14
9.2.7. High kit version ..................................................................................................................................9.14
10. SCHEDULED MAINTENANCE........................................................................................................................10.1
10.1. DAILY MAINTENANCE OPERATIONS................................................................................................................. 10.1
10.1.1. Setting up the operation......................................................................................................................10.1
10.1.2. External cleaning operations..............................................................................................................10.1
10.2. MONTHLY MAINTENANCE OPERATIONS...........................................................................................................10.2
10.2.1. Play of the saddle stem.......................................................................................................................10.2
10.2.2. Check wear of foot straps ...................................................................................................................10.2
10.2.3. Checking the operation of the cardiotester receiver...........................................................................10.2
10.3. TWICE-YEARLY MAINTENANCE OPERATIONS...................................................................................................10.3
10.3.1. Carrying out the monthly maintenance procedure.............................................................................10.3
10.3.2. Setting up the operation......................................................................................................................10.3
10.3.3. Cleaning operations ...........................................................................................................................10.3
10.3.4. Checking the working conditions........................................................................................................10.3
10.3.5. Checking the wear of rubber parts .....................................................................................................10.3
10.3.6. Checking the belt ................................................................................................................................ 10.3
10.3.7. Checking the display...........................................................................................................................10.3
10.3.8. Checking the wiring and connections.................................................................................................10.3
11. APPENDIX ...........................................................................................................................................................11.1
11.1. UPDATING THE SW .........................................................................................................................................11.1
11.2. REQUIRED TOOLS............................................................................................................................................11.2
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BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 1.1
1. GENERAL NOTICES
1.1. INTRODUCTION
This document is reserved for Technogym Service technicians, and is intended to provide
authorized personnel with the necessary information to correctly carry out repairs and maintenance.
A thorough knowledge of the technical information contained in this manual is essential for
completing the professional training of the operator.
In order to facilitate consultation, the paragraphs are accompanied by schematic drawings which
illustrate the procedure being described.
This manual contains notices and symbols which have a specific meanings:
WARNING: non observance may result in accident or injury.
ATTENTION: non observance may cause damage to the machine.
Information about the operation in progress.
OBSERVE: observation about the operation in progress.
1.2. RECOMMENDATIONS
Technogym recommends the following steps for planning repair procedures:
• Carefully evaluate the customer’s description of the machine malfunction and ask all the
necessary questions to clarify the symptoms of the problem.
• Clearly diagnose the causes of the problem. This manual provides the fundamental theoretical
basis, which must then be integrated by personal experience and attendance at the training
courses periodically offered by Technogym.
• Rationally plan the repair procedure so as to minimize the downtime necessary for procuring
spare parts, preparing tools, etc.
• Access the component to be repaired, avoiding any unnecessary operations. In this regard it will
be useful to refer to the disassembly sequence described in this manual.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 1.2
1.3. GENERAL RULES FOR REPAIR PROCEDURES
1. Always mark any parts or positions which may be confused with each other at the time of
reassembly.
2. Use original Technogym spare parts and lubricants of the recommended brands.
3. Use special tools where specified.
4. Consult the Technical Newsletters, which may contain more up-to-date information on
adjustments and maintenance than those contained in this manual.
5. Before starting the repair procedure, make sure that the recommended tools are available and in
good condition.
6. For the procedures described in this manual, use only the specified tools.
OBSERVE: The tool sizes quoted in this manual are expressed in mm.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 2.1
2. TECHNICAL CHARACTERISTICS
2.1. CHARACTERISTICS
Power
30-500 Watt
CSafe
YES
Cardio receiver
HFU
Training programs
Quick start
Goal
CPR
CHARACTERISTIC
Test functions
Fitness test
2.2. MECHANICAL CHARACTERISTICS
Width
52 cm - 20.5 in
Length
110 cm - 43.3 in
Height
150 cm - 59.1 in
Weight
67 kg - 147 lbs
2.3. ELECTRICAL CHARACTERISTICS
Mains voltage
90 - 260 VAC
Frequency
50 - 60 Hz
Consumption
50 VA
Fuses
F 3.15 A
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 2.2
2.4. AMBIENT SPECIFICATIONS
Operating from 5° to 35° C
Temperature
Storage from -10° to 70° C
Operating from 30% to 80% non-
condensing
Humidity
Storage from 5% to 85% non-condensing
2.5. CONFORMITY TO REGULATIONS
The machine conforms to the following standards:
Europe USA
EMI
EN 55014-1
EN 55014-2
EN 61000-3-2
EN 61000-3-3
Safety
EN 60335-1
EN 957-1
EN 957-5 class SA
Directives
73/23/CEE
89/366/CEE
89/392/CEE
UL 1647
In addition:
• Electrical isolation class: Class I;
• Protection rating: IP21.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 2.3
2.6. PRODUCT CODES
The machine codes take into account all the possible variants and options available for the products.
The machine code, which does not include the Serial Number, consists of 16 alphanumeric
characters arranged as follows:
Characters description key to values
1,2,3,4 Machine type: Bike Forma
D725
5 Type of power supply
3 = multi-voltage (110-220)
6 Type of display
L = LED display
7
Device for downloading data used by the Wellness
System
N = not available
T = TGS
8, 9 Color of the frame
AL = aluminum
10, 11 Color of paddings
AG = gray
M0 = bordeaux
12 Guard color
G = gray
13 Type of TV model
0 = none
14,15 Language
IT = Italian
DE = German
FR = French
UK = British English
ES = Spanish
16 Type of packaging
I = Italy
E = standard international
The above coding is used for the entire Excite line. For this reason, options not relevant
to the BikeForma machine have also been included.
For example, a possible product code would be:
D7253LTALM0G0UKE
which is interpreted as follows:
D427 3 L T AL M0 G 0 UK E
standard international packing
British English language
no TV model
gray guards
burgundy paddings
aluminum frame color
interfaced to TGS key reader
LED display
mains powered supply with multi-voltage inlet
Forma model
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 2.4
2.7. WIRING DIAGRAM
BRAKE
POWER
ENTRY
MODULE
VAC
BRAKE
BOARD
C
N
3
C
N
4
C
N
1
C
N
2
SPEED
SENSOR
CB-0
Patch
Conn.
CB-51
CB-4
CB-3
DISPLAY
CPU BOARD
CBQ-32
KEYBOARD
386 BOARD
C
N
3
TGS/
SMART
CARD
BOARD
C
N
1
C
N
2
C
N
7
C
N
9
CBQ-13
CSAFE
BOARD
HFU
RECEIVER
C
N
1
C
N
1
C
N
8
CBQ-28
CONNECTORS
PANEL
C
N
5
C
N
4
CB-14
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 2.5
2.8. CABLES
CB-0: High voltage cable
Power entry module – Brake board
Power entry
module
Signal Color Brake board
CN3
N Neutral White 1
F Line Black 3
T Earth Green 5
C B-3: Cable connecting upper and lower assemblies
Brake board – Digital plan board
Brake board
CN1
Signal Color Digital Plan Board
CN7
2 Digital Gnd White 2
3 Power Gnd Orange 3
4 - sensing +5 Vdc digital Red 4
6 +12 Vdc Black 6
7 +5 Vdc Green 7
8 +sensing +5 Vdc digital Blue 8
CB-4: Serial communication cable between upper and lower assemblies
Brake board – Digital plan board
Brake board
CN4
Signal Color Digital Plan Board
CN14
1 NC Green-White 1
2 NC Green 2
3 Digital Gnd Orange-White 3
4 Download Blue 4
5 Reset Blue-White 5
6 Digital Gnd Orange 6
7 485 Tx/Rx + Brown-White 7
8 485 Tx/Rx - Brown 8
CBQ-13: CSafe board cable
Digital Plan Board – CSafe Board
Digital Plan Board
CN15
Signal Color CSafe Board
CN1
1 Digital #1 Flat cable 1
… … … …
14 Digital #14 Flat cable 14
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Page 2.6
CBQ-14: Cable connecting CSafe – External connectors
CSafe Board – Ext. connectors panel
CSafe Board
CN4
Signal Color Ext. connectors
CN5
1 Digital #1 UPT CAT V 1
… … … …
8 Digital #8 UPT CAT V 8
CBQ-28: HFU receiver cable
CPU board – HFU receiver
CPU board
CN8
Signal Color HFU receiver
1 +5 Vdc power supply Red 2
7 Pulse (beat to beat) Blue 4
8 Gnd Black 1
CBQ-32: TGS/smart card cable
Digital Plan Board – TGS/Smart Card Board
Digital Plan Board
CN10
Signal Color TGS/Smart Card
Board
CN1
1 +12 Vdc power supply Yellow 1
3 Rx White 8
5 Tx Green 7
9 Gnd Brown 3
CBQ-51: Brake supply cable
Brake board – Brake – Speed sensor
Brake board
CN2
Signal Color Brake Speed sensor
1 Brake supply + Brown 10
2 Brake supply - White 5
3 RPM Yellow Faston connected
to brown cable
4 RPM reference Green eyelet
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 3.1
3. PRINCIPLES OF OPERATION
3.1. BLOCK DIAGRAM
The machine block diagram is illustrated in the figure below:
POWER
ENT RY
MODULE
DISPLAY
DISP LAY BOARD
CSAFE
BOARD
TGS/
SM ART CARD
BOARD
BRAKE
BOARD
CARDIO
RECEIVER
VAC
KEYBOARD
SPEED
SENSOR
BRAKE
CONNECTORS PANEL
NET
RJ45
BNC
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Page 3.2
3.1.1. DISPLAY BOARD
The display contains:
• 386
BOARD
This is the circuit board which comprises the CPU, a 386 microprocessor, its logic circuits and
a FLASH EPROM containing the operating program for the machine.
• CPU B
OARD
This is the heart of the display: this board acts as the interconnection hub for all the components
of the display, and serves as the point of connection with the electrical box. In particular, its
functions are:
> receives commands of the machine program from the 386 Board;
> sends to the 386 Board the signals received from:
- Keyboard;
- Cardio receiver;
- TGS/Smart Card Board;
- CSafe Board.
> distributes to the display the voltages received from the Power Supply Board;
> houses the backup battery which maintains the RAM memory on the 386 board;
> exchanges, over the RS-485 serial link to the inverter, and via the Download Board,
commands for controlling the belt and elevation motors;
> illuminates the LEDs and 7-segment displays used for the exercise feedback.
The board includes the following indicator LEDs:
LED name Color Description
DL1 green
if ON the +5 Vdc supply for the digital
circuits, stabilized by the CPU board,
correctly generates.
DL2 green
if ON the +12 Vdc supply for the power
circuits, provided by the Power Supply
Board, correctly reaches the board.
DL3 orange
if ON the +5 Vdc supply for the power
circuits, provided by the Power Supply
Board, correctly reaches the board.
and 2 jumpers:
Jumper Name Setting Description
JP1 close
if short-circuited, keeps the memory powered
when the machine is off
JP2 open if short-circuited, resets the circuit board
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 3.3
3.1.2. CSAFE BOARD
This board makes available a communication port, on 2 externally accessible connectors, which can
be used for connecting compatible CSafe devices such as the CardioTheater readers. These
connectors are situated one on the back of the display and the other on the connectors panel
underneath the front platform.
These connectors can also be interfaced, by means of a special cable, to an external PC for
programming the FLASH EEPROM.
3.1.3. TGS/SMART CARD BOARD
This board enables the machine to read the TGS key or Smart Card inserted by the user for doing
workouts programmed with the Wellness System. The machine can be interfaced with either a TGS
key or Smart Card reader, hence its name TGS/Smart Card Board.
3.1.4. CARDIO RECEIVER
This board manages the signal received from the telemetric transmitter used by the person
exercising, and interfaces it with the Digital Plan Board. The machine uses an OwnZone receiver.
This is a special receiver model produced by Polar, equipped with microprocessor and capable of
independently detecting the heart rate. It receives the power supply signal from the Digital Plan
board, to which it is connected by:
• pulse signal outputs one pulse at each detected heart beat;
• reset signal: external signal received from the digital plan board at the beginning of each
exercise session, to initialize the receiver;
• serial signal with I2C protocol.
Their reception area is approximately a circle with a 1 m radius. If there is electromagnetic noise
(produced by high voltage lines, radio transmitters, monitors, motors etc.) within its reception area,
the receiver becomes saturated and no longer receives any signal. In addition, if there are 2
transmitters within the reception area, it will receive signals from both.
3.1.5. CONNECTORS PANEL
This is located on the side of the front platform, and provides:
• an RJ45 socket for connecting CSafe compatible devices.
3.1.6. BRAKE BOARD
There are 2 versions of the brake board, one which is used on the mains powered version and the
other on the self-powered version. In either case, the brake board consists of:
• Power supply section which generates the low voltages used by the machine: +5 Vdc and +12
Vdc. Depending on the machine version, these voltages will be generated either from the 110
VAC or 220 VAC mains supply, or from the alternator-battery.
• Section for RS-485 serial communications with the Digital Plan Board for:
- commands determining the resistance that is required of the brake;
- brake error messages;
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 3.4
- the commands for modifying the circuit board configuration parameters;
- the commands for viewing the errors logged by the circuit board.
• Section which generates the current for the brake winding: varying the current produces a
proportional variation in the resistance of the brake. The excitation current supplied to the brake
is a function of the effort level selected on the display and the RPM value measured by the speed
sensor (angular velocity of the brake disk).
The board includes the following indicator LEDs:
LED name Color Description
LED1 green
if ON the board is supplying the brake winding.
if BLINKING the brake board is in an error condition.
LED2 yellow
if ON there is the +5 Vdc supply form the circuit
board.
and 2 jumpers:
Jumper Name Setting Description
JP1 open
JP2 open
3.1.7. BRAKE
This is an eddy current brake, consisting of a flywheel mass and a flat copper disk that rotates in the
air gap of a winding to which it is connected. Variations in the winding current produce a change in
the resulting field, which consequently varies the eddy currents induced within the copper disk and
hence its resistance to movement.
The winding has a resistance of approximately 4.8 Ohm.
3.1.8. SPEED SENSOR
This consists of a magnetic induction sensor which detects the heads of the brake disk fixing
screws.
3.1.9. POWER ENTRY MODULE
This is a block consisting of:
• power inlet socket;
• power outlet socket;
• fuse-holder for protecting line voltage and neutral with two 3.15A fast-blow fuses.
Situated on the side of the rear platform. The Power entry module has a maximum current rating of
10A. This determines the maximum number of machines that can be connected together. Therefore,
do not connect more than 30 Bike Forma machines with a 220 VAC mains supply, or 15 machines
with a 110 VAC mains supply.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 3.5
WARNING: If other types of machines are connected together, the maximum number is
determined by their current draw.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 3.6
3.2. BRAKE CONTROL
3.2.1. MECHANICS
The movement of the pedals puts the brake into rotation by means of a belt. The speed sensor,
connected to the machine frame, the speed sensor detects the heads of the brake disk fixing bolts
and provides a signal representing the RPM.
3.2.2. CONTROL
The control block diagram is as follows:
The resistance which the user perceives on the pedals is a combination of 2 factors:
• mechanical: mechanical efficiency of the linkages and more generally the mechanical friction
of the system as a whole. The mechanical friction has been measured in the laboratory and is
determined by a specific SW function of the upper kit.
• electrical: resistance produced by the brake;
To obtain a given exercise effort level, the digital plan board sends the required value of “electrical”
resistance to the brake board via the RS-485 serial link. Based on the commands received and the
feedback signal from the speed sensor, the brake board will then apply the appropriate excitation
current to the brake winding and generate an electromagnetic field.
The value of the current applied is based on the value of the brake table memorized into
the brake board.
Digital Plan Board
Brake Board
RS-485
CN14
CN4
1-2/CN2
Brake
Excitation Current
3-4/CN2
Pulses
Speed
sensor
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 3.7
The electromagnetic field produced by the winding and the rotation of the disk will induce eddy
currents in the disk itself, giving rise to a force which tends to brake its motion. This produces the
exercise resistance.
A higher brake excitation signal will produce a correspondingly higher exercise resistance. In
addition, for a given value of magnetic field, a higher speed of disk rotation will produce a
correspondingly higher exercise resistance.
Due to the eddy currents, energy is dissipated on the brake disk in the form of heat.
The brake board effects an open loop control of the brake, with no provision for
regulating the value of resistance produced. The precision of the braking system has a
tolerance of ±±±±10%.
During the movement, the speed sensor detects the heads of the brake disk fixing bolts, and
produces a speed feedback signal that is sent to the brake board.
If the brake board does not receive a speed signal which indicates that an exercise
session is in progress, the machine will not produce any resistance.
During the movement, the brake board checks for possible malfunctions. The errors which can
occur are:
Error
Code
Description
1
OVERHEATING: this condition occurs when the temperature measured
by the sensor on the circuit board exceeds 90°C.
2
OVERCURRENT: this condition occurs when the current going to the
solenoid measured by the board exceed the max value.
4
UNDERVOLTAGE: this condition occurs when the +12 Vdc voltage
drops below 9.7 Vdc.
8
OVERVOLTAGE: this condition occurs when the +12 Vdc voltage goes
above 13.7 Vdc.
16
WATCHDOG: this condition occurs when the brake board SW crashes.
32
EPROM: SW error on the brake board.
128
MACHINE NOT CALIBRATED: this error condition occurs when the
calibration parameter stored in the brake board is incorrect.
In the case of error 128, the machine will continue to function completely, but the braking resistance
produced will not correspond to the value entered on the display. In all other cases, the brake board
interrupts the supply of current to the brake and sends an error message to the digital plan board
which displays the “THE EQUIPMENT IS BLOCKED” message.
3.2.3. THE SIGNALS INVOLVED
The machine uses the following control signals:
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 3.8
• RS-485 Signal
This is a digital signal exchanged between the brake board and the digital plan board. There is
no provision for monitoring its state.
• Excitation current
This is the current generated by the brake board (pins 1-2 of connector CN2) which supplies the
brake winding. The current supplied is a function of the selected effort level and the speed of the
exercise.
• Pulses
This is the signal produced by the speed sensor, and has the waveform shown below:
Figure 3.2-1
The signal enters the brake board (pins 3-4 on connector CN2), where it is used to determine the
speed value that is sent to the digital plan board via the RS-485 serial link.
This signal can also be measured qualitatively using a multimeter. With the machine
stopped the voltage measured across the sensor terminals should be 0 Vdc, and while
pedaling it should go to a few hundred mV: the higher the speed, the higher the
measured value.
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BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 4.1
4. ACCESSORIES
4.1. CARDIO THEATER CONNECTION
The machine can be connected to the CardioTheater by means of the RJ45 connector on the CSafe
board. The CardioTheater unit must be provided with a power cable having the following pin-out:
RJ45 Connector Signal
5 +5 Vdc
7 Ground
In the RJ45 connector, which is illustrated below, pin 1 is the farthest right when the locking tab is
facing upward.
The remaining pins are not connected.
4.2. PC LINK FOR PROGRAMMING
The machine can be connected to a PC for programming by means of the RJ45 connector on the
CSafe board.
The cable to use (code 0WC00434AA) must be wired as follows:
PC Cable
CSafe Board - PC
CSafe Board
RJ45
Signal Color PC
9 pin D-
connector
3 Rx White-Green 3
4 Tx Blue 2
7 Ground White-brown 5
5 - 6
R = 10 KOhm
- -
In the RJ45 connector, which is illustrated below, pin 1 is the farthest right when the locking tab is
facing upward.
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Page 4.2
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BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 5.1
5. INSTALLATION INSTRUCTIONS
5.1. SPECIFICATIONS AND REQUIREMENTS
For correct machine installation, make sure that:
1. The machine is installed on a level surface that is free of vibrations and has sufficient carrying
capacity for the combined weight of the machine and user.
2. The place of installation is free of dust and sand.
3. The place of installation meets the operating temperature and humidity conditions specified in
paragraph 2.4. “Ambient specifications”.
4. The machine is not positioned close to sources of heat, sources of electromagnetic noise
(television sets, electrical motors, antennas, high voltage lines, household appliances, etc...) or
medical equipment.
5. To eliminate any interference with the cardio receiver, no transmitters should be placed less than
1 meter from the display.
6. The mains voltage must match the value specified on the machine rating plate.
7. The electrical system must be correctly earthed.
8. The wall outlet used should be reserved for the machine and have a rating of at least 50 VA.
9. The maximum number of machines connected in cascade should be that indicated in paragraph
3.1.9. “Power entry module”.
10. Position the mains lead of the machine where it will not be underfoot.
5.2. INSTALLATION
To correctly install the machine, proceed as follows:
1. Ensure that the specifications and requirements for installation have been met (see paragraph
5.1. “Specifications and requirements”).
2. Position the machine as specified above, on a level surface that is free of vibrations and has
sufficient carrying capacity for the combined weight of the machine and user.
3. The machine is shipped fully assembled and packed in a carton fixed to a wooden pallet.
4. Connect the mains lead to the power inlet socket on the machine.
5. Place the on/off switch in the “0” position.
6. Plug the mains lead into the wall outlet.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 5.2
5.3. FIRST POWER-ON
After completing the installation procedure, the machine is ready for use.
Simply turn the on/off switch from position 0 to position 1.
On power-up the machine performs a self test of the upper and lower assemblies. At the end of this
the machine goes into standby, awaiting a keyboard command.
To check the correct operation of the machine:
• get on the machine;
• begin exercising;
• check that the displayed speed varies accordingly;
• check that the exercise resistance varies when the “+” and “-” keys are pressed, and that the
effort level LEDs turn on and off accordingly;
• put on the heart rate meter and check that the machine correctly reads the heart rate value;
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.1
6. TROUBLESHOOTING
The troubleshooting procedures are shown in the form of flow charts. In order to facilitate
consultation, the following standard box shapes are used.
This type of box is the START point of the troubleshooting procedure. It
typically contains a description of the problem or malfunction.
This type of box represents a decision point in the troubleshooting procedure.
It typically contains a description of the CHECK to be made, with an outcome
that can be either a positive (YES) or negative (NO) response.
This type of box is a step in the troubleshooting procedure where an ACTION
must be carried out. It typically contains a description of the ACTION
necessary to resolve the problem. Therefore, after executing the specified
ACTION:
1. Check whether the problem has been resolved;
2. If the problem persists, it is recommended to resume the troubleshooting
procedure from the point before the action was carried out.
A circled number (such as that shown on the left) next to a box of the
troubleshooting procedure indicates that detailed instructions for performing
that particular check or action are provided below the flowchart.
A circled letter (such as that shown on the left) is used to highlight a point in
the procedure. Typically, this indicator is used in page changes.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.2
6.1. SERVICE TROUBLESHOOTING MENU
This section can be used to test the operation of certain machine components (brake board, LED
display, keyboard, serial ports). It is invoked when the machine is in standby by simultaneously
pressing the keys 369. The following prompt appears on the LED display:
ENTER PASSWORD:
To access the procedure, type in the password 2501 which protects against unauthorized access and
press ENTER to confirm. At this point there are two options available:
1 = Tech Config
2 = Troubleshooting
Press the number key 2 to access the troubleshooting menu, which is structured as shown in the
figure below.
MAN. KEYBOARD
TEST
TROUBL ESHOOTING
I2C Devices Test
AUTOMATIC TEST MANUAL TEST
LED Test
SERI AL PORTS
TEST
CSafe COM Test TGS COM Tes tLow Kit COM Test
To scroll through the list of available functions, press the + or – effort level keys to display the next
or the preceding item; confirm the choice by pressing ENTER. To cancel the operation, press the
CLEAR key for a few seconds.
The tests are divided into two groups: Automatic and Manual, and the prompt for a choice appears
immediately on accessing the troubleshooting menu.
6.1.1. AUTOMATIC TEST
The tests grouped under this section conduct checks on the machine’s operation in a fully automatic
manner. After selecting the desired test using the + and – effort level keys, press ENTER to initiate
the test and then await the result. Press ENTER again to continue, and use the CLEAR key to
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.3
return to the higher menu level, holding it down for a few seconds. The various manual tests are
described below.
6.1.1.1. I2C Devices Test
The I2C Device test checks the operation of the OwnZone receiver only for what concerns the data
reception function, but not the detection of the heart rate signal. The test can have two outcomes:
• “Test Successful, press Enter to continue” : Signifies that the transmission and reception of
data packets between the OwnZone and the digital plan board was completed successfully.
• “EEPROM Error, press Enter to continue”: Signifies that the CPU board has
communication problems with the memories.
6.1.1.2. LED Test
The LED test checks the functioning of the display by lighting all the LEDs in the matrix. It also
tests the buzzer by changing the frequency to produce a variation in the tone of the sound.
There is no message displayed concerning the outcome of this test, which the user must therefore
check visually.
6.1.1.3. Serial Ports Test
The serial ports test checks the communications on the port for connecting to:
• CSafe COM test
• Low Kit COM Test
• TGS COM test
Using the + and – effort level keys, select the desired test item and confirm by pressing ENTER.
The test can have two outcomes:
• “Test Successful, press Enter to continue”: This means that the test was completed
successfully, i.e. that the communications on the selected serial port are correct.
• “COMx Error, press Enter to continue”: This means that the outcome of the test was
negative: the message will specify COM1 in the case of the CSafe COM test, COM2 in the case
of communications with the low kit, or COM3 in the case of the TGS COM test.
6.1.2. MANUAL TEST
This section groups together tests for manually checking the operation of certain peripheral devices.
After selecting the desired test using the + and – effort level keys, press ENTER to initiate the test
and then await the result. To exit test mode, hold down the CLEAR key for a few seconds.
6.1.2.1. Man. Keyboard Test
The manual keyboard test checks the functioning of all the keys on the keyboard. After accessing
the test by pressing ENTER, the message “Press all buttons (beep=OK)” appears on the display.
Pressing each key will produce an audible signal, if a key does not produce the “beep” it means it is
not working properly.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.4
6.2. THE DISPLAY FAILS TO ILLUMINATE
This error occurs when the power supply voltage does not reach the upper assembly. This may also
be due to a short circuit on the brake winding, which interrupts the output voltage of the brake
board, causing the upper assembly to switch off.
Does the wall outlet s upply the
correct v oltage?
Is the mains lead OK?
Is the v olt age at the
output of t he machine' s
power entry module
correct?
Plug the m achine into a
working elec trical outlet
Replac e the m ains lead
Replac e the power
entry module on the
machine
THE DISPLAY
DOES NOT
ILLUMINATE
Does the m ains v olt age
reach t he input to t he
brake board?
NO
YES
NO
YES
NO
YES
NO
YES
2
A
Replac e cable CB-0
1
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.5
A
Are the D C v oltages at the
output of the brake board
correct?
NO
3
YES
B
Is the output of the brak e
board short-c ircuited?
NO
4
Is the brake winding short -
circ uited?
YES
YES
Replac e the br ake
win ding
5
Replac e the br ake
board
Is cable C B-51 ok?
Replac e cabl e CB-51
YES
NO YES
Replac e the brake
board
6
B
Are the D C v oltages at the
input to t he digital pl an
board correct ?
Replac e c able CB-3
NO
7
Replac e the C PU
board
YES
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.6
Follow the procedure step by step to correctly diagnose the problem. Take particular care with the
checks highlighted by circled numbers, which are described in detail below:
To speed up the troubleshooting procedure, check the state of the power indicator LEDs
on the various circuit boards.
(1) Slightly lift up the Faston connectors on the machine power inlet socket. Place the tester
probes across the live and neutral pins on the same connector. The measured value should be
approximately 220 VAC or 110 VAC depending on the mains voltage.
(2) As for step (1) but across pins 3 and 1 of connector CN3 on the brake board.
(3) Using a tester, check that all the output voltages on connector CN1 of the brake board are
correct, referring to paragraph 2.8. “Cables”.
(4) With cable CB-51 connected, place the tester probes across pins 1 and 2 of connector CN2 of
the brake board. The measured value of resistance should be different from 0.
(5) Disconnect cable CB-51 from the winding and place the tester probes across the terminals of
the winding. The measured value of resistance should be different from 0.
(6) Using a tester, check that cable CB-51 is correct, referring to paragraph 2.8. “Cables”.
(7) As for step (3) but on connector CN7 of the CPU board.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.7
6.3. “THE EQUIPMENT IS BLOCKED” MESSAGE ON THE
DISPLAY
This error message can be caused by:
• loss of communication between the lower and upper assemblies;
• the brake board has detected an error condition, causing it to generate an alarm and store the
error code in memory.
Is the c omm unication
between the upper and
lower assemblies ok?
Turn the machine of f
and on again
Reins tat e t he
com munic ation link
between the upper and
lower assemblies
NO
"THE EQUIP MENT I S BLOCKED"
MESSAGE ON THE DISPLAY
1
Carry out the "Brak e
board Error"
troubleshoot ing
procedure
YES
2
Follow the procedure step by step to correctly diagnose the problem. Take particular care with the
checks highlighted by circled numbers, which are described in detail below:
(1) Carry out the procedure for testing the serial communications described in paragraph 6.1.1.3
“Serial Ports Test”.
(2) To reinstate communications between the lower and upper assemblies:
• check that cable CB-4 is correct;
• try replacing the brake board and the digital plan board in turn, and check whether the
communication works.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.8
6.4. ERROR DETECTED BY BRAKE BOARD
When the brake board detects an error, it stops and interrupts the power supply to the brake
winding, and an error code identifying the fault condition is shown on the display and saved in the
error history log. When this error is received by the digital plan board, it halts the exercise and
shows the “THE EQUIPMENT IS BLOCKED” message on the display.
The errors logged by the brake board can also be viewed from the machine keyboard as described in
paragraph 9.2.4. “Errors log”.
ERROR DETECTED BY
BRAKE BOARD
Chec k t he error c ode
st ored in memory
Err or 1
Err or 4
Err or 8
Error 16 - 32
Err or 2
Error 128
The following paragraphs describe the troubleshooting procedures for these three cases.
6.4.1. ERROR 1 ON BRAKE BOARD
This code indicates an overheating error: this condition occurs when the temperature detected by the
sensor on the circuit board exceeds 90°C.
Try switching the machine off for 1 hour. If it resumes working correctly, the machine probably
overheated as a result of intensive use. If, on the other hand, the error persists, it is necessary to
replace the brake board.
6.4.2. ERROR 2 ON BRAKE BOARD
This code indicates an overcurrent error: this condition occurs when the current going to the
solenoid measured by the board exceed the max value
This error is caused by an HW problem on the brake board or a short circuit on the solenoid. To
solve the problem, it is necessary to replace the brake board or the solenoid.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.9
6.4.3. ERROR 4 ON BRAKE BOARD
This code indicates a low voltage error: this condition occurs when the +12 Vdc voltage drops
below 9.7 Vdc.
This error is caused by drops in the voltage output by the power supply section of the brake board,
as a result of defective components. If the error persists or recurs frequently, replace the brake
board.
6.4.4. ERROR 8 ON THE BRAKE BOARD
This code indicates an overvoltage error: this condition occurs when the +12 Vdc voltage exceeds
13.7 Vdc.
This error is caused by surges in the voltage output by the power supply section of the brake board,
as a result of defective components. If the error persists or recurs frequently, replace the brake
board.
6.4.5. ERROR 16 OR 32 ON THE BRAKE BOARD
This code indicates an error in the EPROM of the brake board or a watch dog error: this condition
occurs when the board is unable to read the memory.
If the error persists or recurs frequently, replace the brake board.
6.4.6. ERROR 128 ON BRAKE BOARD
This code indicates an error in the calibration of the brake board: this condition occurs when the
value of the calibration parameter read by the board is incorrect. In these conditions, the board
continues to function but will not necessarily produce the correct value of exercise resistance.
When this error occurs, replace the brake board.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.10
6.5. THERE IS NO RESISTANCE
The machine will not produce resistance if:
• the digital plan board does not receive a speed signal;
• the brake board does not generate current;
• the brake is defective.
Does the brak e board s upply
current t o the brake winding?
THERE I S NO
RESISTANCE
Are the W att and R PM values
shown on the display dif f erent
from zero?
NO
YES
1
Carry out t he "RPM value
is incorrect"
troubleshoot ing proc edure
Replac e th e brake board
YES
Does the brak e winding receiv e
current f rom the brak e board?
NO
Replac e the br ake winding
YES
Replac e cable CB-51
NO
2
Follow the procedure step by step to correctly diagnose the problem. Take particular care with the
checks highlighted by circled numbers, which are described in detail below:
(1) Disconnect the brake winding and measure the current output by the brake board with a load
of at least 5 Ohm and 80 Watts. The value should be different from 0 A.
(2) As for step (1) but with everything reconnected, and across the brake winding.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.11
6.6. THE RESISTANCE IS INCORRECT
The machine will produce an incorrect resistance if:
• the mechanics are not in perfect condition;
• the speed measurement is incorrect;
• the brake board is defective
• the brake is defective.
Are the mechanics of t he
mac hine in good c ondition?
Has the brak e board generated
error 128?
Does the brak e board out put
the c orrec t c urrent to t he brak e
wind ing ?
3
Replac e th e brake board
NO
Replac e th e brake winding
YES
THE
RESI S TANCE IS
INCORRECT
1
Repair t he f aulty
mechanical pa rts
NO
Carry out the "Speed is
Inc orrec t" t roubles hooting
procedure
2
Replac e the br ake board
YES
YES
NO
Follow the procedure step by step to correctly diagnose the problem. Take particular care with the
checks highlighted by circled numbers, which are described in detail below:
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.12
(1) Check that the mechanical system, consisting of the pedals, belt and brake, moves smoothly
and without unusually high friction or resistance.
(2) Refer to paragraph 9.2.4. “Errors log”.
(3) Measure the voltage supplied by the brake board to the winding. In constant power mode
(custom – time), pedaling at 80 RPM and with a user weighing 75 kg, the values, should be
approximately those in the table below:
Low kit version 9.57.13
Power (Watt) Voltage (Vdc)
50 2.0
80 2.9
150 4.1
200 4.8
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.13
6.7. THE SPEED SIGNAL IS INCORRECT
The speed signal is incorrect if:
• The brake disk is incorrectly fixed to the flywheel;
• The speed sensor is defective;
• The brake board is defective.
Does the s peed sensor s end
the c orrect s ignal t o the brake
board?
2
Replac e the s peed s ensor
NO
Replac e the br ake board
YES
Is the brake disk correctly f ixed
to t he f ly wheel?
THE SPEED I S
INCORRECT
1
Fix it correctly
NO
YES
Follow the procedure step by step to correctly diagnose the problem. Take particular care with the
checks highlighted by circled numbers, which are described in detail below:
(1) Check that the 6 screws fixing the disk brake to the flywheel are all locked down.
The speed sensor detects the heads of these screws.
(2) Place the tester probes across the terminals of the speed sensor. The measured signal should
be that indicated in Figure 3.2-1. In addition, when pedaling at 80 RPM the frequency of the
signal should be 107 Hz.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.14
6.8. THE MACHINE DOES NOT READ THE TGS/SMART CARD
The machine displays this error if the TGS or Smart Card reader is not working properly, or if it is
not supplied by the digital plan board.
THE MACHI NE DOES
NOT READ THE
TGS/SMART CARD
Does the s upply v olt age
correct ly reach t he input to t he
TGS/Smart Card reader?
Is the s upply v oltage c orrect at
the input to the digital pl an
board correct ?
Replac e c able CBQ-32
1
2
YES
NO
YES
Replac e th e digital plan
board
NO
A
Is the serial com munic ation link
between the di gital plan board
and the TGS/Smart Card
reader OK?
Replac e th e digital plan board.
Is the c omm unication l ink
between the di gital plan board
and the TGS/Smart Card
reader OK?
Digit al plan board
def ectiv e
3
3
YES
NO
YES
Replac e t he TGS/Smart
Card reader
NO
A
Replac e the TGS/Smart
Card reader
Follow the procedure step by step to correctly diagnose the problem. Take particular care with the
checks highlighted by circled numbers, which are described in detail below:
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.15
(1) Place the tester probes across pins 1 and 3 of connector CN1 of the TGS/Smart Card reader.
The measured value should be +12 Vdc.
(2) As for step (1) but across pins 1 and 9 of connector CN10 on the digital plan board.
(3) Use the serial communications test described in paragraph 6.1.1.3 “Serial Ports Test”.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.16
6.9. THERE IS NO HEART RATE SIGNAL
6.9.1. RICEVITORE TELEMETRICO HFU
La macchina mostra questo errore se il ricevitore non funziona o se non alimentato dalla scheda
digital plan.
THERE IS NO HR
SIGNAL
Is the s upply v olt age correct at
the input to the receiver?
Is the s upply v olt age correct at
the out put of t he digit al plan
board?
Replac e the r eceiv er
Replac e CBQ-28 cabl e
1
2
YES
NO
YES
Replac e digit al plan board
NO
Follow the procedure step by step to correctly diagnose the problem. Take particular care with the
checks highlighted by circled numbers, which are described in detail below:
(1) Place the tester probes across pins 1 and 3 of connector CN1 of the receiver. The measured
value should be +5 Vdc.
(2) As for step (1) but across pins 1 and 8 of connector CN11 on the digital plan board.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.17
6.10. THE TELEMETRIC HR SIGNAL IS INCORRECT
The machine displays this error if the receiver is disturbed by sources of electromagnetic noise.
THE TELEMETRIC
HR SI GNAL I S
INCORRECT
Are the m achines c orrect ly
spac ed by t he required minim um
dist ance?
Is the receiver correctly
posit ioned and are the
connec ting cables properly
routed?
Are there sources of
elect romagnetic nois e near the
receiv er?
Reposition the machines
so t hey are adequately
spac ed
Correc t the pos ition of t he
receiv er and the rout ing of
the c ables
Mov e the m achine away
f rom the noi se s ource or
att enuat e the power of the
noise
NO
YES
NO
YES
NO
YES
1
A
Is the t rans mit ter in good
working order?
Use a correc tly
functioning transmitter
YES
NO
2
Continued on the following page.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 6.18
Is the transmitter always within
the 80 c m range f rom the rec eiv er
NO
Repos iti on the t rans mit ter
wit hin ra n ge
YES
Replac e t he receiv er
A
Follow the procedure step by step to correctly diagnose the problem. Take particular care with the
checks highlighted by circled numbers, which are described in detail below:
(1) To check for electromagnetic noise near the machine, use a frequency signal monitor
constructed as shown in the diagram below.
The circuit lights the LED for each heart beat and/or disturbance received: in this way it is
possible to determine whether there is any interference, and identify its sources.
(2) Check the battery power level, using a tester if possible. Otherwise use a receiver or another
“reference” machine to check the operation up to a distance of about 80 cm from the receiver.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 7.1
7. DISASSEMBLY OF COMPONENTS
7.1. DISASSEMBLING THE DISPLAY
Figure 7.1-1
1. Turn off the machine and unplug the mains
lead from the wall outlet.
2. Back off the 6 screws a using a medium
Phillips screwdriver.
Figure 7.1-2
3. Unplug the 3 connectors indicated in the
figure at left.
4. Remove the display.
Figure 7.1-3
5. Back off the 3 screws b, using a 6-mm Allen
wrench, to remove the rear display support.
To reassemble the display, carry out the above
steps in reverse order.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 7.2
7.2. DISASSEMBLING THE CIRCUIT BOARDS ON THE
DISPLAY
Figure 7.2-1
Carry out the procedure described in paragraph
7.1. “Disassembling the display”.
Then place the display on a work bench. It is
now possible to disassemble its five circuit
boards:
• The 386 board a;
• The CPU board b;
• The CSafe board c.
Figure 7.2-2
386 board a:
1. Push open the clip fasteners. The 386 board
will lift up.
2. Remove it from the connector on the digital
plan board.
CPU board b:
1. Unplug the connectors g and f.
2. Back off the 4 screws d, using a medium
Phillips screwdriver.
3. Back off the 4 screws e, using a small
Phillips screwdriver.
4. Remove the circuit board.
CSafe board c:
1. Unplug the connector g.
2. Remove the circuit board.
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Page 7.3
7.3. DISASSEMBLING THE KEYBOARD
Figure 7.3-1
Carry out the procedure described in paragraph
7.1. “Disassembling the display”.
1. Unplug the keyboard connector shown in the
figure.
Figure 7.3-2
With the display placed on a work bench:
2. Use a sharp tool to lift up and detach a corner
of the keyboard.
To assemble a new keyboard, with the display on
a work bench:
1. Remove the backing film which protects the
adhesive.
2. Apply the adhesive part, starting from the left
and working toward the right, without
bending the keyboard.
3. Insert the connector in the special slot on the
display and connect it to the digital plan
board.
4. Remove the protective film.
When reassembling the keyboard, make
sure that none of the keys are bent or
remain pushed in.
The keyboard assembly procedure can
only be carried out once, because
disassembly damages the tracks and
keys.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 7.4
7.4. DISASSEMBLING THE CARDIO RECEIVER
Figure 7.4-1
1. Back off the 2 screws a using a 3-mm Allen
wrench.
Figure 7.4-2
2. Unplug the connector b.
3. Remove the receiver.
To assemble the new receiver, carry out the
above steps in reverse order.
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Page 7.5
7.5. DISASSEMBLING THE HANDLEBAR
Figure 7.5-1
Carry out the procedure described in paragraph
7.1. “Disassembling the display”.
1. Back off the 3 screws a using a 6-mm Allen
wrench.
Support the handlebar before backing
off the last screw.
To assemble the new handlebar, carry out the
above steps in reverse order.
During reassembly, lock down the 3
screws using a torque wrench set for 22
Nm.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 7.6
7.6. DISASSEMBLING THE GUARDS
Figure 7.6-1
1. Back off the 6 screws a on either side of the
machine using a 4-mm Allen wrench.
Figure 7.6-2
2. Remove the right guard first, pushing the
pedal back as shown in the figure, and then
removing the guard as indicated by the
arrows.
Figure 7.6-3
3. Remove the rubber footrest b.
4. Remove the six pins c from the left guard.
5. Push the left pedal back and remove the left
guard in the same way as the right guard.
To reassemble the guards, carry out the above
steps in reverse order.
During reassembly, lock down the
screws using a torque wrench set for 0.8
Nm.
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Page 7.7
7.7. DISASSEMBLING THE SEAT GROUP
Figure 7.7-1
Carry out the procedure described in paragraph
7.6. “Disassembling the guards”.
1. Adjust the saddle to position 2.
2. Back off the screw a using a 3-mm Allen
wrench, accessing it from the hole at the base
of the saddle column.
3. Remove the saddle from the top.
Figure 7.7-2
Disassembling the adjustable bushing:
1. Back off the two screws b using a 3-mm
Allen wrench.
2. Remove the bushing from the top.
Figure 7.7-3
Disassemble the saddle stem bushing c:
1. Back off the three screws d using a 3-mm
Allen wrench.
2. Pull out the plate on which the bushing is
fixed.
During reassembly, lock down the
screws d using a torque wrench set for 5
Nm.
Continued on following page →
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 7.8
Figure 7.7-4
If the machine saddle was disassembled,
during reassembly lock down the screw
e using a torque wrench set for 24 Nm.
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Page 7.9
7.8. DISASSEMBLING THE ADJUSTING KNOB
Figure 7.8-1
Carry out the operations described in paragraph
7.7. “Disassembling the seat group”.
1. Remove the yellow cover a.
2. Use a 3-mm Allen wrench to back off the
screw underneath.
3. Remove the knob b, pulling from the
opposite side of the frame and being careful
to prevent the pin from dropping inside the
frame.
Figure 7.8-2
4. Remove the rubber o-ring c from the pin d
and pull the pin out from inside the frame.
5. Unscrew the threaded bushing e, using a 17mm wrench.
During reassembly, lock down the
threaded bushing l using a torque
wrench set for 40 Nm.
Figure 7.8-3
6. Remove the spring f from the frame.
To reassemble the guards, carry out the above
steps in reverse order.
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Page 7.10
7.9. DISASSEMBLING THE ELECTRICAL BOX
Figure 7.9-1
Carry out the procedure described in paragraph
7.6. “Disassembling the guards”.
1. Back off the screws a using a medium
Phillips screwdriver.
2. Remove the cover from the box.
Figure 7.9-2
3. Unplug the connectors indicated in the
figure.
4. Back off the two screws b shown in figure
7.9-1 using a 4-mm Allen wrench.
5. Remove the electrical box.
To reassemble the electrical box, carry out the
above steps in reverse order.
During reassembly, lock down the
screws b using a torque wrench set for 5
Nm.
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Page 7.11
7.10. DISASSEMBLING THE BELT
Figure 7.10-1
Carry out the procedure described in paragraph
7.6. “Disassembling the guards”
1. Release the spring a of the belt tensioning
mechanism.
2. Remove the belt from the pulley.
To reassemble the belt, follow the disassembly
instructions in reverse order.
After completing this operation, adjust
the belt tension as described in
paragraph 8.1. “Belt tension”.
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Page 7.12
7.11. DISASSEMBLING THE PEDALS AND THE PEDAL CRANKS
Figure 7.11-1
Carry out the procedure described in paragraph
7.6. “Disassembling the guards”.
1. Back off the screw a using a 15-mm wrench
and remove the pedal.
During reassembly, lock down the
screws b using a torque wrench set for
35 Nm.
Figure 7.11-2
2. Remove the plastic caps b from both pedal
cranks.
3. Use a 14-mm socket wrench to back off the
screw underneath.
Figure 7.11-3
4. Use a bicycle pedal extractor tool like the one
shown in the figure to remove the two pedal
cranks.
To reassemble the pedals and the pedal cranks,
carry out the above steps in reverse order.
During reassembly, lock down the
screws b using a torque wrench set for
40 Nm.
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Page 7.13
7.12. DISASSEMBLING THE PULLEY
Figure 7.12-1
Carry out the operations described in paragraphs
7.10. “Disassembling the belt” and 7.11.
“Disassembling the pedals and the pedal cranks”.
1. On the left side of the machine, remove the
plastic cover a.
Figure 7.12-2
2. Remove the snap ring b.
Be careful with the various spacer rings
on the pulley shaft.
Figure 7.12-3
3. Remove the pulley c from the opposite side
of the machine.
4. Back off the 3 screws d using a medium
Phillips screwdriver.
5. Remove the plastic cover, not visible in the
photo, from the pulley c.
To reassemble the pulley, carry out the above
steps in reverse order.
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Page 7.14
7.13. DISASSEMBLING THE BRAKE WINDING
Figure 7.13-1
Carry out the procedure described in paragraph
7.6. “Disassembling the guards”.
1. Unplug the two Faston connectors a from the
winding.
2. Back off the fixing screws b on the machine
frame, using a 3-mm Allen wrench.
Figure 7.13-2
3. Place the winding assembly on a work bench.
4. Back off the two nuts c using a 7-mm
wrench, locking down the 2 through-screws
from the opposite side using a 3-mm Allen
wrench.
5. Remove the assembly with the winding.
To reassemble the brake winding, carry out the
above steps in reverse order.
Be careful to position the brake
assembly so that the copper disk does
not brush against the laminated core,
using a 0.6-mm spacer.
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Page 7.15
7.14. DISASSEMBLING THE BRAKE GROUP
Figure 7.14-1
Carry out the operations described in paragraphs
paragraph 7.6. “Disassembling the guards”, 7.10.
“Disassembling the belt” and 7.13.
“Disassembling the brake winding”.
1. Remove the snap ring a on the left side of the
machine.
Be careful with the various spacer rings
on the pulley shaft.
Figure 7.14-2
2. Remove the brake assembly
3. Place the brake assembly on a work bench.
Take particular care with the copper
disk, as it bends easily and may then
cause problems after reassembly, by
brushing against the winding block.
4. Back off the screws b using a 4-mm Allen
wrench.
5. Remove the copper disk.
Continued on following page →
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 7.16
Figure 7.14-3
Disassembling the brake pulley c:
6. Unscrew the brake pulley c using a 17-mm
wrench, using a 6-mm Allen wrench to hold
the shaft in place on the opposite side.
To reassemble the brake, carry out the above
steps in reverse order.
Remember to fully lock down all the
screws b (in a cross pattern), as they
may knock against the speed sensor if
left loose. Lock down the screws using a
torque wrench set for 6 Nm
After reassembling the brake, use a
comparator to check for any curvature
of the copper disk, with a margin of ±±±±
0.15 mm.
Lock down the screw c using a torque
wrench set for 40 Nm.
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Page 7.17
7.15. DISASSEMBLING THE SPEED SENSOR
Figure 7.15-1
Carry out the procedure described in paragraph
7.6. “Disassembling the guards”.
1. Back off the 2 screws a using a small Phillips
screwdriver.
2. Remove the speed sensor.
3. If it proves difficult to back off the screws a
in their current position, back off the screws
b using a 3-mm T Allen wrench and remove
the sensor together with the support.
If the plastic sensor support is also
removed, adjust the sensor position as
described in paragraph 8.3. “Speed
sensor position”.
To reassemble the speed sensor, carry out the
above steps in reverse order.
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Page 7.18
7.16. DISASSEMBLING THE PLATFORMS WITH CSAFE BOARD
CONNECTORS AND POWER ENTRY MODULE
Figure 7.16-1
The front and rear platforms house the following
components:
• connector of the cable leading to the CSafe
board (front platform, on the right in the
figure);
• Power entry module (rear platform, on the
left in the figure).
1. To access the connectors, turn the machine
over on one side.
2. Back off the screws a of the platform which
houses the desired connector, using a
medium Phillips screwdriver.
Figure 7.16-2
At this point it is possible to:
3. Unplug connector b of the cable which goes
up to the CSafe board.
4. Back off the two screws c and remove the
Power entry module.
Continued on following page →
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 7.19
Figure 7.16-3
Disassembling the platforms (this procedure
applies for both platforms):
5. To disassemble the platforms, back off the 3
screws d using a 17-mm wrench.
To reassemble the platforms and connectors,
carry out the above steps in reverse order.
During reassembly, lock down the
screws b using a torque wrench set for
44 Nm.
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Page intentionally left blank
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Page 8.1
8. ADJUSTMENTS
8.1. BELT TENSION
Figure 8.1-1
Carry out the procedure described in paragraph
7.6. “Disassembling the guards”.
1. To adjust the tension of the belt, simply
select on of the various positions available
for the spring a.
The correct belt tension is between 34 –
40 lbs (15.9-18.1 kg).
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 8.2
8.2. PLAY OF SADDLE STEM
Figure 8.2-1
1. Raise the machine saddle to be able to access
the 2 screws a, on the bushing.
2. Turn the screws a to adjust the play of the
saddle stem, using a 3-mm Allen wrench.
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Page 8.3
8.3. SPEED SENSOR POSITION
Figure 8.3-1
Carry out the procedure described in paragraph
7.6. “Disassembling the guards”.
1. Back off the 2 screws a and shift the speed
sensor support to the side, so that it is 0.7
mm from the screws on the copper disk.
2. Lock the screws back down.
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Page 8.4
8.4. BRAKE ASSEMBLY
Figure 8.4-1
Carry out the procedure described in paragraph
7.6. “Disassembling the guards”.
1. Back off the 2 screws a and shift the brake
winding support to the side, so that it is 0.6
mm from the disk.
2. Lock the screws back down.
WARNING: check the flatness of the
copper disk using a comparator gauge:
the permissible margin is ±±±± 0.15 mm.
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Page 9.1
9. MACHINE CONFIGURATION
9.1. USER MENU CONFIGURATION
The machine configuration procedure is invoked, when the machine is in standby mode, by
simultaneously pressing the keys 369. The following prompt appears on the LED display:
ENTER PASSWORD:
To access the procedure, type in the password 2406 and press ENTER to confirm. At this point the
machine display begins showing the current configuration, structured as in the diagram below:
USER CONFI G
Language
Pause time
MAX time
Dist ance
Default age
Default weight
Default time
Default distance
HR
Custom mess.
Tgs
Keys
Format tgs key
P&P
Default config.
Default calories
9.1.1. LANGUAGE
After selecting a language from the list of those available, all messages subsequently displayed by
the machine will be in the chosen language. To change the selection, when the LED matrix shows
the current setting:
LANGUAGE : xxx
Press the +/- GOAL keys to select the desired language from the options available. Press ENTER
to confirm the choice, use the + or – effort level keys to move to the next or previous parameter.
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Page 9.2
9.1.2. DISTANCE
It is possible to choose between EUROPEAN units (kg and km) or IMPERIAL units (pounds and
miles). To change the selection, when the LED matrix shows the current setting:
DISTANCE : xxx
Press the +/- GOAL keys to select the desired unit of measurement from the options listed in the
table below:
DISTANCE
KM <default>
MLS
Press ENTER to confirm the operation, use the + or – effort level keys to move to the next or
preceding parameter.
9.1.3. MAXIMUM EXCERCISE TIME
It is possible to set a maximum duration for the exercise in minutes, with a value ranging from 1 to
9999. To change the setting, when the LED matrix shows the current maximum exercise time:
MAX TIME: xxx
Press the ENTER key to modify the value: when the current parameter value starts to blink, press
the CLEAR key to erase the current value and then use the number keys to enter the desired new
value.
Press ENTER to confirm the operation, use the + or – effort level keys to move to the next or
preceding parameter.
The default value of this parameter is 9999.
9.1.4. PAUSE TIME
It is possible to set a maximum pause time for each exercise in seconds, with values ranging from
10 to 999. To change the setting, when the LED matrix shows the current maximum time:
PAUSE TIME : xxx
Press the ENTER key to modify the value: when the current parameter value starts to blink, press
the CLEAR key to erase the current value and then use the number keys to enter the desired new
value.
Press ENTER to confirm the operation, use the + or – effort level keys to move to the next or
preceding parameter.
The default value of this parameter is 60.
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Page 9.3
9.1.5. DEFAULT AGE
It is possible to set the default age for a generic user, with values ranging from 10 to 99. To change
the setting, when the LED matrix shows the current setting:
DEFAULT AGE : xx
Press the ENTER key to modify the value: when the current parameter value starts to blink, press
the CLEAR key to erase the current value and then use the number keys to enter the desired new
value.
Press ENTER to confirm the changes made, and use the + or – effort level keys to move to the next
or preceding parameter.
The default value of this parameter is 30.
9.1.6. DEFAULT WEIGHT
It is possible to set the default weight of a generic user in KG, with values ranging from 10 to 999.
To change the setting, when the LED matrix shows the current setting:
DEFAULT WEIGHT : KG xxx
Press the ENTER key to modify the value: when the current parameter value starts to blink, press
the CLEAR key to erase the current value and then use the number keys to enter the desired new
value.
Press ENTER to confirm the changes made, and use the + or – effort level keys to move to the next
or preceding parameter.
The default value of this parameter is KG 70.
9.1.7. DEFAULT TIME
It is possible to set the default duration of the exercise in minutes, with values ranging from 10 to
999. To change the setting, when the LED matrix shows the current time:
DEFAULT TIME : MIN. xxx
Press the ENTER key to modify the value: when the current parameter value starts to blink, press
the CLEAR key to erase the current value and then use the number keys to enter the desired new
value.
Press ENTER to confirm the changes made, and use the + or – effort level keys to move to the next
or preceding parameter.
The default value of this parameter is MIN 15.
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Page 9.4
9.1.8. DEFAULT CALORIES
It is possible to set the calories for every exercise, with values ranging from 10 to 999. To change
the setting, when the LED matrix shows the current setting:
DEFAULT CALORIES : xxx
Press the ENTER key to modify the value: when the current parameter value starts to blink, press
the CLEAR key to erase the current value and then use the number keys to enter the desired new
value.
Press ENTER to confirm the changes made, and use the + or – effort level keys to move to the next
or preceding parameter.
The default value of this parameter is 300.
9.1.9. DEFAULT DISTANCE
It is possible to set the distance for every exercise in Km, with values ranging from 1 to 999. To
change the setting, when the LED matrix shows the current setting:
DEFAULT DISTANCE : KM xxx
Press the ENTER key to modify the value: when the current parameter value starts to blink, press
the CLEAR key to erase the current value and then use the number keys to enter the desired new
value.
Press ENTER to confirm the changes made, and use the + or – effort level keys to move to the next
or preceding parameter.
The default value of this parameter is KM 10.
9.1.10. ENABLE TGS
It is possible to enable or disable the use of the TGS reader. To change the selection, when the LED
matrix shows the current setting:
TGS : xxx
Press the +/- GOAL keys to select the desired option out of those listed in the table below:
TGS
ENABLED <default>
DISABLED
Press ENTER to confirm the operation, use the + or – effort level keys to move to the next or
preceding parameter.
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Page 9.5
9.1.11. ENABLE KEYBOARD
It is possible to disable the keyboard so that the machine can only be used with the TGS. To change
the selection, when the LED matrix shows the current setting:
KEYS : xxx
Press the +/- GOAL keys to select the desired option out of those listed in the table below:
KEYS
ENABLED <default>
DISABLED
Press ENTER to confirm the operation, use the + or – effort level keys to move to the next or
preceding parameter.
9.1.12. MODIFIABLE TARGET HEART RATE
It is possible to enable or disable modification of the target heart rate during a constant heart rate
exercise. To change the selection, when the LED matrix shows the current setting:
HR : xxx
Press the +/- GOAL number keys to select the desired option out of those listed in the table below:
HR
MODIFIABLE <default>
NOT MODIFIABLE
Press ENTER to confirm the operation, use the + or – effort level keys to move to the next or
preceding parameter.
9.1.13. ENABLE CUSTOM MESSAGES
It is possible to configure whether a custom message is displayed when the machine is in the
standby state. To change the selection, when the LED matrix shows the current setting:
CUSTOM MESS. : xxx
Press the +/- GOAL number keys to select the desired option out of those listed in the table below:
CUSTOM MESS.
YES <default>
NO
Press ENTER to confirm the operation, use the + or – effort level keys to move to the next or
preceding parameter.
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Page 9.6
9.1.14. RESETTING PARAMETERS TO DEFAULT VALUES
It is possible to reset the user menu parameters to their default values. To select the function, when
the LED matrix shows:
DEFAULT CONFIG.
Press ENTER to confirm the operation, use the + or – effort level keys to move to the next or
preceding parameter. If the ENTER key is pressed the LED matrix will show:
CONFIRM ?
press ENTER to confirm, or cancel by pressing the CLEAR key for a few seconds.
At the end of the configuration procedure, hold down the CLEAR key for a few seconds to exit.
The CLEAR key can be pressed at any time to interrupt the procedure and revert to standby mode.
9.1.15. FORMAT P&P
This function formats a TGS key for Plug&Play mode operation. To select the function, when the
LED matrix shows:
FORMAT P&P
press ENTER to confirm. At the end of the format procedure, hold down the CLEAR key for a few
seconds to exit. The CLEAR key can be pressed at any time to interrupt the procedure and revert to
standby mode.
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Page 9.7
9.2. SERVICE MENU CONFIGURATION
The machine configuration procedure is invoked, when the machine is in standby mode, by
simultaneously pressing the keys 369. The following prompt appears on the LED display:
ENTER PASSWORD:
To access the procedure, type in the password 2501 which protects against unauthorized access and
press the “Enter” key to confirm. At this point there are two options available:
1 = Tech Config
2 = Troubleshooting
Press the number key 1 to access the menu for configuring technical parameters; the machine
display begins showing the current configuration, structured as in the diagram below:
TECHNI CAL
CONFI GURATI ON
OPERATING
DATA
LOW KIT
MENU
TI ME AND
DATE
LOW KIT
PARAM .
HIGH KIT
VERSION
STANDARD
SETTINGS
ERRORS LOG
To scroll through the list of parameters, press the + or – effort level keys to display the next or the
preceding item.
To modify a parameter value, it is necessary to press the ENTER key: when the current parameter
value starts to blink, press the CLEAR key to erase the current value and then use the number keys
to enter the desired new value. Save the changes made by pressing the ENTER key.
To cancel the operation, press the CLEAR key for a few seconds.
The various parameters are described below.
9.2.1. TIME AND DATE
This function sets the internal clock of the lower assembly. To access this menu, when the LED
display shows:
TIME AND DATE
press ENTER. This function is structured as follows:
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 9.8
TI MES AND DAT E
Day (DD)
Minutes (MM)
SET CLOCK ?
Month (MM)
Year (YYYY)
Hours (HH)
9.2.1.1. Hour
This parameter sets the hour of the internal clock.
9.2.1.2. Minutes
This parameter sets the minutes of the internal clock.
9.2.1.3. Day
This parameter sets the date of the internal clock.
9.2.1.4. Month
This parameter sets the month of the internal clock.
9.2.1.5. Year
This parameter sets the year of the internal clock.
9.2.1.6. Set Clock
This item is used for programming the internal clock chip with the values entered previously. To do
this, when the LED matrix shows:
SET CLOCK
press the ENTER key.
9.2.2. LOW KIT PARAMETER
This function provides access to parameters used for modifying certain settings of the lower
assembly, or for monitoring the state of the machine. To access this menu, when the LED display
shows:
LOW KIT PARAM.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 9.9
press ENTER. This function is structured as follows:
LOW KI T PARAM.
Par.13
Par.01
WRITE TO
LOW KIT ?
DEFAULT
SETTINGS ?
READ FROM
LOW KIT ?
.......................
In addition to the 8 configuration parameters, this function also includes the 3 sub-functions
described below:
9.2.2.1. Read from low kit
To read the parameter values from the low kit memory and view them on the display, scroll using
the +/- keys until the LED display shows:
READ FROM LOW KIT ?
press ENTER to read the errors from the low kit, and return to the upper menu level by pressing
CLEAR for a few seconds.
9.2.2.2. Write to low kit
To write the values of the currently displayed parameters to the low kit, scroll using the +/- keys
until the LED display shows:
WRITE TO LOW KIT ?
press ENTER to write the parameters to the low kit, and return to the upper menu level by pressing
CLEAR for a few seconds.
9.2.2.3. Default Setting
To load the default parameter values, scroll using the +/- effort level keys until the LED display
shows:
DEFAULT SETTING ?
press ENTER to write the default values to the low kit, and return to the upper menu level by
pressing CLEAR for a few seconds.
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Page 9.10
9.2.2.4. Configuration parameters table
Display
parameter
Description
Default value
Par 01 Transmission ratio 143
Par 02 Coefficient for conversion of RPM to speed 9
Par 03 Minimum braking current 500
Par 04 200
Par 05 100
Par 06 15
Par 07 125
Par 08 30
Par 09 1
Par 10 30
Par 11 0
Par 12 5
Par 13 0
9.2.3. OPERATING DATA
This function makes it possible to access the machine usage data stored in the low kit. To access
this menu, when the LED display shows:
OPERATING DATA
press ENTER. This function is structured as follows:
OPERATI NG DATA
Life Kit H
Life Brake
WRITE TO
LOW KIT ?
READ FROM
LOW KIT ?
Life Kit L
Tot. Km
In addition to the machine usage data, this function also includes the 2 sub-functions described
below:
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Page 9.11
9.2.3.1. Read from low kit
To read the parameter values from the low kit memory and view them on the display, scroll using
the +/- keys until the LED display shows:
READ FROM LOW KIT ?
press ENTER to read the errors from the low kit, and return to the upper menu level by pressing
CLEAR for a few seconds.
9.2.3.2. Write to low kit
To write the values of the currently displayed parameters to the low kit, scroll using the +/- keys
until the LED display shows:
WRITE TO LOW KIT ?
press ENTER to write the new data to the low kit, and return to the upper menu level by pressing
CLEAR for a few seconds.
9.2.3.3. Machine usage data
The machine usage data on the display is updated every 10 minutes. This means that, whenever the
machine is switched off, any data modified after the last memory update will be lost.
MESSAGE ON DISPLAY DESCRIPTION
Life Brake: Minutes x 10 of operation of the brake
Life Kit H: Minutes x 10 of operation of the upper assembly
Life Kit L: Minutes x 10 of operation of the lower assembly
Tot. Km: Total km traveled
By selecting one of the items in the above table it is possible to modify its content, but only after
having cleared its value. When the ENTER key is pressed the message "Reset life..." appears,
followed by the name of the selected item; pressing ENTER again resets the value of the selected
item, while pressing CLEAR reverts to the preceding value.
9.2.4. ERRORS LOG
This function accesses the machine’s error history log. To access this menu, when the LED display
shows:
ERRORS LOG
press ENTER. This function is structured as follows:
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Page 9.12
ERRORS LOG
Error 10
Error 1
RESET ERRORS ?
READ FROM
LOW KIT ?
.......................
In addition to the error history log, this function also includes the 2 sub-functions described below:
9.2.4.1. Read from low kit
To read the errors stored in low kit memory and view them on the display, scroll using the +/- keys
until the LED display shows:
READ FROM LOW KIT ?
press ENTER to read the errors from the low kit, and return to the upper menu level by pressing
CLEAR for a few seconds.
9.2.4.2. Reset Errors
To clear the error history in both the low and high kit memory, scroll using the +/- keys until the
LED display shows:
RESET ERRORS ?
press ENTER to clear the error history logs, and return to the upper menu level by pressing
CLEAR for a few seconds.
9.2.4.3. View Errors
For every error generated by the machine, the error history log records the information in the table
below:
• Counter
• Error code
• date (dd-mm-yyyy – hh:mm)
• Current when the error occurred
• Distance in km when the error occurred
The correspondence between error codes and descriptions is given in the table below:
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Page 9.13
Error
Code
Description
1
OVERHEATING: this condition occurs when the temperature measured
by the sensor on the circuit board exceeds 90°C.
2
OVERCURRENT: this condition occurs when the current going to the
solenoid measured by the board exceed the max value.
4
UNDERVOLTAGE: this condition occurs when the +12 Vdc voltage
drops below 9.7 Vdc.
8
OVERVOLTAGE: this condition occurs when the +12 Vdc voltage goes
above 13.7 Vdc.
32
EPROM: SW error on the brake board.
128
MACHINE NOT CALIBRATED: this error condition occurs when the
calibration parameter stored in the brake board is incorrect.
Use the + speed key to advance to the next error, otherwise the message with the details of the
current error will continue to reappear.
9.2.5. STANDARD SETTINGS
This function simultaneously resets the User menu and the brake board parameters to their default
values. To access this menu, when the LED display shows:
STANDARD SETTINGS ?
press ENTER, the following message appears:
CONFIRM ?
Press ENTER again to reset all parameters to their default values, or return to the upper menu level
by pressing CLEAR for a few seconds.
This function does not alter the language setting.
9.2.6. LOW KIT MENU
This function directly accesses the firmware of the brake board. To access this menu, when the LED
display shows:
LOW KIT MENU
press ENTER. This function is structured as follows:
LOW KIT MENU
Low Kit Version
Low Kit fault code
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Page 9.14
9.2.6.1. Low kit version
This function displays the brake board firmware version. To access this menu, when the LED
display shows:
LOW KIT VERSION
press ENTER, the following message appears:
H:x L:x B:x
Which identifies the firmware version.
9.2.6.2. Low Kit fault code
This function accesses the lower electronics’ error log. To access this menu, when the LED display
shows:
LOW KIT FAULT CODE
press ENTER, the following message appears:
FAULT=XX
9.2.7. HIGH KIT VERSION
This function displays the SW version of the display. To do this, when the LED display shows:
HIGH KIT VERSION
press ENTER, the message that identifies the SW version, will appear.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 10.1
10. SCHEDULED MAINTENANCE
To keep the machine in perfect working order and forestall possible problems it is necessary to carry
out the scheduled maintenance operations described below. The maintenance operations can
essentially be classified according to the frequency with which they need to be performed:
• Daily maintenance operations;
• Monthly maintenance operations;
• Twice-yearly maintenance operations.
The operations require different levels of operator qualification. The following paragraphs describe
the recommended procedures.
10.1. DAILY MAINTENANCE OPERATIONS
These operations can be carried out by the machine owner and do not require any
special skills.
The daily machine maintenance consists of simple external cleaning, for the purposes of general
hygiene.
For the daily maintenance of the machine, proceed as follows:
10.1.1. SETTING UP THE OPERATION
1. Turn off the machine by placing the switch in position 0 (OFF).
2. Unplug the mains lead from the wall outlet.
10.1.2. EXTERNAL CLEANING OPERATIONS
1. Using a cloth moistened with a neutral detergent (non acidic), clean the entire machine, taking
care not to rub too vigorously, especially on the keys of the display.
Never spray the cleaning product directly on the machine.
WARNING: do not use alcohol, petrol or other chemical products.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 10.2
10.2. MONTHLY MAINTENANCE OPERATIONS
These operations can be carried out by the machine owner and do not require any
special skills.
The monthly maintenance operations consist of simple checks on the machine’s operation and state
of wear, to ensure its safe and correct functioning.
For the monthly maintenance of the machine, proceed as follows:
10.2.1. PLAY OF THE SADDLE STEM
1. Get on the machine and begin exercising, moving your body weight backward and forward, and
from right to left. Check whether the saddle stem follows these shifts in weight, exhibiting play.
Adjust the amount of play if necessary.
10.2.2. CHECK WEAR OF FOOT STRAPS
1. Check the state of wear of the foot straps. Replace if there are evident signs of wear.
10.2.3. CHECKING THE OPERATION OF THE CARDIOTESTER RECEIVER
1. Using a separate heart rate monitor, put on the transmitter band and check that the machine and
the separate monitor both measure the same heart rate, and that when the band is disconnected
the machine does not receive any signal.
2. Using a heart rate frequency simulator, check that the machine detects variations in the heart
rate.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 10.3
10.3. TWICE-YEARLY MAINTENANCE OPERATIONS
These operations can only be carried out by a qualified technician specifically trained by
Technogym and authorized to carry out machine installation and adjustments, as well as
special maintenance operations or repairs which require special knowledge of the
machine, its operation, safety systems and working procedures.
The twice-yearly maintenance operations involve checking the functioning, wear and tension of the
mechanical components so as to ensure the correct and safe operation of the machine.
For the twice-yearly maintenance of the machine, proceed as follows:
10.3.1. CARRYING OUT THE MONTHLY MAINTENANCE PROCEDURE
1. Carry out the procedure described in paragraph 10.2. “Monthly maintenance operations”.
10.3.2. SETTING UP THE OPERATION
1. Turn off the machine by placing the switch in position 0 (OFF).
2. Unplug the mains lead from the wall outlet.
10.3.3. CLEANING OPERATIONS
1. Use a vacuum cleaner to clean the interior, paying particular attention to the brake.
WARNING: when carrying out these operations, be careful not to damage the cables.
10.3.4. CHECKING THE WORKING CONDITIONS
1. Using a multimeter, check that the machine earth node is correctly connected to earth.
10.3.5. CHECKING THE WEAR OF RUBBER PARTS
1. Check the state of wear of the rubber components. Replace if there are evident signs of wear.
10.3.6. CHECKING THE BELT
1. Check the state of wear of the belt, using the pulley to turn it by hand, paying special attention to
the edges and the inner part. Replace if there are evident signs of wear.
2. Also check the tension of the belt.
10.3.7. CHECKING THE DISPLAY
1. Check the operation of all the keys on the keyboard.
2. Check the operation of all the LEDs and the buzzer.
10.3.8. CHECKING THE WIRING AND CONNECTIONS
1. Check the condition of all the cables:
• External conditions;
• Possible rusting of the connectors;
• Electrical continuity of the individual wires;
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 10.4
• Isolation of the individual wires toward ground.
Repair and/or replace any non-conforming wires.
2. Check the condition of the fuses using a tester.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 11.1
11. APPENDIX
11.1. UPDATING THE SW
To update the machine SW it is necessary to change the contents of the FLASH EPROM on the 386
board by means of an external PC connected to the CSAFE port on the machine, situated on the
lower part of the display panel.
The PC can only update the FLASH EPROM while the machine is being switched on,
before the power-on reset procedure begins.
BIKE FORMA: Service & Maintenance Manual - rev. 1.0
Page 11.2
11.2. REQUIRED TOOLS
The following tools are required for carrying out the various disassembly, adjustment and
maintenance action on the machine:
• Small Phillips screwdriver;
• Medium Phillips screwdriver;
• 7-mm wrench;
• 15-mm wrench;
• 17-mm wrench;
• 3-mm Allen T-wrench;
• 4-mm Allen T-wrench;
• 6-mm Allen T-wrench;
• 14-mm socket wrench;
• 25-mm Torx wrench;
• Snap ring pliers;
• Bicycle pedal extractor;
• Torque wrench;
• Flatness comparator.
ATTENTION: The tool sizes are expressed in mm.
0SM00280AA-UK
TECHNOGYM S.p.A.
Via G. Perticari, 20
47035 Gambettola (FC)
ITALIA
Tel.: +39-0547-650438
Fax: +39-0547-650150
e-mail: service@technogym.com
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