Technogym JOG EXCITE, Service Maintenance Manual

Page 1: ...SERVICE MAINTENANCE MANUAL REV 1 1 ...

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Page 3: ...ES 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 tha...

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Page 5: ...Emergency switch 3 3 3 1 5 Belt motor 3 3 3 1 6 Elevation motor 3 3 3 1 7 Limit switch 3 3 3 1 8 AT driver 3 3 3 1 8 1 AT driver board 3 4 3 1 8 2 AT power supply board 3 5 3 1 8 3 Fans 3 5 3 1 8 4 Breaking resistor 3 5 3 1 9 Power supply box 3 5 3 2 TREAD BELT MOTOR DRIVE 3 6 3 2 1 Mechanics 3 6 3 2 2 Controls 3 6 3 2 3 The signals involved 3 7 3 3 ELEVATION MOTOR DRIVE 3 8 3 3 1 Mechanics 3 8 3 ...

Page 6: ...d sensor 6 27 6 10 THE TELEMETRIC HR SIGNAL IS INCORRECT 6 29 7 DISASSEMBLY OF COMPONENTS 7 1 7 1 DISASSEMBLING THE DISPLAY 7 1 7 2 DISASSEMBLING THE CIRCUIT BOARDS OF THE DISPLAY 7 2 7 3 DISASSEMBLING THE KEYBOARD 7 3 7 4 DISASSEMBLING THE EMERGENCY BUTTON 7 4 7 5 DISASSEMBLING THE CARDIO RECEIVER HAND SENSOR BOARD 7 5 7 6 DISASSEMBLING THE SENSORS 7 7 7 7 DISASSEMBLING THE READY TO RUN BOARD 7 8...

Page 7: ...low kit 9 12 9 2 3 3 Machine usage data 9 13 9 2 4 Errors log 9 13 9 2 4 1 Read from low kit 9 13 9 2 4 2 Reset errors 9 14 9 2 4 3 COM Fault 9 14 9 2 4 4 View Errors 9 14 9 2 5 Standard settings 9 15 9 2 6 Low kit menu 9 15 9 2 6 1 Low kit version 9 16 9 2 6 2 Config registers 9 16 9 2 7 High kit version 9 20 9 2 8 BOOT version 9 20 9 2 9 Key Reader Version 9 20 9 3 DRIVER AUTOTUNING 9 21 9 4 REC...

Page 8: ...d running deck 10 5 10 4 5 Checking the wear of the driving roller 10 5 10 4 6 Checking the wear of the rear roller 10 5 10 4 7 Checking the shock absorbers 10 5 10 4 8 Checking the tread belt motor drive belt 10 5 10 4 9 Checking and centering the tread belt 10 5 10 4 10 Checking the display 10 6 11 APPENDIX 11 1 11 1 UPDATING THE SW 11 1 11 2 TOOLS TO USE 11 2 ...

Page 9: ...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 ...

Page 10: ... 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 ...

Page 11: ...ED display 7 Device for downloading data used by the Wellness System N not available T TGS 8 9 Color of the frame AL aluminium 10 11 Color of the paddings 00 none 12 Color of the guards 0 none 13 Type of TV model 0 none 14 15 Language BR portoguese CN chinese DE german ES spanish FR franch IT italian JP japanese NL dutch RU russian UK british english US american english 16 Type of packaging I Ital...

Page 12: ... LED display European driver Jog 700 model Excite 2 2 FEATURES AND FUNCTIONS VERSION 700 Mains voltage 180 260 Vac Frequency 50 60 Hz Consumption 2200 W Speed 0 8 18 Km h 0 5 12 mph Incline 0 15 Fast track control NO Hand sensor YES Cardio receiver HFU Ready to Run YES Calorie coach YES Runner Detection YES Training programs Quick Start Goal Time Distance Calorie 6 profiles CPR Test C HARACTERISTI...

Page 13: ...chine conforms to the following standards Europe USA Standards EN60335 1 EN55014 1 EN55014 2 EN61000 3 2 EN61000 3 3 EN957 1 EN957 6 class SA Directives 73 23 CEE 89 336 CEE 98 37 CEE UL 60601 1 In addition Electrical isolation class under EN60335 1 Classe I Protection rating IP20 2 5 AMBIENT SPECIFICATIONS Operating from 10 to 25 C Temperature Storage from 10 to 70 C Operating from 20 to 90 non c...

Page 14: ...gurations illustrated below 2 6 1 LOWER ASSEMBLY AT DRIVER BOX MAIN BOARD POWER SUPPLY BOARD J8 XPWR LIMIT SWITCH MOTOR ELEVATION MOTOR Fan 24VDC POWER SUPPLY BOX ON OFF SWITCH C I R C U I T B R E A K E R VAC C I R C U I T B R E A K E R FILTER BOARD J3 J4 J5 J7 Fan 24VDC J2 J1 RESISTANCE XR1 XR2 JF XPWR XU2 XU2 XU1 XU1 Fan 24VDC XV1 POWER SUPPLY SOCKET CU143 CU143 IN2 IN1 L4 N1 L N CU143 L3 N2 CU1...

Page 15: ...LED ARM VERSION EMERGENCY BUTTON DISPLAY DISPLAY BOARD KEYBOARD HS RECEIVER BOARD CN4 TGS BOARD CN1 CN7 CN9 CN1 CN5 CN8 MICRO L LOWER SENSOR R UPPER SENSOR L UPPER SENSOR R LOWER SENSOR READYtoRUN BOARD CU133 CU135 CU136 MICRO CU138 CBQ 32 CU137 CN6 RJ45 HD4 HD3 2 HD1 NC C C NC ...

Page 16: ...nd 12 Vdc Black J3 pin 2 2 Not connected 3 485 Tx Rx White brown J4 pin 7 4 485 Tx Rx Brown J4 pin 8 5 12 Vdc Red J3 pin 6 6 Digital Gnd Light orange J4 pin 6 7 Emergency Orange J3 pin 9 8 Reset Purple J3 pin 10 ATTENTION The pins 1 2 3 4 5 on the J4 connector are engaged by cables not connected anywhere The pins 3 4 3 12 6 11 and 7 8 are short circuited each other CU135 HS cardio receiver board c...

Page 17: ...ard Display board CN1 Signal Color Ready to Run board 1 5 Vdc power supply Brown 1 4 Reference White 2 CU138 Emergency button cable Display board Microswitch Display board CN8 Signal Color Micro Micro 1 Emergency Brown C 2 Reference White C Bridge Black NC NC CU143 High voltage cable Power supply box AT driver box Filter board Signal Color AT driver board OUT1 Neutral Brown 1 OUT2 Line Blue 2 TRM ...

Page 18: ...or Elevation motor 1 Motor Black 2 Motor Black 4 Gnd Black 5 5 Vdc power supply for encoder Red 6 Pulses White internally connected cable TRM 54 Limit switch cable AT driver board Limit switch AT driver board J8 Signal Color Limit switch 3 Contact White COM 8 Reference Brown NC EAM2068 AT Driver board connecting cable AT Power supply board AT driver board AT Power supply board XU2 Signal Color AT ...

Page 19: ... 1 Page 2 9 EAM2069 AT Driver board connecting cable AT Power supply board AT driver board AT Power supply board XU1 Signal Color AT driver board XU1 1 24 Vdc power supply Blue 1 2 Gnd 24 Vdc Blue 2 3 5 Vdc power supply Blue 3 4 Gnd 5 Vdc Blue 4 ...

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Page 21: ...re below DISPLAY DISPLAY BOARD RIGHT SENSOR LEFT SENSOR HS CARDIO REC BOARD TGS READER EMERGENCY BUTTON KEYBOARD AT DRIVER BOX AT DRIVER BOARD AT POWER SUPPLY BOARD LIMIT SWITCH MOTOR ELEVATION MOTOR Fan 24VDC AT POWER SUPPLY BOX POWER ENTRY SOCKET C I R C U I T B R E A K E R VAC C I R C U I T B R E A K E R FILTER BOARD Fan 24VDC RESISTANCE Fan 24VDC ...

Page 22: ...exercise session The board includes the following indicator LEDs LED name Color Description LED1 green if ON the 12 Vdc power supply from the AT Driver correctly reaches the board 3 1 2 TGS READER This board enables the machine to read the TGS key inserted by the user for performing workouts programmed with the Wellness System 3 1 3 HS CARDIO RECEIVER BOARD This is the board which manages the hand...

Page 23: ...t is equipped with a high inertia flywheel to permit more gradual deceleration of the tread belt in the event of a power outage or emergency stop ATTENTION dangerous voltages are present at the motor the flywheel and the metal plate on which the motor is fixed 3 1 6 ELEVATION MOTOR This is a linear actuator equipped with 24 Vdc motor integral reduction gear and a rod that is pushed backward and fo...

Page 24: ...ply voltage Connector Description 24 Vdc XU1 Power supply for the fans of the electrical box 5 Vdc XU1 Power supply for elevation motor encoder 12 Vdc XU2 Power supply for display The board includes the following indicator LEDs LED name Color Description H2 green 5 Vdc H3 green 12 Vdc H4 green 24 Vdc H5 red 400 Vdc It contains The AT driver board The AT power supply board 2 fans A breaking resisto...

Page 25: ...ning of elevation motor encoder if blinking indicates that the board is receiving the pulses from the encoder DWN_SW green status of Limit switch contact if ON indicates that the microswitch is pressed 3 1 8 2 AT power supply board It is the lower board of the assembly and it receives the 400 Vdc from the AT driver board and outputs to the AT driver board the low voltages used by the machine 3 1 8...

Page 26: ...happen in Open loop where the AT driver provides to the motor a sinusoidal voltage at a frequency that theoretically set the motor running at the selected speed During its movement the AT driver continually checks the motor by monitoring its current draw If any problems are detected low voltage overcurrent SW or HW problems with the AT driver itself etc it halts the motor and sends an alarm signal...

Page 27: ...ariable alternating voltage signal output by the AT driver pins 1 2 3 connector J5 to supply the motor Increasing the frequency of this signal increases the motor speed Thermal cut out signal Each motor phase is equipped with a normally closed thermal cutout which opens when the temperature exceeds a preset threshold The 3 thermal cutouts are connected in series and exit the motor via a 2 wire cab...

Page 28: ... the motor the display board communicates over the RS 485 serial link with the AT driver Based on the commands received the AT driver by means of a relay on the board that switches applies a 24 or 24 Vdc voltage to the motor When the motor is powered it starts turning To control the incline position the machine reads the signals outputted by a limit switch which defines a zero reference position a...

Page 29: ...disable the usage of the elevation motor If an exercise is started the machine will resume operation with only the tread belt motor enabled Only if the machine is turned off and on again it will reset the Par 07 to 0 and will restart using the elevation motor too 3 3 3 THE RESET PROCEDURE On power up the machine performs a reset procedure in order to determine the zero reference position for the i...

Page 30: ...tween a low value of 0 Vdc and a high value of 5 Vdc When measured with a multimeter this signal is at either 0 or 5 Vdc when the motor is stopped while during motor movements it is approximately 2 5 Vdc In order to function correctly the Hall sensor requires a 5 Vdc supply voltage which it receives from the elevation board pins 5 4 of connector J7 Limit switch signal The limit switch is a NC cont...

Page 31: ...e Emergency signal locks out with error code EM and the machine displays the error message HW EMERGENCY ERROR Once the AT driver has received an alarm signal even if the emergency reverts to the non tripped state the alarm condition will persist until the display board sends the reset signal resulting from any key being pressed This forces the AT driver to reinstate the serial communication to the...

Page 32: ...al generated by the display board pins 7 1 of connector CN7 sent to the AT driver pins 9 2 of connector J3 This signal is 0 Vdc under normal conditions and goes to 11 9 Vdc in the emergency condition Reset signal This is the signal generated by the display board pins 8 1 of connector CN7 sent to the AT driver pins 10 2 of connector J3 to signal to the lower assembly the resumption of normal operat...

Page 33: ...ith a power cable having the following pin out RJ45 Connector Signal 5 5 Vdc 7 Ground ATTENTION for the numbering of the pins on RJ45 connector please refer to the diagram below 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 must be wired as follows ATTENTION for the numbering of the pins on RJ45 c...

Page 34: ...llows Programming cable and plug can be ordered using the code H0002534AA 4 3 MONITOR PLUG FOR CSAFE PORT When the plug code 0WC00639AA is fitted into any one of the CSafe ports on the machine the corresponding LED should illuminate to indicate the presence of the 5 Vdc supply on the port During the CSafe port test function the plug connects the transmit channel directly to the receive channel the...

Page 35: ...nes household appliances etc or medical equipment 5 Each machine must have a dedicated supply line 6 The socket outlet and other devices on the dedicated line should be appropriately sized for the required load of 16A 7 The socket outlets must be earthed 8 No multiple connections are permitted on the earth and or the neutral cables 9 The ratio between the length and cross section ratio of the cabl...

Page 36: ...the machine 5 Place the on off switch in the 0 position 6 Plug the mains lead into the wall outlet 5 3 FIRST POWER ON After completing the installation procedure the machine is ready to be powered up To turn on the machine simply toggle the on off switch from the 0 position to the 1 position During power up the machine resets the incline After completing the power on reset the machine goes into st...

Page 37: ...onse 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 ca...

Page 38: ...assword without the numeric keypad enter one digit at a time using the and keys to change the value and the GOAL keys to scroll to the next character At this point there are two options available Tech Config Troubleshooting Press the number key 2 to access the troubleshooting menu which is structured as shown in the figure below TROUBLESHOOTING I2C Devices Test AUTOMATIC TEST MANUAL TEST UpDown Te...

Page 39: ...der corresponds to the values of the UpDown table stored in the low kit During the test the machine incline is moved from 0 to 15 and then back to 0 Each incline position is converted into a number of pulses and compared with the value in the UpDown table Two messages appear during the test Incline 15 This message appears during the upward movement when the machine incline reaches 15 Incline 3 Thi...

Page 40: ...e 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 NOTE The communication with the CSafe port and the TGS is not working if any device is not connected to the port 6 1 2 MANUAL TEST This section groups together tests for manually checking t...

Page 41: ... correct voltage Is the mains lead OK Is the voltage at the output of the machine s power inlet block correct Plug the machine into a working electrical outlet Replace the mains lead Replace the power inlet block on the machine THE DISPLAY FAILS TO ILLUMINATE Is the voltage at the input to the circuit breakers correct NO YES NO YES NO YES NO YES 2 A Replace cable CU143 1 Continued on the following...

Page 42: ... driver board correct NO YES NO YES 6 Replace the power supply board 5 A B Is the voltage at the input to the AT driver box Replace f ilter board NO 4 Is the voltage at the output of the circuit breakers correct when they are pressed Replace the circuit breakers NO 3 YES YES Is the EAM2068 cable correct check pin to pin Replace the EAM2068 cable NO YES Continued on the following page ...

Page 43: ...it boards 1 Slightly lift 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 voltage should be approximately 220 VAC 2 As for step 1 but across the input of the circuit breakers 3 As for step 1 but across the output of the circuit breakers 4 Unplug the cable coming from the filter board from the connec...

Page 44: ...nce Manual rev 1 1 Page 6 8 7 Using a tester check that the output voltage 12 Vdc on connectors J3 of the AT driver board are correct by referring to paragraph 2 7 Wiring 8 As for step 7 but on connector CN7 of the display board ...

Page 45: ...e contact In order to reinstate normal operation simply press any key If communication between the upper and lower assemblies is not immediately re established the message will remain on the display while the machine continues trying for 30 seconds after which the THE EQUIPMENT IS BLOCKED message will appear The machine keeps count of the attempts to reinstate communication by incrementing the COM...

Page 46: ...g using the Test Box Excite try replacing each of the circuit boards in turn display board or AT driver board and check whether the communication works If the outcome of the test is OK move on to step 2 2 Access the item TROUBLESHOOTINGÆAUTOMATIC TESTÆInverter Test If the outcome of the test is negative check the error code stored in the ERRORS LOG and perform the corresponding troubleshooting pro...

Page 47: ...E 6 EEPROM error Is generated when there is an error detected in the data stored on the EEprom EdC1 7 Elevation motor encoder error OtM 9 AC motor thermal cutout open Oli 10 Inverter overload caused by a DC current exceeding for the maximum allowed time I2 t the maximum permissible threshold for the inverter OLm 11 Motor overload caused by a DC current exceeding for the maximum allowed time I2 t t...

Page 48: ... Check the error code stored in memory OH OC OLi OLm Ot MST OCH SHC UU OU EdC1 OtM EM Carry out the GRADIENT NOT WORKING troubleshooting procedure OLr Carry out the SW EMERGENCY troubleshooting procedure PE The following paragraphs describe the troubleshooting procedures for these three cases ...

Page 49: ...5 1 ERROR OH This error indicates overheating of the heat sink on the AT driver board YES Replace the AT driver board OH Does the machine resume correct operation af ter being switched of f f or 1 hour Probable overheating of the AT driver The machine is OK NO ...

Page 50: ...imum weight limit 180 kg 397 lbs NO Are the bearings of the rollers in good condition NO Replace the rollers YES Replace the tread belt motor NO MST SHC 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 motor cable from the AT driver box and place the tester pr...

Page 51: ...he cause of the excessively low line voltage This error can be generated by even transient glitches in the mains supply due to overloading or other factors Therefore it can be useful to check in the inverter error log the value of mains voltage recorded at the time when the error occurred Follow the procedure step by step to correctly diagnose the problem Take particular care with the checks highl...

Page 52: ...orrect the cause of the excessively high line voltage NO This error can be generated by even transient spikes in the mains voltage resulting from overloading or other factors Therefore it can be useful to check in the error log the value of the mains voltage recorded at the time when the error occurred Follow the procedure step by step to correctly diagnose the problem Take particular care with th...

Page 53: ...e machine is OK NO Replace the AT driver board 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 Disconnect the cable TRM 06 and place the tester probes across pins 4 and 5 of its connector The measured value of the resistance should be less than 1 Ohm This value may be h...

Page 54: ... machine resume correct operation af ter being switched of f f or 1 minute YES Possible disturbance The machine is OK Replace the AT driver board NO NO OLr 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 With the machine switched off disconnect the fastons of the resistor f...

Page 55: ...rrect operation af ter being turned of f f or 10 minutes Programming correct The machine is OK Replace the AT driver board NO YES PE 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 Determine the frequency of the errors by counting the number of occurrences and by running ...

Page 56: ...ently YES Replace the AT driver board Probable interf erence The machine is OK NO Does the machine resume correct operation af ter being turned of f f or 1 minute YES 1 Replace the AT driver board NO EM 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 Determine the frequency...

Page 57: ...ead belt motor windings resistance correct NO 1 YES Replace the tread belt motor Replace the AT driver 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 cable from the motor and place a tester across its terminals U V U W and V W The measured value of the resis...

Page 58: ...be caused by a problem with the lower limit switch In fact if the limit switch malfunctions or accidentally remains in the open contact state rather than in the normally closed state the error is not generated immediately but will occur as soon as the elevation is increased beyond 1 At this point the elevation function will be locked out and parameter PAR 07 set to 1 3 The error message may be due...

Page 59: ...y step to correctly diagnose the problem Take particular care with the checks highlighted by circled numbers which are described in detail below 1 Check the parameter setting as detailed in paragraph 9 2 1 4 Table of configuration parameters 2 Place the tester probes across pins 1 and 2 of connector J7 on the AT driver board The measured value should be approximately 24 Vdc 3 Place the tester prob...

Page 60: ...ct at the output to the display board Replace cable CBQ 32 1 2 YES NO YES Replace the display board NO A Is the serial communication link between the display board and the TGS reader OK Replace the TGS reader Is the communication link between the display board and the TGS reader OK TGS reader def ective 3 3 YES NO YES Replace the display board NO A Replace the TGS reader Follow the procedure step ...

Page 61: ... tester probes across pins 1 and 3 of connector CN1 of the TGS reader The measured value should be 12 Vdc 2 As for step 1 but across pins 1 and 9 of connector CN3 on the display board 3 Use the serial communications test described in paragraph 6 1 1 5 Serial Ports Test ...

Page 62: ...eplace the receiver 2 3 YES Is the supply voltage correct at the output of the display board Replace cable CU135 Replace the display board NO YES NO Carry out the troubleshooting procedure THE TELEMETRIC SIGNAL IS INCORRECT 1 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 ...

Page 63: ...S NO YES NO Is the supply voltage correct at the input to the HS cardio receiver board Replace the HS cardio receiver board 3 YES NO Check the earth connection of the machine 1 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 the earthing of the machine using a tester ...

Page 64: ...Manual rev 1 1 Page 6 28 3 Place the tester probes across pins 2 and 1 of connector HD4 on the HS cardio receiver board The measured value should be 5 Vdc 4 As for step 2 but across pins 1 and 5 of connector CN9 on the display board ...

Page 65: ...e Is the HS cardio receiver board correctly positioned and are the connecting cables properly routed Are there sources of electromagnetic noise near the HS cardio receiver board Reposition the machines so they are adequately spaced Correct the position of the HS cardio receiver board and the routing of the cables Move the machine away f rom the noise source or attenuate the power of the noise NO Y...

Page 66: ...ng of the machine using a tester to measure the resistance between the ground pin on the power supply cable and the ground node to which the receiver is connected inside the display The value must be less than 1 Ohm 2 In the table below the minimum distances at which machines should be installed to avoid crosstalk problems DISTANCE CASING CASING machine 2 machine 2 machine 2 machine 2 Bike Recline...

Page 67: ...e cardio receiver 4 To check for electromagnetic noise near the machine use Test Box Excite as detailed here below You can use one of the following cables ELT 16 0WC00518AB CBQ 28 0WC00390AC or TRM 28 0WC00336AC as connection cable 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 so...

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Page 69: ... and unplug the mains lead from the wall outlet 2 Back off the 2 screws a using a medium Phillips screwdriver Figure 7 1 2 3 Open the display leaving it attached to the machine as shown in the figure To remove the display 4 Disconnect the connectors indicated 5 Remove the display To reassemble the display carry out the above steps in reverse order ...

Page 70: ...Disassembling the display 1 Place the display on a work bench 2 Unplug the connector indicated in the figure 3 Back off the 5 screws a using a small Phillips screwdriver 4 Remove the circuit board To reassemble the circuit boards carry out the above steps in reverse order After the reassembling of the board remember to fix the keyboard connector using a drop of hot glue ...

Page 71: ...ench 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 display board 4 Remove the protective film When reassembling the keyboard make sure that none of the keys are bent or remain pushed in After the reassembl...

Page 72: ...river 2 Remove the front display casing and place it on a work bench Figure 7 4 2 3 Disconnect the cable b from the two faston connectors on the emergency button 4 Back off the 4 screws c using a small Philips screwdriver 5 Remove the emergency button from the front side 6 Back off the 2 screws d using a medium Philips screwdriver and remove the two microswitch To reassemble the emergency button c...

Page 73: ... 7 1 Disassembling the display 1 Back off the 8 screws a using a medium Philips screwdriver 2 Remove the front display casing Figure 7 5 2 3 Cut the cable tie and remove the Receiver hand sensor board from the nylon bag Figure 7 5 3 To assemble the new receiver 1 Connect the cable to the board and bend the cables on the rear side of the board Continued on following page ...

Page 74: ... board as shown in the picture 4 Secure the sponge on the board with some tape or with a cable tie Make sure it is secured but not too fasten Figure 7 5 6 5 Encase the board in a plastic bag 6 Close and secure the plastic bag with some tape on the cable as indicated in the figure the receiving coil must be oriented upwards and toward the user as shown in the figure to side ...

Page 75: ...achine and unplug the mains lead from the wall outlet For each sensor 2 Back off the 2 screws a using a small Phillips screwdriver Figure 7 6 2 3 Lift up the top sensor 4 Remove the lower sensor 5 To disconnect the sensors unplug the two fastons b To reassemble the sensors carry out the above steps in reverse order ...

Page 76: ...ack off the screw a using a small Phillips screwdriver 3 Remove the plastic cover b from the handlebar Figure 7 7 2 4 Disconnect the connector c from the board 5 Remove the board from the plastic cover To reassemble the board carry out the above steps in reverse order During the reassembling procedure do not forget to place again the light conveyor d between the board and the cover ...

Page 77: ...handlebar pulling it out from the rear side Figure 7 8 2 To disassemble the central handlebar 3 Carry out the procedure described in paragraph 7 1 Disassembling the display 4 Back off the 8 screws b using a medium Phillips screwdriver 5 Figure 7 8 3 6 Back off the 2 screws c using a 6 mm hex wrench 7 Remove the handlebar taking care of the cable coming from the hand sensor To reassemble the handle...

Page 78: ... unplug the mains lead from the wall outlet 1 If possible lift up the machine at the elevation of 10 to make the procedure easier 2 Back off the 6 screws a using a 4 mm hex wrench 3 Remove the motor casing pulling it out from the front side of the machine To reassemble the motor guard carry out the above steps in reverse order ...

Page 79: ...onnectors a indicated in the figure of the fan and of the limit switch Figure 7 10 2 2 Turn the machine over on one side 3 Back off the 7 screws b using a 4 mm hex wrench 4 Remove the lower casing plate Figure 7 10 3 5 Back off the 4 screws c using a medium Phillips screwdriver 6 Remove the fan from the lower casing plate To reassemble the fan carry out the above steps in reverse order Remember to...

Page 80: ...t the procedure described in paragraph 7 9 Disassembling the motor guard 1 Disconnect the connector of the limit switch cable from the AT driver 2 Press on both the sides of the limit switch and pull it out from the lower side of the machine To reassemble the limit switch carry out the above steps in reverse order ...

Page 81: ...sing a medium Phillips screwdriver 2 Disconnect the cables entering the electrical box Power supply cable from the power supply box Cable connecting upper and lower assemblies Limit switch cable Ground connection cable Fan cable Tread belt motor cable Elevation motor cable TRM 08 3 Remove the entire box from its compartment in the machine To reassemble the electrical box carry out the above steps ...

Page 82: ...crewdriver 2 Lift up the cover Figure 7 13 2 1 Unplug the fan cable from the AT driver board 2 Unscrew the two screws b using a medium Phillips screwdriver 3 Remove the fan Figure 7 13 3 AT driver board 1 Unplug the flat cable coming from the AT power supply board shown in the picture 2 Unscrew the screw c using a medium Phillips screwdriver 3 Lift up the board paying attention to the cables conne...

Page 83: ...w the two screw f using a Phillips screwdriver 2 Remove the resistance Figure 7 13 6 AT power supply board 1 Unplug the cable coming from the fan g and disassembling the fan 2 Unscrew the screws h using a Phillips screwdriver 3 Unscrew the spacers i using a 7 mm wrench 4 Remove the board detaching the adhesive tape which fix the bracket indicated by the arrow on the box metal casing To reassemble ...

Page 84: ...he procedure described in paragraph 7 9 Disassembling the motor guard 1 Unplug the power supply cable from the AT driver box 2 Unplug the ground cable from the frame 3 Back off the 3 screws a using a 4 mm hex wrench 4 Remove the power supply box To reassemble the power supply box carry out the above steps in reverse order ...

Page 85: ...echanism between the drive belt and the front roller of the tread belt Figure 7 15 2 2 Unplug connector of the tread belt motor cable on the AT driver 3 Use a 13 mm wrench to back off the 4 nuts b locking down the screws on the lower side with a 6 mm hex wrench 4 Remove from the machine the plate on which is mounted the tread belt motor and disassemble it To reassemble the tread belt motor carry o...

Page 86: ...agraph 7 12 Disassembling the electrical box 1 Turn the machine over on one side 2 Remove the split pin a and then the pin b securing the elevation motor assembly to the elevation frame Figure 7 16 2 3 Remove the split pin c and then the pin d 4 Remove the elevation motor e To reassemble the elevation motor carry out the above steps in reverse order ...

Page 87: ...hese operations it is necessary to slacken the tread belt tension If the belt is to be used again follow the instructions given in paragraph 8 2 Tensioning a used tread belt to correctly re tension the belt Figure 7 17 1 Carry out the procedure described in paragraph 7 9 Disassembling the motor guard 1 Back off the screw a using a 3 mm hex wrench 2 Back off the 2 screw b using a 3 mm hex wrench 3 ...

Page 88: ...machine 7 Slacken the belt tension by backing off the two screws f which act on the rear machine roller using an 8 mm hex wrench Slacken the screws acting by turns on both the sides of the machine so that the rear roller is always parallel to the front one and to avoid to damage the roller bearings Figure 7 17 3 8 Release the spring g of the tensioning mechanism between the drive belt and the fron...

Page 89: ... motor drive belt from the motor pulley Figure 7 17 5 12 Back off the 2 screws i which are fixing the running deck to the frame of the machine using a 6 mm hex wrench 13 Remove the running deck from the side 14 Fully back off the screws which release the tension of the rear roller 15 Remove the rear roller 16 Remove the tread belt Figure 7 17 6 When reassembling the running deck remember to insert...

Page 90: ...d back off the screws using a 3 mm hex wrench accessing it from below To reassemble the various components carry out the above steps in reverse order At the end of the procedure check the tension and alignment of the tread belt as detailed at paragraph 8 1 Tensioning a new tread belt or 8 2 Tensioning a used tread belt and 8 3 Centering the tread belt ...

Page 91: ...re 8 1 2 2 Lock down by turns the screws a until the distance between the reference marks increases by 7 mm Take care that the roller is always approximately parallel with the one on the front to counteract the tension exerted by the belt on the roller bearings After completing this procedure any further adjustments should be performed using only the left hand alignment screw After completing this...

Page 92: ...ween the two reference marks made previously on the tread belt are once again spaced 1 meter apart Take care that the roller is always approximately parallel with the one on the front to counteract the tension exerted by the belt on the roller bearings This procedure is normally carried out after replacing the rear or driving roller or in cases where a used tread belt needs to be reassembled it is...

Page 93: ...e the movement of the tread belt correcting any tendency to shift to the right or left exclusively by adjusting the left tension screw a Locking down this screw favors shifting of the belt to the right and vice versa 3 Gradually increase the speed to 16 km h making any small adjustments that are necessary until the tread belt is perfectly centered ...

Page 94: ...WITCH Figure 8 4 1 1 Back off the 2 screws a fixing the limit switch stop plate 2 Adjust the position of the plate so that setting 0 of elevation the distance x from the microswitch and the plate is about 5 mm 3 After making the adjustment lock down the screws a backed off previously ...

Page 95: ...t at a time using the and keys to change the value and the GOAL keys to scroll to the next character At this point the machine display begins showing the current configuration structured as in the diagram below USER MENU Language MAX time Distance Pause time Default age Default weight TGS Custom mess Up Down Keys HR User detect Default config Default time SN Format P P Default calories Default dis...

Page 96: ... xxx Press the ENTER key to modify the parameter when the current value of the parameter starts to blink press the CLEAR key to erase the current value and then enter one digit at a time using the and keys to change the value and the GOAL keys to scroll to the next character Press ENTER to confirm the selection use the or speed keys to move to the next or preceding parameter The default value of t...

Page 97: ... KG xxx Press the ENTER key to change the parameter the current value of the parameter will start to blink at this point press the CLEAR key to erase the current value and then enter one digit at a time using the and keys to change the value and the GOAL keys to scroll to the next character Press ENTER to confirm the changes made and use the or speed keys to move to the next or preceding parameter...

Page 98: ...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 change the parameter the current value of the parameter will start to blink at this point press the CLEAR key to erase the current value and then enter one digit at a time using the and keys to change the value and the GOAL keys t...

Page 99: ...nstant heart rate exercise To change the selection when the LED matrix shows the current value 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 selection use the or speed keys to move to the next or preceding parameter 9 1 13 ENABLE CUSTOM MESSAGES It is possible to configure whethe...

Page 100: ...ressed the LED matrix will show CONFIRM press ENTER to confirm or cancel by pressing the CLEAR key for a few seconds 9 1 16 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 the operation use the or speed keys to move to the next or preceding parameter At the end of the format procedure hold do...

Page 101: ...EAR key can be pressed at any time to interrupt the procedure and revert to standby mode 9 1 18 SN This parameter shows the serial number of the machine 9 1 19 READY2RUN It is possible to set how many time in minutes before the end of the exercise the green light on the handlebar should starts blinking to indicate the soon end of the exercise Ready2Run function is managed in minutes with values ra...

Page 102: ...ress numeric key to access the menu for configuring technical parameters the machine display will begin showing the current configuration structured as in the diagram below Configuration TECHNICAL CONFIGURATION ERRORS LOG KEY READER VERS LOW KIT PARAM UPDOWN SETTINGS OPERATING DATA LOW KIT MENU BOOT VERSION STANDARD SETTINGS HIGH KIT VERSION Scroll through the parameter list using the or speed key...

Page 103: ...ed below 9 2 1 1 Read from low kit To read the parameter values from the low kit memory to view them on the display scroll using the keys until the LED display shows READ FROM LOW KIT press ENTER to read the parameters from the low kit then return to the upper menu level by pressing CLEAR for a few seconds 9 2 1 2 Write to low kit To write the values of the currently displayed parameters to the lo...

Page 104: ... position for tread belt incline 2 10 40 0 Par 04 PID proportional gain 100 0 9999 7 Par 05 PID Integral gain 100 0 9999 150 Par 06 Ramp Type 0 100 0 Par 07 Error status on DC motor encoder 0 1 0 Par 08 Serial communication timeout 10 msec 0 255 0 Par 09 DC motor encoder error timeout msec 0 255 15 Par 10 FREE 0 Par 11 Driving roller diameter mm 0 1000 74 Par 12 Pulley ratio 0 9000 211 Par 13 Erro...

Page 105: ...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...

Page 106: ...ncludes the 2 sub functions described below 9 2 3 1 Read from low kit To read the parameter values from the low kit memory to view them on the display scroll using the keys until the LED display shows READ FROM LOW KIT press ENTER to read the parameters 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 curren...

Page 107: ...ts 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 old 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 ER...

Page 108: ...the error history log records the information in the table below Counter Error Code Voltage when the error occurred Current 10 when the error occurred Speed km h when the error occurred The correspondence between error codes and descriptions is given in the table below Error code Error number Description OH 1 Overheating of the heat sinks of the AT drive and of the PFC OC 2 Overcurrent even if onl...

Page 109: ...rcuit Is generated in the event of a short circuit between a motor phase and earth 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 low kit UpDown table parameters to their default values and the operating data of the machine To access this m...

Page 110: ...ect a different parameter or press to read the value of the currently selected parameter the following message will appear READ FROM LOW KIT press ENTER to load the parameter value the following message will appear VALUE Y press ENTER to begin editing the parameter value When finished press and the following message will appear WRITE TO LOW KIT press ENTER to confirm writing the changes to the low...

Page 111: ...ator R 0 C 2 802 Load default 0 C 200 807 Reset AC Flag 0 C 20 803 Alarm clear 0 C 201 808 Reset DC Flag 0 C 40 804 Recall key prog 0 MENU D Par Address Description Value Par Address Description Value D 0 1 Output frequency 0 D 200 26 An in 1 cnf mon 0 D 1 2 Frequency ref 0 D 201 27 An in 1 monitor 0 D 2 3 Output current 0 D 202 28 An in 1 term mon 0 D 3 4 Output voltage 0 D 210 29 An in 2 cnf mon...

Page 112: ...36 Dec time 4 Jog 50 F 105 316 Frequency ref 5 0 F 250 337 Ramp S shape 0 F 106 317 Frequency ref 6 0 F 260 338 Ramp extens src 0 F 107 318 Frequency ref 7 0 F 270 339 Jump amplitude 0 F 108 319 Frequency ref 8 0 F 271 340 Jump frequency 1 0 F 109 320 Frequency ref 9 0 F 272 341 Jump frequency 2 0 MENU I Par Address Description Value Par Address Description Value I 0 100 Dig input 1 cfg 1 I 313 14...

Page 113: ...453 DC braking stop 0 P 42 408 Motor power fact 78 P 320 454 Autocapture mode 0 P 43 409 Motor stator R 100 P 321 456 Autocapture Ilim 120 P 44 410 Motor cooling 1 P 322 457 Demagnetiz time 8 P 45 411 Motor thermal K 30 P 323 458 Autocap f scan 10 P 60 412 V f shape 1 P 324 459 Autocap V scan 2 P 61 413 Max out voltage 230 P 325 460 Enc for FlyRes 0 P 62 414 Base frequency 600 P 326 461 Fre for Fl...

Page 114: ...ake res OL en P 999 490 Param prot code 0 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 9 2 8 BOOT VERSION This function displays the BOOT version To do this when the display shows BOOT VERSION press ENTER to display the message which identifies th...

Page 115: ...hine or result in malfunctions potentially dangerous to the user Therefore only attempt to program the inverter if you are certain of performing the procedure correctly 9 4 RECALL PARAMETERS It is possible to restore all the parameters to the values they had at the last save operation Carry out the operation by setting parameter C 1 address 801 to 1 following the detailed instructions provided in ...

Page 116: ... following the detailed instructions provided in paragraph 9 2 6 2 Config registers Although the changes made to the parameters come into effect immediately they are not automatically stored in permanent memory this requires a specific write operation effected using the command C 0 Save the data by setting parameter C 0 address 800 to 1 following the detailed instructions provided in paragraph 9 2...

Page 117: ...scribe 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 swit...

Page 118: ... the machine halts displaying the PRESS A KEY message 10 2 2 COMPLETE OPERATION 1 When the machine is switched on check that it performs the power on self test procedure which sounds the buzzer resets the incline At the end of which the machine goes into standby awaiting a keyboard command 2 To check the correct operation of the machine get on the machine press the Start key to begin the exercise ...

Page 119: ...ge the cables 5 Move the machine and clean the floor underneath using a vacuum cleaner 10 3 2 CHECKING THE STATE OF WEAR 1 With the machine stopped check the state of wear of the entire surface of the tread belt turning it by hand If any anomalies are found call in an authorized Technogym service technician 10 3 3 CHECKING THE OPERATION OF THE CARDIOTESTER RECEIVER 1 Using a separate heart rate mo...

Page 120: ...nthly maintenance of the machine proceed as follows 10 4 1 CARRYING OUT THE MONTHLY MAINTENANCE PROCEDURE 1 Carry out the procedure described in paragraph 10 3 Monthly maintenance operations 10 4 2 CHECKING THE WORKING CONDITIONS 1 Check that the machine is connected directly to the wall outlet without any extension cords and that the outlet is correctly earthed 2 Using a multimeter check that the...

Page 121: ...ers running deck and tread belt disassembled check the state of wear of the rear roller Replace if there are evident signs of wear 2 With the machine in motion check the noisiness of the bearings Replace in the event of excessive noise 10 4 7 CHECKING THE SHOCK ABSORBERS 1 With the front and rear rollers running deck and tread belt disassembled check the condition of the shock absorbers on either ...

Page 122: ...JOG EXCITE Service Maintenance Manual rev 1 1 Page 10 6 10 4 10 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 ...

Page 123: ...l The PC can only update the FLASH EPROM during machine power up before the self test sequence begins After the Display SW update it is necessary to restore all the parameters to the default values following the detailed instructions provided in paragraph 9 1 15 Resetting parameters to default values After the lower electronic SW update it is necessary to restore all the parameters to the default ...

Page 124: ...intenance operations on the machines Small Phillips screwdriver Medium Phillips screwdriver Flat head screwdriver 7 gauge wrench 13 gauge wrench 17 gauge wrench 3 gauge hexagonal T wrench 4 gauge hexagonal T wrench 4 gauge hexagonal T wrench 6 gauge hexagonal T wrench 8 gauge hexagonal T wrench Torque wrench CAUTION Tool measurements are expressed in mm ...

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Page 126: ...0SM00484AA UK TECHNOGYM S p A Via G Perticari 20 47035 Gambettola FC ITALIA Tel 39 0547 650638 Fax 39 0547 650150 e mail service technogym com ...