ergoselect III service manual

ergoselect 1

201000563000 • Version 2018-11-01 • Rev. 01 • english

Contents
General informations to the service manual . . . . . . . . . . . . . . . . . . . . 5

General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Leakage currents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection according to German Medical Device Operator Ordinance. . . . . . . . . . . . . . . . 7

Preventive Maintenance / Funtional tests . . . . . . . . . . . . . . . . . . . . . 8

Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Test procedure “RPM / Load“. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Electronic modules / Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Description of electronic and cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
abbreviations (Electronic modules / PCBs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Placement of electronic bioards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembling of CMU board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power supply unit exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Block diagrams bike ergometer electronics ergoselect 1. . . . . . . . . . . . . . . . . . . . . 17
Wiring diagrams bike ergometer electronics ergoselect 1 . . . . . . . . . . . . . . . . . . . . 18
Control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CDU - Control unit type C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BT - Bluetooth module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
WLAN (WiFi) - module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Load regulation and interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CMU - Load regulation and interface board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Mechanical assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Mounting the Handlebar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Handlebar - Adjust fixture (inclination). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Handlebar - Dismounting / mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Remove Ergometer Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Dismount pedal cranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Remove housing ergoselect 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Saddle height fixture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Clamping plate exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Load unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Assembly of the load unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Load unit exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Exchange of the timing belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Strain gauge module exchange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Control unit C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Dismounting the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Open the control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
LC-Display exchange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

-3-
Service menu control unit P. . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Activating service menu control unit P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Service functions control unit C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Baudrate 8N2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Software Update. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Dynamic Load Cal.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
System Config. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Reset DMS values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
PC-Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Service Date. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Ergometer Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Dynamic Load Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Software update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Addendum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Errorcodes Software ergoselect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Error code bits CDU (Control terminal C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Error code bits CMU (Load regulation and interface PCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

-4-
General informations to the service manual
• ergoline GmbH considers itself responsible for the effects on safety,reliability, and performance of the equipment, only
if:
- assembly operations, extensions, readjustments, modifications, or repairs are carried out by ergoline GmbH or by
persons authorized by ergoline GmbH,
- the electrical installation of the relevant room complies with the applicable national and local requirements,
- and the instrument is used in accordance with the intended use and the instructions for use.

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

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

• This manual is valid for the following instrument types:

ergoselect 1

with control unit C and all optional modules

and software versions from CF 1.0

• All rights are reserved for instruments, circuits, techniques, and names appearing in the manual.

• This manual was written with the utmost care. Should you still find details that do not correspond with the system,
please let us know and we will correct the issue as soon as possible.

• We reserve the right to modify the design and technical features of the device and are not bound by the information
and illustrations provided in this manual.

• All trademarks appearing in this document are trademarks of their respective owners. Their protection is acknowledged.

• No part of this manual may be reprinted, translated or reproduced without the manufacturer's written permission.

• This manual is not subject to any change order service. Please contact the manufacturer for the latest document
revision.

Printed in Germany

ergoline GmbH
Lindenstrasse 5
72475 Bitz
Germany

Phone: +49-(0)-7431 - 9894 -0

Fax: +49-(0)-7431 - 9894 -128
e-mail: service@ergoline.com
http: www.ergoline.com

-5-
General Information
• The products ergoselect bear the CE marking CE‑0123
(Notified Body: TÜV), indicating their compliance
with the provisions of the Council Directive 93/42/
EEC about medical devices and fulfills the essential
­requirements of Annex I of this directive. • The regulations about handling ESD sensitive components
The CE marking covers only the accessories listed in
the Order Information chapter.
The ergometers are a MDD class IIa product.
• The device fulfills the requirements of standard
EN 60601-1 "Medical Electrical Equipment, Part 1:
General Requirements for Safety" as well as the
interference protection requirements of standard
EN 60601-1-2 "Electromagnetic Compatibility –
Medical Electrical Devices". • The requirements of §11 section 6, §11 section 5
The radio-interference emitted by this product is
within the limits specified in EN 55011, class B.
• The user manual is an integral part of the equipment.
It should be available to the equipment operator at
all times. Close observance of the information given
in the user manual is a prerequisite for proper device
performance and correct operation and ensures
patient and operator safety.
• Observance of the safety information protects from
injuries and prevents inappropriate use of the device.
All equipment users and persons responsible for
assembly, maintenance, inspection and repair of the
device must read and understand the content of the
user manual and this service manual, before using or
work on it. the different device categories.
Paragraphs with special symbols are of particular
importance.
• This manual reflects the equipment specifications
and applicable safety standards valid at the time of
printing. All rights are reserved for devices, circuits,
techniques, software programs, and names appearing
in this manual.
• The ERGOLINE quality management system complies
with the standards EN ISO 13485: 2016.
-6-
Electrical Safety
Warning
• Equipment Damage •
must be observed.
Hint
Requirements for Persons stipulated in the German
Medical Device Operators Ordinance
sentence 1 and §6 section 4 of the MPBetreibV
(German Medical Device Operator Ordinance) must be
satisfied.
Warning
• Patient Hazard, Equipment Damage •
• IEC 60601-1 requirements must be satisfied during repair,
modifications and inspections of medical
electrical equipment.
• To ensure that equipment functions faultlessly and wit-
hout presenting any hazard after service interventions,
it must be subjected to the test procedures stipulated for
• A device is considered to be unsafe, when:
- it cannot be repaired
- the user does not wish to have the device repaired.
In this case, the operator must be informed in
writing of the hazard presented by the device.
The same remark must be annotated on the
service report and on the service invoice..
• Patient Hazard, Equipment Damage •
• Use original spareparts only.
• For information about product changes, refer to the
manufacturer’s original documentation only.
• Observe the fuses’ original ratings, characteristics and
Ampere interrupting capacity.
• Parts of the device that ensure its safe operation must be
neither damaged nor obviously unsuitable. This applies to
insulation and insulating components in particular.
• Power cords must be visually inspected for signs of
damage before connecting them to the power line.
Leakage currents
Measuring equipment
The measuring equipment used for the electrical safety
tests must be inspected and calibrated at regular intervals.
As per the German Medical Device Operator Ordinance, the
measurement results must be documented in the medical
device book.

ergoselect 1
These ergometers are protection class II equipment
(no connection of ergometer frame to protective ground).
The necessary electrical safety tests for these devices
together with the limit values are listed in the chapters
„Preventive maintanance“.

Inspection according to German Medical

Device Operator Ordinance

Technical Safety Inspections and Inspections of the

Measuring Systems
According to §6 and §11 of the German Medical Device
Operator Ordinance, the load unit must be inspected to
the approved rules of the art at intervals of 2 years by an
ergoline GmbH authorized service technician, and repaired
if necessary.
Hint
• §11 of the German Medical Device Operator Ordinance
demands that ergometers used in medicine, i.e. ergome-
ters for exercising patients with a defined and reprodu-
cible physical load, be calibrated with a dynamic load.

Static and dynamic inspections of the ergometer must be

performed according to DIN VDE 0750-238.

The measurement results must be documented in the

medical device book..

According to the German Medical Device Operator

Ordinance, the next due inspection is indicated on the Test
Sticker next to the ergometer’s label.

-7-
Preventive Maintenance / Funtional tests
Hint

• ergoselect 1 are protection class II devices (no connection to protective ground)

• preventive maintenance has to be performed every 2 years

Functional test
• Check the setup for stability, adjust with leveling device if required.

Expected result: No instability Pass/Fail

• Visually inspect the device:

- inspect coat of lacquer
- inspect cables / power cord

Expected result: No damage or wear detected Pass/Fail

• Check cranks and pedals:

- pedals have no signs for damage / wear
- pedals securely fixed on cranks
- crank screws securely fixed (torque 40 Nm) on axis

Expected result: Cranks and pedals OK Pass/Fail

• ergoselect 1
- Check handlebar adjustment (angle)
- Check saddle height adjustment (mechanical)
- Check that the clamping levers (saddle (height) and handlebar (angle adjustment) are tight.
Grease the threads of the clamping levers (every 2 to 6 months, depending on applicationpurpose).
(Use of an universal high-performance lubricant such as OKS 470 is recommended)

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

• Using the power cord, connect the device to the mains power line and place the power switch in the ON position
Wait for self test to end:
- check LCD for error messages
- check the software version in the service menu for correct version
- check the “error log file“ in service menu

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

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

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

-8-
• Set manual load (service menu > manual load), change load (for example, 50 W, 100 W)
- Check load level and load indication

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

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

- Check connecting cable
- Check load control via ECG recorder or PC ECG system
- Check remote start if applicable

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

-9-
Electrical Safety
Current leakage test results meet requirements?
Perform electrical safety checks when indicated.
All indicated electrical safety checks require a pass/fail indication for steps performed.
Record the measurement values in your debrief.

Step Condition UUT - ON Result Leakage

(1) (2) Current limits

Earth Leakage Current

1. Forward Polarity N/A

2. Neutral open, Forward Polarity N/A

3. Neutral open, Reverse Polarity N/A

4. Reverse Polarity N/A

Enclosure Leakage Current

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

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

3. Ground open, Forward Polarity N/A

4. Ground open, Reverse Polarity N/A

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

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

Patient Leakage Current to Ground

1. Forward Polarity NC

2. Neutral open, Forward Polarity SFC

3. Ground open, Forward Polarity N/A

4. Ground open, Reverse Polarity N/A

5. Neutral open, Reverse Polarity SFC

6. Reverse Polarity NC

Ground Continuity Resistance

1. AC mains power cord ground prong to N/A

exposed metal surface (ground lug)

(1) NC = Normal Condition

SFC = Single Fault Condition
N/A = Not Applicable
(2) UUT = Unit Under Test

- 10 -
Test procedure “RPM / Load“
Note
• Unless regulatory requirements of the country define a different test procedure or test intervall, it is recommended to perform the
test “RPM / load“ at least every 2 years..

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

Test preparation

• Dismount BOTH (!) pedal cranks of the ergoselect ergometer

• Follow the operator manual of the used calibration device to connect the calibration device with the axis
of the ergoselect ergometer.

• If supported by the calibration device, connect the ergoselect ergometer interface (RS-232 or USB) with the calibration
device.

• Connect the calibration device with the PC / notebook belonging to the device.
Start the test software of the calibration device.

RPM test protocol

• Apply a load of 100 W to the ergoselect ergometer

(-either by command of the test software or manually on the ergoselect ergometer).

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

Step Target RPM Actual RPM Deviation max. Pass / Fail

#1 30 ± 1 rpm

#2 40 ± 1 rpm

#3 50 ± 1 rpm

#4 100 ± 1 rpm

#5 120 ± 1 rpm

- 11 -
Load test protocol

• Perform the load test (RPM is set by the calibration device / load of the ergoselect ergometer is set either by command
of the test software or manually on the ergoselect ergometer step by step.

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

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

#1 40 25 ± 3 Watt

#2 40 50 ± 3 Watt

#3 40 100 ± 5 Watt

#4 70 200 ± 10 Watt

#5 90 300 ± 15 Watt

#6 100 450 ± 25 Watt

- 12 -
Tools

The following tools (metric) are recommended to disassemble the ergoselect 1 devices:

Philips screwdrivers:
1 pc. PH 2

Fork wrenches:
1 pc. 17 mm

Allan keys: Socket wrench

1 pc. 2.5 mm straight / elbow 1 pc. 5,0 mm
1 pc. 3 mm straight / elbow 1 pc. 5,5 mm
1 pc. 4 mm straight / elbow
1 pc. 5 mm straight / elbow

Ratchet with socket wrenches Pliers

1 pc. 13mm 1 pc. side cutter
1 pc. flat nose pliers

Special tools
1 pc. crank extractor
1 pc torque wrench (10 - 100 Nm)
1 pc. external calibration device for dynamic load testing
(“ergoline ergotest 550“ PN 705890) or equivalent device

- 13 -
Electronic modules / Assembly
Overview
Description of electronic and cabling

The electronic of the ergoselect 1 is based on a modular

concept.
Each module has its own processor with the appropriate
software.

To communicate between different modules, the CAN bus

is used - a stable and standardized protocol used in the
automotive industrie.

The connection between different modules is made by use

of a standard shielded CAT-5 patch cable

The cable carries the power lines (24 volt) and the CAN bus
signal lines. Standard connecting cablel (CAT-5 patch cable, shielded)

abbreviations (Electronic modules / PCBs)

CDU Compact display unit (main board)

CMU Load regulation and interface unit

DMS Torque sensor

LCD Display

BT Bluetooth Interface module

WiFi WiFi (WLAN) interface module

Placement of electronic bioards

The CDU PCB (optionally with Bluetooth or WiFi module)

is mounted in the user control unit.

The CMU PCB is mounted in the rear part of the ergometer

housing.

Position of CMU board

- 14 -
Disassembling of CMU board
For dismounting the CMU board, loose all 4 screws.

Disconnect all cables from the board - the CMU board can
be removed

- 15 -
Power supply
Power supply unit exchange
The power supply is mounted in the rear part of the
ergometer.

To exchange the power supply cut the cable ties and

remove the power supply.

Cut the cable tie at the main switch and disconnect the
power cable from the switch.

When mounting the new power supply, ensure that the

feet of the power supply housing fit into the holes in the
side panel. Tightne the new cable ties using a flat-nosed
pliers.

Connect the power cable to the main switch and fix all
cables at the switch with a cable tie.

- 16 -
 ergoselect
1
Control unit M Brake unit + interface Power supply
patient rpm
keys for eddy current strain gauge rpm sensor 1
saddlemotor brake module
power
switch
LCD supply unit
power cable

NIBP key 24 V

LIU RS-232
USB

- 17 -
DTU
Block diagrams bike ergometer electronics ergoselect 1
 Control unit C Brake unit Main switch Power supply
Eddy current brake Torque module rpm module

ergoselect
1
white white

brown black

rot

blau
RJ-45

X 14 X 13 X5 X 11

Load regulation / interface X2

CMU PCB

X3

Patch cable RJ-45 RS 232

- 18 -
USB
Wiring diagrams bike ergometer electronics ergoselect 1

X 13

POLAR
receiver
REHAB only
Control unit
CDU - Control unit type C

The CDU board represents the „mainboard“ of the

ergoselect 1 electronics.

Control unit C

CDU board (top view)

The Display (LCD) is plugged on the CDU PCB and fixed by

screws.

CDU with LCD mounted

- 19 -
The foil keyboard is plugged on the connector at the front
side of the CDU board.

Foil keyboard connector

CDU - Connectors

CDU backside

1 RJ-45 connector (patch cable to OMU)

CDU - Patient display

The LEDs for patient display (rpm) are mounted at the rear
side of the CDU board.

CDU Patient rpm display

- 20 -
BT - Bluetooth module

An optional bluetooth module for wireless communication

is available for the ergoselect 1 ergometers.

BT - Bluetooth module

WLAN (WiFi) - module

An optional bluetooth module for wireless communication

is available for the ergoselect 1 ergometers.

The WLAN parameters have to be configured using the

ergoline service programm (- download from the ergoline
internet site).

WIFI - WLAN module

Hint BT / WLAN - module mounted on CDU

• Only one interface module for wireless control can be

mounted on the CDU - either Bluetooth OR WiFi

- 21 -
Load regulation and interfaces
CMU - Load regulation and interface board

The elctronics of the CMU-PCB stabilizes the actual load of

the eddy current brake with the given accuracy.
The signal of the rpm sensor (non -contact hall sensor)
and the feedback signal of the strain gauge module are
analysed and the actual brake force adjusted accordingly.

In addition, the processor of the CMU board generates the

interface signals (RS-232 and USB) to external devices (e.g.
PC-ECG or ECG recorders).
Both signals (RS-232 and USB) are galvanically isolated
(opto couplers).

The CMU board is mounted in the rear part of the

ergometer housing.

The power supply (24 Volt) is connected to the CMU and

fed into the bus system.

The connection between CDU (control unit) and CMU is

made by a patch cable (RJ-45 jacks).

2
7
3

4 5 6
CMU board

1 RJ-45 connector for internal BUS system (CDU/MBU)

2 connector to eddy current brake
3 connector POLAR® receiver (optional for REHAB only)
4 connector power supply 24 V (from main switch)
5 connector rpm sensor
6 connector DMS module (torque sensor)
7 RS-232 interface connector (galv. isolated)
8 USB interface connector (galv. isolated)

- 22 -
Mechanical assembly
Controls and Indicators
1 Control terminal C 1 2
2 Speed readout for patient (rear)

3 Adjustment of handlebar angle

4 Castors 3
5 Leveling feet to adjust the ergometer to uneven floors

6 Sockets for power cord and connection cables 8

(underside of ergometer)

7 Power switch (toggle switch [ I / 0 ] )

7
8 Saddle adjustment with clamping lever
6

ergoselect 1

- 23 -
Mounting the Handlebar
Handlebar - Adjust fixture (inclination)

• Use an Allen key to adjust the 2 screws

• Open the handlebar lever

• Start with a quarter turn clockwise for both screws

• Close the lever and check if the handlebar is fixed

Handlebar - Dismounting / mounting

• Open the handlebar lever and turn the handlebar

downwards

• Before the handlebar can be dismounted, the control

unit has to be removed.
Unscrew the two fixing screws.

• Remove the control unit and disconnect the patch

cable.

- 24 -
• By turning the lever counterclockwise unnscrew the
lever out of the terminal adapter

• Remove the two screws fixing the rear plastic part.

• Carefully remove the rear plastic cover

• Remove the two Allen screws and dismount the rear

part of the handlebar block

• The handlebar can be changed

• Mounting in reverse order

- 25 -
Remove Ergometer Housing
Dismount pedal cranks

• Carefully lift the protective cover off the crank, using a

small flat screw driver.

• Plug the puller onto the screw of the crank

• Lose the screw with an open ended wrench (17 mm)

• Remove the scre and the lock washer

• Turn the puller and screw it strongly into the winding

of the crank screw

• Use an open ended wrench (17 mm) to remove the

crank by screwing the bolt onto the axis.

• Dismount the crank on the other side in the same way.

- 26 -
Remove housing ergoselect 1

• Untighten the lever for saddle fixation by turning it

counterclockwise - it is not necessary to remove the
lever.

• Pull the saddle tube completely out the guide tube.

• Remove the plastic ring

• Remove the two Allen screws connecting the housing

parts

• Remove the two corresponding nuts from the other

side (- press them with a tool out the housing)

- 27 -
• Remove the rear connecting screws (2 x 3 pcs.) in both
housing parts.

Remove the two front connecting screws (#2) from
one side only - they fix the connecting bolts in the #2
housing (see pictures)

#2

• The two housing parts can be removed carefully.

• Assembly of the ergoselect 1 housing in reverse order

- 28 -
Saddle height fixture
Clamping plate exchange

• Remove the housing of the ergometer.

• Remove the lever

• Untighten the Allen screw - hold the clamping plate

inside the saddle guide to prevent it from falling
down.

• Remove the clamping plate

• Insert the new clamping plate and fix it with the Allen
screw.

• ATTENTION

The Allen screw should not protrude the plate inside
the guide tube!

CORRECT WRONG

- 29 -
Load unit
Assembly of the load unit

The ergoselect 1 ergometers are equipped with an

electronically regulated eddy current brake with a
maximum load of 450 Watt.

Assembly of the load unit

1 Cast aluminium carrier

2 Calibrated strain gauge module s
3 Eddy current brake (450 W)
4 Special drive belt
5 RPM sensor (hall sensor)

Load unit exchange

• Disconnect all cables from the electronic boards and

remove them carefully through the holes.

• The load unit is fixed with 6 Allen screws at the

ergometer chassis.
Loose the screws with a ratchet (through the holes in
the bottom profile) - prevent the load unit from falling
down (weight approx.10 kg)

- 30 -
Exchange of the timing belt

• Remove the ergometer housing

• Shift the large timing belt off the timing belt pulley.

• Fix the new timing belt in the lower free wheel first
and then shift it onto the large timing belt pulley.

- 31 -
Strain gauge module exchange

• Remove the housing of the ergometer.

• Disconnect the cable of the strain gauge module from

the CMU electronic, cut the cable tie and carefully pull
out the cable.

• Remove the 2 Allen screws fixing the strain gauge

modul.

• Remove the strain gauge module (#1) and the heat

sink (#2).

• When reassembling the new module take care to

allign the module and the heat sink PARALLEL (!) to
the eddy current brake.

• The module is sensitive - the 2 Allen screws have to be

fixed carefully (do not tighten them too fast).

• Lead the connecting cable through the hole in the

saddle unit, fix it with a cable tie and connect it to the
CMU board.

- 32 -
Control unit C
Dismounting the control unit

Remove the two Phillips screws at the control unit.

Carefully remove the control unit from the handlebar pole.

Disconnect the patch cable (1) from the CDU board.

Open the control unit

Remove the 4 Allen screws (M2.5) at the bottom of the
control unit housing and lift the bottom part of the
housing.

The front and rear panel are plugged in the upper part of
the housing and can easily be removed.

- 33 -
Remove 4 nuts (M3 - socket wrench 5,5) and flip the CDU
board.

Carefully disconnect the connecting cable of the foil

keyboard from the CDU board.

LC-Display exchange

The display is fixed to the CDU board with 4 nuts (M2,5).

Use a socket wrench (5,5) to remove the nuts.
Carefully pull the display off the connector on the CDU
board..

- 34 -
Service menu control unit P
The functions of the servicemenu are described in this Hint
chapter. • The service menu in the ergometers is available in english
only.
Depending on the actual configuration of the ergoselect
4/5 ergometer, some servce functions are not visible or • Leaving the service menu is only possible by switching the
activ, device off.

• The sequence of the following descriptions does not

follow the sequence in the service menu.

Activating service menu control unit P

Turning the System On

ergoline
Turn the ergometer on by pressing the power switch
marked I/O.
The ergometer runs a self-test. Subsequently, the standard

GmbH
display appears.

Self-test screen

Note
• Do not pedal while the ergometer is being turned on and
during the self-test.
• No blood pressure cuff should be applied.
• If an error message appears immediately after the self-
test, please refer to the Addendum / Error Messages
section for advice.

- 35 -
As soon as the self test appears on the ergometer display,
press and hold the two keys synchronously:

Selftest

Activating the Service menu

To prevent settings from being changed by chance, the

service menu is „protected“ by a password.
Select „999“ with the arrow keys and confirm with SET.
Service Code

999

ENTER

Password for service menu

The service menu displays

The service software of control unit P uses the

softkeys (↑ ↓) for selection and parameter adjustments
and softkey [SET] or [ENTER] for confirmation.

Select the desired function with the softkeys (↑ ↓) and Service Menu
confirm with [ENTER]. Baudrate 8N2
Software Update
The key returns one menu level. Dynamic Load Cal.
PC Mode
Service Date
Leaving the service menu is only possible by switching the
ergometer off. ENTER

Selection of functions in service menu

- 36 -
Service functions control unit C

Note
• Modules / options have to be activated in the system
configuration before the related functions appear in the
service menu.

Functions of service menu:

• Baudrate 8N2
• Software Update
• Dynamic Load Calibration
• PC-Mode
• Service date
• Ergometer type
• System Config.
• Error log
• Reset DMS values

The sequence of the functional descriptions does not reflect the sequence in the service menu of the ergometer.

- 37 -
Baudrate 8N2
The baudrate can be selected between 1.200 Baud and Baudrate 8N2
115.000 Baud.
1.200
Default value for standard ergometers is 4.800 Baud. 2.400
Default value for REHAB ergometers is 38.400 Baud. 4.800
9.600
Select the desired parameter by use of the right and left 19.200
softkeys (↑ ↓) and confirm with ENTER.
ENTER

Selection of serial baudrate

Software Update
For a description of a software update of the ergometer
(firmware) see the separate chapter „software update“.

Dynamic Load Cal.

To perform a dynamic load calibration, a calibrated
dynamic test bench is needed.

The dynamic calibration of the load unit is described in the

separate chapter „Calibration / alignment“.

System Config.
The hardware configuration of the ergometer is defined in
this setup.

The following modules can be activated:

• Heartrate belt (nur Reha-Ergometer) System Config.

• 60 Hz. Power Freq. Heart Rate Belt 0 I
• Bluetooth (Bluetooth Interface) 60Hz Power Freq. 0 I
• WiFi (WiFi / WLAN Interface)
Bluetooth 0 I
• NIBP Dummy (*)
Wifi 0 I
• HR Screen (nur Reha-Ergometer)
NIBP Dummy 0 I
If the parameter NIBP-Dummy is set to I , a bloodpressure
value of 000/000 is sent from ergometers without ENTER
integrated NIBP module.
This enables the connection to ECG recorders which Settting of ergometer configuartion
support ergometers with NIBP module only

Select the module / option and change the setting to I

if the module is integrated in the actual ergometer.

[ESC] returns to the service menue

- 38 -
Heartrate belt
The type of the heartrate belt used can be selected. Heart rate belt
POLAR receiver 0 I
POLAR - POLAR chestbelt (e.g. T31) MM5-Modul 0 I
MM5-Modul - digital ergoline belt
MM6-Modul 0 I

ENTER

Settting of heartrate belt

60Hz Power Freq

If a 60 Hz power line is used, this setting has to be
activated.

Bluetooth
This setting is used to activate an integrated Bluetooth Bluetooth Config.
module.
Default name used is ‚Ergo01‘ - the default channel
used is ‚1‘.
Bluetooth 0 I
Name and channel can be changed by using the ergoline Name Ergo01
PC service program (- the Bluetooth module has to be Channel 1
deactivated temporarily).

ENTER

Wifi
This setting is used to activate an integrated Wifi module. Wifi Config.
IP: 192.168.200.010
IP - the actual configured IP-address
of the Wifi module
Wifi 0 I
Auto Reset - default setting is 1 Auto Reset 0 I
Reset Wifi Defaults - following an exchange of the Reset Wifi Defaults
Wifi module, the actual stored Module Reset
configuration of the defect
module can be restored to the ENTER
new one
Module Reset - a module reset is performed
(for test purposes only)

The configuration of the Wifi module is only possible by

using the ergoline PC service program .
the ergometer has to be connected via cable (RS-232
or USB) - the Wifi module has to be deactivated during
configuration..
(see manual of ergoline service program).

- 39 -
NIBP Dummy
If the parameter NIBP-Dummy is set to I , a bloodpressure
value of 000/000 is sent from ergometers without
integrated NIBP module.
This enables the connection to ECG recorders which
support ergometers with NIBP module only

HR Screen
This setting is only used for ergoselect 1 rehab ergometers
with integrated cardio set (‚heart rate belt“).
Activating this setting results in showing the actual patient
heart rate on the ergometer display during PC mode.

Reset DMS values

This function restores the calibration values of the DMS
module to standard values.

After exchange of the DMS module, this function should

only be used, if no calibrated load test bench is available to
perform a dynamic load calibration.

PC-Mode
PC-Mode „Automatic“ PC Mode
If „YES“ is activated, the ergometer automatically switches
to remote mode (PC mode) as soon as a valid signal is
Automatic
received from the interface.
Yes
No

ENTER

Automatic Mode

Service Date
The next inspection date can be set in this menu (the Service Date
inspection date is visible under „settings“ for the user.
08. 12. 2011
A hint „Service“ when switching the ergometer on can be Show message
activated. NO
The operating hours represent the time, the ergometer was
Operating Hours
powered on, independently from any load or activity on 127
the bike. ENTER

Adjustment of the service date

Display of operating hours

- 40 -
Ergometer Type
If in PC mode an „I“ command is received, the ergometer Ergometer Type
sends an identification data string to the PC. / ECG
recorder.
ER 900
To maintain compatibility to ergoline ergometers of the
former generation, the ergoselect ergometer identify as ER 800
Ergometrics 900 ergometers.

The identification may be changed by use of this ENTER

parameter:
Configuration of identification data string
setting ER900 identifies with: 0900P10V243
setting ER800 identifies with: V3.3

Error log
Error log
The software of the ergoselect ergometers stores internal Err. Log Quantity: 2
error messages in a special memory area (error log file). Show Error Logs
These error messages can be checked and cleared in this
Clear Error Logs
menu.

To display the stored error messages select „Show Error ENTER

Log“ and confirm with [ENTER].
Error log memory

The first error message is displayed: Error No.: 1/3

Source: DTU
• Source: The unit generating the error
1. Date: 02.09.2018
• Err.Code: Corresponding error code of 1. Time: 14:20
the software Err.Code: 0008
Quantity: 3
• Quantity: Number of occurences of
this error RETURN

Displaying a single error

By using the arrow keys, the following error messages can
be displayed.

The [RETURN] key closes the error log display

- 41 -
Dynamic Load Calibration
• Dismount BOTH (!) pedal cranks of the ergometer.

• Follow the operator manual from the manufacturer

of the calibration device being used to connect the
calibration device with the axis of the ergometer.

When a dynamic calibration is performed, the measured

actual load values are entered into the ergometer software.

The ergometer calculates the exact characteristic load

curve for regulating the eddy current brake.

The following load / rpm combinations have to be

measured during the calibration process:

• offset at no load / no rotations

• 50 Watt at 50 rotations / min

• 50 Watt at 110 rotations / min

• 400 Watt at 110 rotations / min

To activate the service menu the ergometer has to be

switched off and on again.

As soon as the self test appears on the ergometer display,

press the two softkeys synchronously:
Selftest

Activating the service menu

To prevent settings from being changed by chance, the

service menu is „protected“ by a password. Service Code
Select „999“ with the arrow keys and confirm with ENTER.
999

ENTER

Password for service menu

- 42 -
Navigate through the menus by using the arrow keys Service Menu
(saddle height) to position the cursor bar. Baudrate 8N2
Confirm the selection by pressing ENTER.
Software Update
Dynamic Load Cal.
PC Mode
Select „Dynamic load calibration“ and confirm with ENTER Service Date
ENTER

Selection of functions in service menu

• Start the offset calibration process with ENTER Dynamic Load Cal.
Calibration offset
Gain: 1,00
• The line „DMS“ shows:
stored DMS value / actual DMS value DMS: 3277 / 3219
RPM: 0 B 0 P
Load: 0 SW 0 AW
START

Dynamic load offset calibration - waiting for START

• By pressing START the actual value is averaged for 5 Dynamic Load Cal.
sec and stored
Calibration offset
Gain: 1,00
DMS: 3277 / 3222
RPM: 0 B 0 P
Load: 0 SW 0 AW
WAITING...

Dynamic load offset calibration - averaging

• Press START to start calibration step #1 Dynamic Load Cal.

Dyn. Calibration
Gain: 1,00
• Set the calibrator unit to 50 rpm
DMS: 3219 / 3219
• The line „RPM“ shows the measured rotations/min RPM: 0 B 0 P
(issued by the calibrator unit) Load: 0 SW AW
[the value „P“ is not used in the ergometer)
START

• The line „Load“ shows the target load in Watt-
automatically set by the ergometer (e.g. 50 Watt) Dynamic load calibration step 1 - waiting for START
[the value „AW“ is not used in the ergometer)

Dynamic Load Cal.

• Wait approx. 20 seconds, until the load display is At 50 /50 W 51,3 W
stable Gain: 1,00
DMS: 3219 / 3219
• By using the arrow keys, input the actual measured RPM: 50 B 0 P
load value of the calibrator (e.g. 51,3 Watt) Load: 50 SW AW

• Store the value with SET. SET

Dynamic load calibration step 1 - input load value

- 43 -
• Set the calibrator unit to 110 rpm. Dynamic Load Cal.
Dyn. Calibration
Gain: 1,00
• Press START to start calibration step #2
DMS: 3219 / 3219
RPM: 110 B 0 P
• Wait approx. 20 seconds, until the load display is Load: 50 SW AW
stable
START

Dynamic load calibration step 2 - waiting for START

• By using the arrow keys, input the actual value of the Dynamic Load Cal.
calibrator (e.g. 50,8 Watt) at the ergometer. At 110 /50 W 50,8 W
Gain: 1,00
DMS: 3219 / 3219
RPM: 110 B 0 P
Load: 50 SW AW

• Store the value with SET. SET

Dynamic load calibration step 2 - input load value

• The ergometer automatically sets the load to 400 Watt Dynamic Load Cal.
• Wait approx. 20 seconds, until the load display is
Dyn. Calibration
stable Gain: 1,00
DMS: 3219 / 3219
RPM: 110 B 0 P
Load: 400 SW AW
START

Dynamic load calibration step 3 - waiting for START

• By using the arrow keys, input the actual value of the Dynamic Load Cal.
calibrator (e.g. 403,2 Watt) at the ergometer. At 110 /400 W 403,2 W
Gain: 1,00
• Store the value with SET. DMS: 3219 / 3219
RPM: 110 B 0 P
Load: 400 SW AW
SET


Dynamic load calibration step 2 - input load value

The successfull completion of the dynamic load calibration

is confirmed. Dynamic Load Cal.

• Stop the calibration unit.

• Dismount the calibration unit and reassemble the

cranks / pedals to the ergometer Calibration successfull

Dynamic load calibration successfull

- 44 -
Software update
Hint
The software update process is identical for all ergoselect
ergometers. • Always use the latest software version for the appropriate
ergometer.
To load a new version of the internal software into the The software can be downloaded from the ergoline
ergoselect I ergometers, a PC or Laptop with USB or a website (www.ergoline.com / infoportal/software) after
serial port (RS-232) is needed. LOGIN.

To use the ergometer USB port, a special driver has to be • Use the PC update program included in the software
installed on the PC (virtual COM driver). package.

The driver software can be downloaded from the ergoline

website („Infoportal“ / „Software“) after Login.
Hint
Copy the complete software package onto the PC and
unzip it. • A software update via WiFi or Bluetooth Interface is NOT
possible.
Connect the PC or Laptop with a serial cable or USB cable Installed BT/WiFi modules have to be deactivated in the
with the egometer (Port 1 oder USB). service menu.

The software update is started in the service menu.

Activate the service menu in the control unit and select

„Software update“.

The actually installed software version is displayed. Software Update

CF 1.0
Press (↓) to display the installed software versions of the UPDATE
different electronic modules.

Grp: name of the module Grp Ap-SW X S-No.

Ap-SW: actually installed version CDU 1.0 0 80
(if =0 no connection to module) CMU 1.0 0 105
X: XCUT of software-version (always 0)
S-No.: serial number of PCB, if electronically available)

Press (↓) to display the installed bootloader versions of the UPDATE

different electronic modules.

Grp: Op-SW: Bootlo:

Grp: name of the module CDU 1.0 0.1
Op-SW: required software version
CMU 1.1 0.3
(has to be equal to the Ap-SW in previous display)
BootLo: actual bootloader version of PCB

Start the software update by pressing „UPDATE“. UPDATE

- 45 -
Update
Activate the PC- update program.

Hint

• Always use the PC update program included in the soft-

ware package.

Adjust the serial (or virtual) COM-Port used for the

connection with the ergometer.

Press CONNECT to establish the software connection.

As soon as the connection is established, the START button

becomes active (- or an error message appears).

Initiate the update by pressing „START“.

The update progress is displayed on the ergometer display

and on the PC.

After the update is performed, the ergometer has to be

switched off and on again.

- 46 -
Addendum
Errorcodes Software ergoselect 1
Every electronic module of the ergoselect 1 ergometers has its own error codes.
If an error occurs, a hexadecimal code is displayed on the ergometer display and internally stored with date/time of first
occurence and numbers of recurrences.
The displayed hexadecimal code is a combination of single error bits, each representing a special fault condition.

example: Displayed Error Source: DTU

Err.Code: 0018 (hexadecimal)

Bit conversion: 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 (0018 hex)

Bit 15
Bit 14
Bit 13
Bit 12

Bit 11
Bit 10
Bit 9
Bit 8

Bit 7
Bit 6
Bit 5
Bit 4

Bit 3
Bit 2
Bit 1
Bit 0
Error bits set: Bit 3 LCD communication error
Bit 4 +24V out of range

Note
• A service software to download Error codes and device settings from the ergoselect ergometers is available (downloadable) from
the ergoline website.

- 47 -
Error code bits CDU (Control terminal C)

Bit Error Reaction Display / Info Troubleshooting

0 Illegal program jump Safety shut down - restart ergometer (OFF / ON)
- if error persists:
replace CDU

1 Wrong SW configuration Warning - perform software update

2 not used

3 LCD communication error Safety shut down - check LCD connection

- if error persists:
replace CDU

4 +24V out of range Internal error - check power supply

- check connections:
power supply to switch to CMU
cable CDU <-> CMU

7 Safety state mode Safety shut down - restart ergometer (OFF / ON)
- if error persists:
replace control terminal

10 Bluetooth error Internal error - restart ergometer (OFF / ON)

- if error persists:
check connection Bluetooth
board to CDU
replace bluetooth board

11 WLAN (WiF) error Internal error - restart ergometer (OFF / ON)

- if error persists:
check connection WLAN (WiFi)
board to CDU
replace WLAN (WiFi) board

12 WiFi connection abort Internal error - restart ergometer (OFF / ON)

- if error persists:
check connection WLAN (WiFi)
board to CDU
replace WLAN (WiFi) board

13 WiFi connection abort / PC Internal error - restart ergometer (OFF / ON)

- if error persists:
check connection WLAN (WiFi)
board to CDU
replace WLAN (WiFi) board

14 not used

15 not used

- 48 -
Error code bits CMU (Load regulation and interface PCB)

Bit Error Reaction Display / Info Troubleshooting

0 To high rotation Warning none

- advise user to cycle less than 130 rpm

1 Load out of limit Warning - advise user to cycle between

30 and 130 rpm
- perform static calibration

2 DMS Offs. invalid Safety shut down - perform static calibration OFFSET
- if error persists:
reset DMS default values
- if error persists:
replace strain gauge module

3 DMS Gain invalid Safety shut down - perform dynamic calibration

- if error persists:
replace strain gauge module

4 +24V out of range Internal error - check power supply

- check connections:
power supply to switch to CMU
cable CDU <-> CMU

5 not used

6 Brake not released. Safety shut down - check connections:

CMU <-> brake
CMU <-> strain gauge module
- perform static calibration
- if error persists:
reset DMS default values

7 Safety state mode Safety shut down - restart ergometer (OFF / ON)
- if error persists:
replace CMU

8 Setup not ready Internal error - restart ergometer (OFF / ON)

- if error persists:
check cable CDU <-> CMU
- replace CMU

9 CAN zykl. Timeout Safety shut down - restart ergometer (OFF / ON)
- if error persists:
check cable CDU <-> CMU
- replace CMU

10 not used

11 not used

12 not used

13 not used

14 not used

15 not used

- 49 -
- 50 -
- 51 -
ergoline GmbH
Lindenstrasse 5
72475 Bitz
Germany
Fon.: +49 (0) 7431 - 98 94 0
Fax: +49 (0) 7431 - 98 94 128
email: info @ ergoline.com
http: www.ergoline.com