Technogym Runrace, Service Maintenance Manual

Page 1: ...SERVICE MAINTENANCE MANUAL REV 2 0 ...

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Page 3: ...HEN THE MACHINE IS TURNED OFF 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 propriet...

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Page 5: ... receiver 3 2 3 1 3 Display 3 2 3 1 4 Inverter 3 2 3 1 5 Inverter interface board 3 3 3 1 6 Belt motor 3 3 3 1 7 Up down motor 3 3 3 1 8 Photocell 3 3 3 1 9 Up down board 3 3 3 1 10 Microswitches 3 4 3 1 11 Power supply 3 4 3 1 12 Serial ports 3 4 3 1 13 Emergency button 3 4 3 2 TREAD BELT MOTOR DRIVE 3 5 3 2 1 Mechanics 3 5 3 2 2 Controls 3 5 3 2 3 The signals involved 3 5 3 3 UP DOWN MOTOR DRIVE...

Page 6: ... ELEVATION IS INCORRECT 6 39 6 11 THE LCD SHOWS WARNING CHECK BATTERY 6 41 6 12 THE LCD SHOWS BELT LUBRICANT OUT REFILL 6 41 6 13 THE LUBRICATION CIRCUIT DOES NOT WORK 6 42 6 14 THE MACHINE DOES NOT PRINT 6 44 6 15 THERE IS NO HEART RATE SIGNAL 6 46 6 16 THE HEART RATE SIGNAL IS INCORRECT 6 47 7 DISASSEMBLY OF COMPONENTS 7 1 7 1 DISASSEMBLING THE DISPLAY 7 1 7 2 DISASSEMBLING THE EPROM 7 2 7 3 DIS...

Page 7: ...TERS 9 4 9 3 1 Machine utilization 9 4 9 3 2 Type of lubrication 9 4 9 3 3 Distance covered since the last lubrication 9 4 9 3 4 Number of manual lubrication cycles 9 5 9 3 5 Number of automatic lubrication cycles 9 5 9 3 6 Total lubrication time 9 5 9 4 COMPLETE DISPLAY OF WORKING PARAMETERS 9 6 9 4 1 Machine utilization 9 6 9 4 2 Lubrication interval 9 6 9 4 3 Duration of automatic lubrication 9...

Page 8: ...ck absorbers 10 5 10 3 11 Checking the speed calibration 10 5 10 3 12 Checking the operation of the cardio receiver 10 5 10 3 13 Checking the oil level 10 6 11 APPENDIX 11 1 11 1 TECHNICAL NOTES ON CARDIO RECEIVERS 11 1 11 1 1 Type of ASIC 11 2 11 1 2 Presence of electromagnetic fields 11 2 11 1 3 Reducing receiver sensitivity 11 3 11 1 4 Mechanical vibrations 11 4 11 1 5 Position of the receiver ...

Page 9: ... observance may cause damage to the machine Information about the operation in progress OBSERVE observation about the operation in progress 1 2 RECOMMENDATIONS Technogym recommends the following steps for planning repair procedures Carefully evaluate the customer s description of the machine malfunction and ask all the necessary questions to clarify the symptoms of the problem Clearly diagnose the...

Page 10: ...recommended brands 3 Use special tools where specified 4 Consult the technical circulars 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 WARNING The...

Page 11: ...VAC Frequency 50 60 Hz Consumption 2500 Watt 11 A Fuse 5x20 4 A slow blow 2 3 AMBIENT SPECIFICATIONS Operating from 5 to 35 C Temperature Storage from 20 to 55 C Operating from 30 to 80 non condensing Humidity Storage from 5 to 85 non condensing 2 4 CONFORMITY TO REGULATIONS The machine conforms to the following directives Europe EMI EN 60601 1 2 Safety EN 60601 1 EN 957 1 Directive 73 23 CEE 93 6...

Page 12: ...rgone modifications for component upgrades and improvements In certain cases these modification have entailed changes to the wiring diagram In the interests of simplicity the following paragraphs give the diagrams for the most important versions 2 5 1 220 MODEL CONFORM TO IEC 601 Valid from SN 03000131 ...

Page 13: ...CK 12 pin F To CPU board CN4 AMP MOD I 4 pin M To power supply Up down board Name Type of connector Connection CN1 AMP MOD II 4 pin M To photocell CN2 AMP MATE N LOCK 4 pin F To CPU board CN3 AMP MATE N LOCK 6 pin F To up down motor and microswitches CN4 AMP MATE N LOCK 2 pin F To mains electricity supply CN5 Sauro 2 pin To transformer CN6 Sauro 2 pin To rectifier bridge Patch cables Name Type of ...

Page 14: ...k 10 11 Not used Blue 2 11 12 Status Red 2 12 13 Up Gray 2 13 14 Down White 2 14 15 Ground Violet 2 15 RN 2 Internal connection cable Patch cable Inverter interface board Up down board Patch cable CN2 Signal Color Inverter interf board CN2 Up down board CN2 1 12 V Blue 1 1 2 5 V Brown 1 2 3 Ground Gray 1 3 4 Ground White 1 4 5 12 V Violet 1 5 6 Not used Red 1 6 7 Not used Black 7 8 Start Orange 8 ...

Page 15: ...t used Grey2 12 Patch cable CN9 Signal Color Patch cable CN5 White cable 12 Vdc Blue 1 Green cable NC contact on button Brown 2 RN 4Q Internal connection cable Patch cable Serial ports Patch cable CN4 Signal Color Serial ports CN1 1 CTS Blue 1 1 2 DSR Brown 1 2 3 RX Gray1 3 4 RTS White 4 5 TX Violet 5 6 GND Red 6 7 BUS A Black 7 8 BUS B Orange 8 9 GND Brown 2 11 Level of the oil tank Blue 2 Short ...

Page 16: ...ut 1 Reference White PV24 1 Thermal cutout ref Red 1 NC thermal cutout Red 3 2 2 Start Gray 1 3 NC Alarm Violet AL1 4 Alarm reference Red AL0 5 Vref 0 10 Vdc Brown 0 6 Vref reference Black L RN 17Q Belt motor cable Inverter Belt motor Inverter Signal Color Belt motor U Phase U Blue U V Phase V Black V W Phase W Brown W PE ground Yellow Green Casing RN 6Q Up down motor cable Up down board Up down m...

Page 17: ... down board CN1 Signal Color Photocell 1 5 Vdc Red 1 2 Clock Orange 2 3 Direction Blue 3 4 Ground Black 4 RX 8Q Low voltage power supply cable Power supply Inverter interface board Power supply CN2 Signal Color Inverter interf board CN4 1 12 V Red 2 3 5 V Yellow 4 4 Ground Black 3 6 12 V Blue 1 The high voltage power supply cables and the ground connections are not described here in that they can ...

Page 18: ...RUNRACE Service Maintenance Manual rev 2 0 Page 2 8 2 5 2 220 MODEL WITH SJ100 INVERTER Valid from SN 0200531 ...

Page 19: ...erter interface board Name Type of connector Connection CN1 AMP MATE N LOCK 6 pin F To inverter CN2 AMP MATE N LOCK 12 pin F To CPU board CN4 AMP MOD I 4 pin M To power supply Up down board Name Type of connector Connection CN1 AMP MOD II 4 pin M To photocell CN2 AMP MATE N LOCK 4 pin F To CPU board CN3 AMP MATE N LOCK 6 pin F To up down motor and microswitches CN4 AMP MATE N LOCK 2 pin F To mains...

Page 20: ...nk 10 11 Not used Blue 2 11 12 Status Red 2 12 13 Up Gray 2 13 14 Down White 2 14 15 Ground Violet 2 15 RN 2 Internal connection cable Patch cable Inverter interface board Up down board Patch cable CN2 Signal Color Inverter interf board CN2 Up down board CN2 1 12 V Blue 1 1 2 5 V Brown 1 2 3 Ground Gray 1 3 4 Ground White 1 4 5 12 V Violet 1 5 6 Not used Red 1 6 7 Not used Black 7 8 Start Orange 8...

Page 21: ... 9 GND Brown 2 9 11 Level of the oil tank Blue 2 11 RN 4 Internal connection cable Patch cable Serial ports Patch cable CN4 Signal Color Serial ports CN1 1 CTS Blue 1 1 2 DSR Brown 1 2 3 RX Gray 3 4 RTS White 4 5 TX Violet 5 6 GND Red 6 7 BUS A Black 7 8 BUS B Orange 8 9 GND Brown 2 11 Level of the oil tank Blue 2 Short BK 7 Heart rate monitor cable CPU Cardio receiver CPU board K7 Signal Color Re...

Page 22: ...erence Red 1 NC thermal cutout Red 3 2 2 Start Gray 1 3 NC Alarm Violet AL1 4 Alarm reference Red AL0 5 Vref 0 10 Vdc Brown 0 6 Vref reference Black L RN 14 Belt motor cable Inverter Belt motor Inverter Signal Color Belt motor U Phase U Blue U V Phase V Black V W Phase W Brown W PE ground Yellow Green Casing RN 6 Up down motor cable Up down board Up down motor Limit Switches Up down board CN3 Sign...

Page 23: ...down board CN1 Signal Color Photocell 1 5 Vdc Red 1 2 Clock Orange 2 3 Direction Blue 3 4 ground Black 4 RX 8Q Low voltage power supply cable Power supply Inverter interface board Power supply CN2 Signal Color Inverter interf board CN4 3 5 V Yellow 4 4 Ground Black 3 1 12 V Red 2 6 12 V Blue 1 The high voltage power supply cables and the ground connections are not described here in that they can b...

Page 24: ...l rev 2 0 Page 2 14 2 5 3 220 MODEL Valid from SN 5866 The differences between the 220 model and the 220 model with SJ100 inverter are Inverter cable change from RN 5TQ to RN 5T Low voltage power supply cable change from RX 8Q to RN 8 ...

Page 25: ...tout 1 Reference White PV24 Thermal cutout reference Red PV24 1 NC thermal cutout Red 1 2 2 Start Gray FW 3 NC Alarm Violet AL1 4 Alarm reference Red AL0 5 Vref 0 10 Vdc Brown 0 6 Vref reference Black L RN 8 Low voltage power supply cable Power supply Inverter interface board Power supply CN2 Signal Color Inverter interf board CN4 1 5 V Yellow 4 2 4 5 Ground Black 3 3 12 V Red 2 6 12 V Blue 1 ...

Page 26: ...RUNRACE Service Maintenance Manual rev 2 0 Page 2 16 2 5 4 220 MODEL WITH HITACHI E2 INVERTER Valid from SN 2043 ...

Page 27: ...RUNRACE Service Maintenance Manual rev 2 0 Page 2 17 2 5 5 220 MODEL WITH LENZE INVERTER Valid to SN 2042 ...

Page 28: ...RUNRACE Service Maintenance Manual rev 2 0 Page 2 18 Page intentionally left blank ...

Page 29: ... 3 PRINCIPLES OF OPERATION 3 1 BLOCK DIAGRAM The machine block diagram is shown in the figure below 3 1 1 CARDIO TRANSMITTER It is worn by the person using the machine and transmits to the cardio receiver one pulse for every heart beat that is detected ...

Page 30: ...processor and all the logic circuits for controlling the machine and the LCD LED board contains the circuits pertaining to the display and indicators LEDs and 7 segment display The CPU board contains 2 banks of 4 dip switches each which are used for configuring the machine 3 1 4 INVERTER This is the device which supplies the three phase belt motor It receives a DC reference voltage from the invert...

Page 31: ...s when the temperature exceeds a preset threshold in order to safeguard the integrity of the motor The 3 bimetallic safeties are connected in series and reach the inverter as a NC external input signal When this contact opens the inverter generates an alarm The tread belt motor has a power of 2 2 KW 3 Hp 3 1 7 UP DOWN MOTOR It is a DC motor 48 Vdc 5 A which by means of a mechanical reduction unit ...

Page 32: ...tage at its input and outputs the DC voltages 5 V 12 V and 12 V which supply the display and the inverter interface board The model actually used is the Lambda SWT 40 This model has been starting used when the new Hitachi SJ100 inverter has been used The previous model used was the Lambda ZT 30 3 1 12 SERIAL PORTS These are ports which enable the machine to communicate with the outside world Three...

Page 33: ...into an analog input voltage to the inverter The relationship between the analog input voltage and the inverter output frequency is determined by the values of the configuration parameters in the inverter program During its movement the inverter checks the motor and if any problems are detected overvoltage overcurrent SW and HW problems to the inverter etc it halts the motor and sends an alarm sig...

Page 34: ... generated by the CPU board pins 10 3 of connector CN1 to control the motor speed It is a PWM signal that is to say a fixed frequency square wave with a variable duty cycle The logic of this control has the duty cycle decreasing with increasing speed The measurement of its DC component with a multimeter shows a value that decreases with increasing speed from a maximum of approximately 5 Vdc down t...

Page 35: ...at least one thermal cutout is triggered the contact opens and the inverter detecting the open circuit condition generates an alarm signal Alarm signal This is the signal generated by the inverter pin Al1 AL0 if a problem is detected in the motor drive or if the motor thermal cutouts open It enters the inverter interface board pins 3 4 of connector CN1 and its value is 0 Vdc under normal condition...

Page 36: ... direction by supplying it with a positive or negative voltage When the motor moves the photocell generates the pulses which are received by the up down board The up down board counts the pulses received and when the number corresponds to a 0 5 variation in the incline toggles the level of the Status signal transmitted to the CPU board The CPU board counts the number of Status signal transitions r...

Page 37: ... signal This is a square wave signal alternating between logic level low 0 Vdc and logic level high 5 Vdc generated by the photocell in response to movements of the up down motor Each pulse corresponds to a slot of the encoder wheel which is incorporated into and moves with the motor itself The signal enters the up down board pin 2 4 of connector CN1 and is used by the up down board for controllin...

Page 38: ... is a NC contact input to the up down board pin 4 6 of connector CN3 When this contact opens the circuit board inhibits movement in the down direction The upper microswitch is a NO contact input to the up down board pin 3 6 of connector CN3 The upper microswitch is always pressed therefore it provides a NC contact When this contact opens the circuit board inhibits movement in the up direction ...

Page 39: ...d of the up down motor photocell In response to a start command transmitted by the CPU board a long connecting tube conveyed the oil from the reservoir to the area indicated in the figure below 3 4 2 CONTROL SIGNALS To start the pump the CPU board sends a signal to the power distribution board which by means of a relay closes the contact carrying the supply voltage 220 VAC to the pump The CPU boar...

Page 40: ...nge 8 9 GND Brown 2 9 10 12 Vdc 10 11 Oil reservoir level Blue 2 11 12 Start pump command 12 RN 4 Internal connecting cable Free connector Serial ports Free CN4 Signal Color Serial ports CN1 Pump inter board K1 1 CTS Blue 1 1 2 DSR Brown 1 2 3 RX Gray 3 4 RTS White 4 5 TX Violet 5 6 GND Red 6 7 BUS A Black 7 8 BUS B Orange 8 9 GND Brown 2 1 10 12 Vdc 2 11 Oil reservoir level Blue 2 3 12 Start pump...

Page 41: ...signal disconnecting the supply voltage from the pump and thus causing it to stop Oil low signal This is the signal output by the pump to the pump interface board pin 4 5 of connector KR6 to indicate that the oil level in the reservoir is low The signal is normally at logic level low 0 Vdc and is asserted 5 Vdc to indicate the oil low condition The signal goes out from the pump interface board pin...

Page 42: ...RUNRACE Service Maintenance Manual rev 2 0 Page 3 14 thermal cutouts of the tread belt motor and sends it to the LENZE inverter interface board ...

Page 43: ...nector via the cable described below which is supplied together with the upgrade kit 4 1 1 NON TGS ADAPTED MACHINES TGSRN3RACE Internal cable CPU board Free connectors for cables RN1 and RN3 DB9 connector CPU board Free CN1 CN2 15 pin 12 pin Signal Color DB9 male 1 1 12 V Yellow 8 2 2 3 3 GND Green 6 4 15 4 15 1 6 1 6 7 7 Serial Brown 1 8 8 Serial White 2 9 12 9 12 4 1 2 TGS ADAPTED MACHINES TGSRN...

Page 44: ...er is as follows RUNRACE PRINTER CABLE Serial ports Printer Serial Port RS 232 Signal Color Printer 1 Screen 1 2 Tx 3 3 Rx not used 2 6 DTR 20 7 Gnd 7 The above cable can be ordered using code A434 WARNING To enable the print function dip switch No 1 of the right hand bank must be placed in the ON position as described in paragraph 9 1 The printer used must conform to the following specifications ...

Page 45: ...In order to be compatible with the machine an ECG must have a digital RS 232 port and support one of the two above named protocols The table below lists the devices which have been successfully tested MANUFACTURER MODEL TYPE PROTOCOL USED Marquette Max 1 ECG Marquette Marquette Max personal ECG Marquette Cardio Control Cardio Perfect ECG Marquette Schiller CS 100 ECG TrackMaster Schiller AT 60 ECG...

Page 46: ... a 25 pin female connector It can be used to connect the printer or an external device Its pin out is PIN SIGNAL 1 Shield 2 Tx 3 Rx 4 RTS 5 CTS 6 DSR 7 GND 4 4 2 RS 485 PORTS These connectors are actually not used however on report the pin out in the next table PIN SIGNAL 1 A BUS 3 GND 5 B BUS 7 Shield ...

Page 47: ...at least 2500 Watt 9 Do not connect other machines or users to the same wall outlet 10 Position the mains lead of the machine where is will not be underfoot For this purpose it is recommended to use the special trackways supplied with the machine 5 2 INSTALLATION To correctly install the machine proceed as follows 1 Ensure that the specifications and requirements for installation have been met see...

Page 48: ...eting this power on test the machine enters standby mode awaiting a keyboard command To check the correct operation of the machine get on the machine press the Start key on the keyboard to begin exercising check that the belt motor starts press the and keys on the keyboard and check that the tread belt speed changes accordingly press the and keys on the keyboard and check that the machine elevatio...

Page 49: ...his type of box corresponds to 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 ...

Page 50: ...ach the display Is the fuse OK Is mains lead OK Does the wall output supply the correct voltage Replace the blown fuse Replace the mains lead Connect machine to a suitable electrical output THE DISPLAY DOES NOT ILLUMINATE Is the mains voltage present at the power supply input NO YES NO YES NO YES NO YES 1 A B Continued on the following page ...

Page 51: ...t the output of the inv erter interf ace board Replace the display CPU board Replace cable RX 8Q Replace the inverter interf ace board YES NO NO YES NO YES 3 4 5 Are DC voltages output by the power supply correct 2 Replace the power supply YES A Are all DC voltages present at the f ree connector CN2 6 NO Replace cable RN 2 Replace cable RN 1 YES Continued on the following page ...

Page 52: ...automatic circuit breaker NO Is the mains voltage present at the output of the automatic circuit breaker 9 NO Replace the automatic circuit breaker YES Is the mains voltage present at the input to the filter 10 NO Replace the cable connecting the automatic circuit breaker to the filter YES Is the mains voltage present at the output of the filter 11 NO Replace the filter YES 12 Is the fuse holder c...

Page 53: ...raph 2 5 3 As for point 2 but on connector CN1 of the display CPU board 4 As for point 2 but on connector CN4 of the inverter interface board 5 As for point 2 but on connector CN2 of the inverter interface board 6 As for point 2 but on free connector CN2 7 Slightly lift the Fastons on the machine power inlet socket Place the tester probes between the live and neutral terminals of the connector The...

Page 54: ... the emergency button Correct operation YES NO NO YES 1 Is the v oltage at the output of the CPU board correct Replace cable RN 13Q Replace the CPU board NO YES 2 Follow the procedure step by step to correctly diagnose the problem Take particular care with the checks highlighted by circled numbers which are described in detail below 1 Place the tester probes between pins 2 and 3 of the emergency b...

Page 55: ...IS OFF Is the emergency button pressed Is the v oltage at the output of the CPU board correct Replace the CPU board Correct operation YES NO NO 1 Is the v oltage at the CN9 patch connector correct Replace emergency button NO YES 3 Is the v oltage at the emergency button correct Replace RN 13Q cable YES YES NO 2 A Continued on the following page ...

Page 56: ...s the v oltage at the input of the inv erter correct Replace the inverter NO YES Check the mains cables going to the inv erter Follow the procedure step by step to correctly diagnose the problem Take particular care with the checks highlighted by circled numbers which are described in detail below 1 Place the tester probes between pins 1 and 3 of the CPU board The measured voltage should be 12Vdc ...

Page 57: ... and 2 of the patch connector CN5 5 As for point 1 but on pin 0 and 1 of the relay 6 Place the tester probes between pins 6 and 8 of the relay The measured voltage should be 0 Ohm 7 Place the tester probes between pins L1 and N of the inverter The measured voltage should be 220 VAC ...

Page 58: ... down for protection from a mains voltage fluctuation spike or glitch In both cases it is recommended to turn off the machine for at least one hour in the first case and for a few minutes in the second case before resuming normal operation If the machine still does not operate correctly follow the procedures which differ depending on the inverter model used set out in the following paragraphs LENZ...

Page 59: ... the error message displayed and or memorized by the inverter E01 E02 E03 E04 E05 E06 E07 E08 E10 E11 E22 E09 E12 E14 E15 E21 None The inv erter is on YES NO Execute the procedure The inverter is of f The paragraphs below illustrate the troubleshooting procedures for each individual error code ...

Page 60: ...e 1 NO Replace the inverter YES Is the inverter output short circuited Is there a short circuit on the motor cable terminals Is the belt motor short circuited Replace the belt motor Replace the belt motor cable 2 3 YES YES NO Does the machine resume correct operation after being turned of f f or 1 minute YES Probable interference The machine is OK Replace the inverter NO NO E02 E03 E04 E05 E01 Rep...

Page 61: ...sured resistance should be very high in the order of MOhms It is difficult to obtain a stable resistance measurement however a phase can be considered short circuited or defective when the measured resistance is in the order of a few tens of Ohms 2 Place the tester probes between the blue black blue brown and black brown wires of the motor cable The measured resistance should be approximately 1 7 ...

Page 62: ...ble interf erence The machine is OK Replace the inverter NO NO E07 E06 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 turned off disconnect one of the resistor wires from the inverter terminal block and place the tester probes across the resistor The measu...

Page 63: ...ect The machine is OK Replace the inv erter NO YES E10 E08 E11 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 in the inverter error memory and by running targeted checks An error is considered freq...

Page 64: ...YES 2 Is the supply v oltage at the f ilter input correct NO Check and reinstate the wiring between the power input socket automatic circuit breaker and f ilter NO 3 Is the supply v oltage at the f ilter output correct NO Replace the f ilter YES Check and reinstate the wiring between the f ilter and inverter YES Follow the procedure step by step to correctly diagnose the problem Take particular ca...

Page 65: ...cables and place the tester probes across the filter terminals The measured voltage should be 220 VAC This error may be generated even by brief drops in the line voltage due to overloads or other causes Therefore it can be very useful to check the value of the mains voltage recorded in the inverter memory at the time when the error occurred To obtain the mains voltage the displayed value must be d...

Page 66: ...inverter correct Programming error Reprogram the inv erter NO YES Follow the procedure step by step to correctly diagnose the problem Take particular care with the checks highlighted by circled numbers which are described in detail below 1 Disconnect the motor thermal cutout cables from the inverter and place the tester probes between their terminals The measured resistance should be less than 1 O...

Page 67: ...tput Replace the inverter NO 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 Disconnect the motor cable from the inverter and place the tester probes between terminals U V and W of the inverter and the ground screw PE The measured resistance should be MOhm or higher 2 Dis...

Page 68: ...he f ilter correct NO Check and reinstate cable between the circuit breaker and the f ilter NO 3 Is the supply v oltage at the output of the f ilter correct NO Replace the f ilter YES Check and reinstate cable between the f ilter and the inv eter YES Follow the procedure step by step to correctly diagnose the problem Take particular care with the checks highlighted by circled numbers which are des...

Page 69: ...he measured voltage should be 220 VAC This error may be generated even by brief drops in the line voltage due to overloads or other causes Therefore it can be very useful to check the value of the mains voltage recorded in the inverter memory at the time when the error occurred To obtain the mains voltage the displayed value must be divided by 1 41 ...

Page 70: ... DISPLAY SHOWS E21 This inverter error message is associated with problems of high inverter temperature YES Replace the inv erter E21 Does the machine resume correct operation af ter being switched of f f or 1 hour Probable overheating of the inv erter The machine is OK NO ...

Page 71: ...None Is LED DL2 on the inv erter interf ace board illuminated Replace the inv erter NO 1 Is the alarm signal present at the inverter output YES Is the alarm signal present at the input to the inv erter interf ace board Check and or replace cable RN 5TQ Replace the inv erter interf ace board NO NO YES Is the alarm present at the input to the display Check and or replace cable RN 1 NO YES Replace th...

Page 72: ...hould be 0 Vdc under normal conditions it should be 10 Vdc 2 As for point 1 but between pins 3 signal and 4 ground of connector CN1 on the inverter interface board 3 Place the tester probes between pins 9 signal and 3 ground of connector CN2 on the inverter interface board Under an alarm condition the measured voltage should be 0 Vdc under normal conditions it should be 5 Vdc 4 As for point 3 but ...

Page 73: ...2 NO Check and or replace cable RN 17Q connecting the inv erter to the belt motor Replace the belt motor 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 motor and place a tester across its terminals U V U W and V W The measured resistance...

Page 74: ...he measured voltage should be 4 5 Vdc To check the speed PWM signal place a tester between pins 10 signal and 3 ground of connector CN1 on the CPU board When the belt is halted the measured voltage should be 5 Vdc whereas immediately after pressing the Start key on the display the reading should rapidly decrease until it reaches a fixed value corresponding to the selected speed The variation of th...

Page 75: ...RUNRACE Service Maintenance Manual rev 2 0 Page 6 27 speed The variation of the signal must be accompanied by a corresponding variation in the belt speed see Table 6 7 1 ...

Page 76: ... relationship between the display ed speed and the inv erter f requency correct Is the inverter control voltage correct YES NO YES Replace the inv erter 1 3 NO The machine is operating correctly Is the inv erter control voltage at the output of the inv erter interf ace board correct Check and or replace cable RN 5TQ between the inverter interf ace board and the inv erter YES 4 NO A 2 Check the inv...

Page 77: ...graph 9 1 to set the inverter and 8 7 to regulate the speed 2 When the machine is in operation check that the speed shown on the machine display and inverter SJ100 operating frequency correspond to the values shown in the tables below SPEED Km h PWM SIGNAL Vdc ANALOG SIGNAL Vdc FREQUENCY Hz CPU BOARD INVERTER INTERFACE BOARD INVERTER DISPLAY 10 3 CN1 10 3 CN2 5 6 CN1 L 0 DISPLAY 2 0 4 66 4 66 0 77...

Page 78: ...at during machine operation the speed shown on the display and the measured voltage correspond to the values shown in Table 6 7 1 5 Place the tester probes between pins 10 signal and 3 ground of connector CN2 of the inverter interface board Check that during machine operation the speed shown on the display and the measured voltage correspond to the values shown in Table 6 7 1 6 Place the tester pr...

Page 79: ...F Is the supply to the up down motor correct when the actuation command arrives YES NO YES 1 2 A Does the CPU board send the correct control signal NO NO Replace the CPU board Does the up down board receive the correct control signal NO Check and or replace cable RN 2 YES Replace the up down board YES 3 5 B Does the free connector CN1 receive the correct control signal 4 NO Check and or replace ca...

Page 80: ...lectricity supply NO Check and or replace the cable connecting the up down board to the filter YES Does the voltage at output by the transformer rectifier reach the up down board NO Replace the up down board YES Is the voltage at the transformer output correct Replace the transformer Replace the rectifier bridge YES NO 6 7 8 Continued on the following page ...

Page 81: ... motor NO YES Replace the photocell NO YES Does the up down board output the status signal NO Replace the up down board YES Does the free connector CN1 receive the Status signal NO Check and or replace cable RN 2 YES Is the pulse signal at the photocell output correct 10 11 12 Does the status signal reach the CPU board Replace the CPU board 13 NO Check and or replace cable RN 1 YES ...

Page 82: ...r probes between pins 15 ground and 14 signal of connector CN1 on the CPU board When the key is pressed the measured value should be approximately 4 Vdc Place the tester probes between pins 15 ground and 13 signal of connector CN1 of the CPU board When the key is pressed the measured voltage should be approximately 4 Vdc 4 Place the tester probes between pins 15 ground and 14 signal of the free co...

Page 83: ... When the motor moves the tester should detect the pulses generated by the photocell 11 Place the tester probes between pins 4 ground and 1 signal of connector CN2 on the up down board When the motor moves there should be a level changing for each 0 5 change in the machine elevation 12 As for step 11 but with the tester probes between pins 15 ground and 12 signal of the free connector CN1 13 As fo...

Page 84: ... ONLY ONE DIRECTION Are 2 LEDs on the up down board both illuminated Is the machine in one of the 2 travel limit positions YES NO YES 1 2 Does the up down board receive the correct control signal in the inactive direction NO Replace the up down board Does the free connector CN1 receive the correct control signal in the inactive direction NO Check and or replace cable RN 2 NO YES 3 A YES B Continue...

Page 85: ... switch associated with the non illuminated LED correct YES Replace the limit switch NO Does the up down board send the correct power supply to the limit switch associated with the non illuminated LED NO Check and or replace cable RN 6Q YES Replace the up down board 7 6 5 Replace the CPU board Does the CPU board send the correct control signal in the inactive direction 4 Check and or replace cable...

Page 86: ...e approximately 4 Vdc If the machine fails to move upward place the tester probes between pins 15 ground and 13 signal of the free connector CN1 the measured voltage should be approximately 4 Vdc 4 If the machine fails to move downward place the tester probes between pins 15 ground and 14 signal of connector CN1 on the CPU board the measured voltage should be approximately 4 Vdc If the machine fai...

Page 87: ...result of excessively high currents THE DISPLAYED ELEVATION IS INCORRECT Is the position of the limit switch correct Is the up down motor current correct YES NO YES Lubricate the elevation bars 2 NO Regolare la posizione dei microswitch Is the photocell clean Clean the photocell YES Replace the photocell and cable RN 12Q connecting the up down board and the photocell NO Are the elev ation bars lub...

Page 88: ... with the checks highlighted by circled numbers which are described in detail below 1 See the following table Photocell Photocell board SW Siemens SFH910 GF92015 B M3S10 Optek OPB610 GF970711 RR52V2 2 Place the tester probes in series with the motor cable When the or keys are pressed the measured steady state current should be less than 6 A ...

Page 89: ... 6 12 THE LCD SHOWS BELT LUBRICANT OUT REFILL WARNING Old SW version shows BELT LUBRICANT OUT ACT NOW instead of this message The machine displays this message when the oil level in the reservoir has reached the minimum mark WARNING This message is ambiguous and may be misinterpreted In fact it does not mean that the oil is completely out but only that its level is low Under these conditions the l...

Page 90: ...rd is working YES NO 1 2 Replace the distibutor and the oil tube Disconnect the distributor and check whether the oil comes out from the pump Replace the pump YES NO Check whether the pump command signal at the input of the pump interface board is correct Replace the pump interface board YES YES NO Check whether the pump command signal at the free connector CN3 is correct Replace cable RN 4 Check ...

Page 91: ...nd and 4 signal of connector K1 on the pump interface board During lubrication the measured voltage should be 5 Vdc 3 Place the tester probes between pins 9 ground and 10 signal of free connector CN3 The measured voltage should be 12 Vdc Place the tester probes between pins 9 ground and 12 signal of free connector CN3 During lubrication the measured voltage should be 5 Vdc 4 Place the tester probe...

Page 92: ... output of the printer cable correctly Correctly configure the machine Replace or rewire the printer cable Replace the CPU board There is a problem with the printer or the PC serial port or their respective configurations YES NO YES NO YES NO 1 2 3 THE MACHINE DOES NOT PRINT Follow the procedure step by step to correctly diagnose the problem Take particular care with the checks highlighted by the ...

Page 93: ... the other end is connected to the machine Select any training program as soon as the last input is confirmed and training starts the machine will transmit the data through the serial port The RD LED should blink red 3 Use a tester to check the continuity of printer cable A434 see paragraph 4 2 Connecting to the printer ...

Page 94: ...e BK 7 Replace the display CPU board 1 2 YES NO YES NO Follow the procedure step by step to correctly diagnose the problem Take particular care with the checks highlighted by circled numbers which are described in detail below 1 Place the tester probes between pins 1 signal and 3 ground corresponding to the red and black wires of the 4 pin receiver connector the measured voltage should be 5Vdc 2 P...

Page 95: ...itioned correctly and are the connecting cables correctly routed If the TGS is present is the TGSRN3RACE TGSRN2RACE cable correctly routed Are there sources of electromagnetic noise near the receiver Move the machines to the minimum distance see paragraph 5 1 Position the receiver and the cable correctly see paragraph 11 1 Correctly route the cable see paragraph 11 1 Move the machine away from the...

Page 96: ... numbers which are described in detail below 1 To check for electromagnetic noise near the machine use a frequency signal monitor constructed as shown in the schematic below The circuit lights the LED for every heart beat and or disturbance that is received in this way it possible to determine whether there is any interference and identify its sources 2 Check the battery power level using a tester...

Page 97: ...off the 2 screws a 3 Remove guard b Figure 7 1 2 4 Back off the 4 screws c using a 4 mm hex T wrench 5 Disconnect the cable connectors 6 Pull out the DISPLAY To disassemble the side panels 1 Back off the 4 screws d using a 4 mm hex T wrench 2 For the right hand panel disconnect the emergency cable connector 3 Remove the side panel To reassemble the DISPLAY carry out the above steps in reverse orde...

Page 98: ...e each EPROM 1 Place EPROM A on the upper socket and EPROM B on the lower socket 2 Insert the EPROM pins into the sockets starting from the left hand side so that the holes of the right hand socket remain free 3 Ensure that reference index d on the EPROM coincides with the reference notch e on its socket 4 Be careful to center the EPROM pins on the corresponding holes of the socket 5 Push the pins...

Page 99: ...ug the mains lead from the wall outlet 2 Back off the 4 screws a using a small Philips screwdriver 3 Remove guard plate b Figure 7 3 2 4 Disconnect connector c 5 Remove the BACKUP BATTERY d The BACKUP BATTERY is correctly charged if the voltage measured at the terminals of its connector is 3 6 Vdc and in any case greater than 2 5 Vdc ...

Page 100: ...crews a using a small Philips screwdriver 3 Disconnect the cardio receiver cable from connector b Figure 7 4 2 4 Push on the screw studs with a pointed tool and with the help of a flat blade screwdriver separate the outer housing c from the keyboard electronic circuit board group d Figure 7 4 3 Rest the keyboard electronic circuit board group on a work bench 5 Disconnect connectors e 6 Unscrew the...

Page 101: ...8 Using your hands disconnect strip i from the CPU board side 9 Remove the circuit boards 10 To disconnect the LCD from the CPU board back off the 4 screws l using a small Philips screwdriver or release the 4 spring fasteners 11 Disconnect or unsolder the cables on the CPU board side 12 Remove the LCD To reassemble the circuit boards carry out the above steps in reverse order ...

Page 102: ...lips screwdriver 3 Disconnect the cardio receiver cable from connector b Figure 7 5 2 4 Push on the screw studs with a pointed tool and with the help of a flat blade screwdriver separate the outer housing c from the keyboard electronic circuit boards group d Figure 7 5 3 Rest the keyboards electronic circuit boards group on the work bench 5 Disconnect the connector from the keyboard 6 Use a sharp ...

Page 103: ...e part starting from the left and working toward the right being careful not to bend the KEYBOARD 3 Plug the connector into the CPU board 4 Remove the protective film 5 Reassemble the display When reassembling the KEYBOARD make sure that none of the keys are bent or remain pushed in The KEYBOARD assembly procedure can only be carried out once because disassembly damages the tracks and keys ...

Page 104: ...sticker 4 Back off the 2 screws a using a 3 mm hex T wrench 5 Open the housing b which contains the RECEIVER Figure 7 6 2 If the receiver is situated inside the display 6 With the help of a flat blade screwdriver remove the housing c which contains the RECEIVER 7 Open the housing Figure 7 6 3 8 Disconnect connector d of cable BK 7 from the RECEIVER 9 Remove the RECEIVER To reassemble the RECEIVER ...

Page 105: ...TOP BUTTON With the side panel on a work bench 1 Back off the 2 screws a using a 4 mm hex T wrench 2 With the help of a flat blade screwdriver open the cover of the side panel from the outer housing Figure 7 7 2 3 Disconnect the three electrical cables b of the EMERGENCY STOP BUTTON using a medium Philips screwdriver 4 Back off the 2 screws c which fix the EMERGENCY STOP BUTTON to the cover using ...

Page 106: ... elastic strap provided inside the guard itself as shown in figure at left To reassemble the MOTOR GUARD carry out the above steps in reverse order Figure 7 8 3 The MOTOR GUARD can also be removed completely in order to work more freely inside the machine 1 On each side back off the dowel c using a 3 mm hex T wrench 2 Back off screw d with an 8 mm hex T wrench 3 Remove the bar guard by lifting it ...

Page 107: ...For each SIDE GUARD 2 Back off the 4 screws a using a large Philips screwdriver 3 Remove the SIDE GUARD Figure 7 9 2 4 Pull out cable clamp b and pulling on cable c expose the free connectors d CN1 CN2 on the right hand side of the machine or CN3 CN4 and CN5 CN6 on the left hand side of the machine To reassemble the SIDE GUARD carry out the above steps in reverse order ...

Page 108: ...embling the motor guard 1 Back off the 4 screws a using a 6 mm hex T wrench 2 Remove the 2 side plugs b 3 Back off the 4 self tapping screws c using a large Philips screwdriver 4 Rotate the FRONT PLATE d downward The front plate remains attached to the frame by means of two steel cables To reassemble the FRONT PLATE carry out the above steps in reverse order ...

Page 109: ...1 2 2 Back off the screw b using a medium Phillips screwdriver in the rear part of the shield grid Figure 7 11 3 3 Back off the nut c using a 10 mm wrench 4 Back off the bolt d using an 8 mm Allen T wrench 5 Disconnect the 4 fastons e of the fans power supply cables 6 Remove the shield grid pulling it out from the top To reassemble the SHIELD GRID carry out the above steps in reverse order To reas...

Page 110: ...quent tightening of the belt shift the join to the underside of the machine and measure out a distance of 1 m marking its ends with a white marker pen 5 Release the tension of the belt by backing off the 2 screws c using a 6 mm hex T wrench Figure 7 12 3 6 Raise the loosened belt and on both sides depending on the machine version new models back off the screw d using a 6 mm hex T wrench and holdin...

Page 111: ...he rear screw removed there will be enough space to move REAR ROLLER forward until it comes out of its guide and drops onto the belt 8 Pull out the REAR ROLLER To reassemble the REAR ROLLER carry out the above steps in reverse order After completing the procedure center the belt and adjust its tension as instructed in 8 2 and 8 3 ...

Page 112: ...d and 7 11 Disassembling shield grid for tread belt motor and inverter 4 Working from the lower part of the machine back off the screw a on each side using a 6 mm hex T wrench Figure 7 13 2 5 Pulling on the drive belt of the tread belt motor lift the MOTOR ROLLER so that it comes out of its support If it proves difficult to raise MOTOR ROLLER try loosening the belt tension as described in paragrap...

Page 113: ...t side If the automatic lubrication system is installed ensure that the oil reservoir cap is securely closed 3 Slightly shifting the belt on either end of the BRUSH back off the 2 knobs a fixing it to the frame 4 Pull out the BRUSH from the side If the automatic lubrication system nozzles are installed proceed as above to remove them To reassemble the BRUSH carry out the above steps in reverse ord...

Page 114: ... 2 Depending on the type of shock absorber installed New type back off the 2 rear screws a using a 6 mm T wrench Old type back off the 2 rear screws a and the 2 front screws b using a 6 mm T wrench Figure 7 15 2 3 Pull out the RUNNING TRACK and TREAD BELT group from the rear 4 Remove the TREAD BELT from the RUNNING TRACK 5 To separate the 2 tables of the RUNNING TRACK new models back off the 8 4 o...

Page 115: ...ted by the arrow on the inner side the TREAD BELT is correctly centered on the RUNNING TRACK the TREAD BELT is not pinched in the RUNNING TRACK Lubricate the RUNNING TRACK before reassembling The RUNNING TRACK must be reassembled with the 45 beveled part toward the rear roller After completing this procedure adjust the tension and centering of the tread belt as described in paragraphs 8 2 and 8 3 ...

Page 116: ...arry out the procedure described in paragraph 7 15 Disassembling the tread belt and running track For the new model 1 On each side of the machine back off the 2 nuts a using a 13 mm wrench 2 Pull out the SHOCK ABSORBERS from the top To reassemble the SHOCK ABSORBERS carry out the above steps in reverse order ...

Page 117: ... 4 screws b on the TREAD BELT MOTOR cover using a large Philips screwdriver 4 Back off the cable clamp c 5 Open the cover Figure 7 17 2 6 Disconnect the 3 phase cables d using a 7 mm wrench the earth cable e using a large Philips screwdriver the motor thermal cutout f using a small flat blade screwdriver Be careful not to drop the nuts and washers inside the TREAD BELT MOTOR Figure 7 17 3 7 Back o...

Page 118: ...EAD BELT MOTOR pushing it first inward and then upward to remove the motor drive belt To reassemble the TREAD BELT MOTOR carry out the above steps in reverse order When locking down the cover screws ensure that the cables are correctly routed inside the box to avoid pinching them with the cover When reassembling the TREAD BELT MOTOR remeber to put the insulating washer and spacer After completing ...

Page 119: ...by the motor itself in the figure at left fixing the tread belt motor to the machine frame using a 17 mm wrench and holding the screw underneath in place with a 17 mm wrench 2 Raise the tread belt motor by pushing it first inward and then upward to remove the MOTOR DRIVE BELT To reassemble the MOTOR DRIVE BELT carry out the above steps in reverse order After completing the procedure adjust the ten...

Page 120: ...ff the screws fixing the board to the plate support using a 7 mm socket wrench 5 Manually unscrew the fixing studs of the protective grille 6 Remove the ELECTRONIC CIRCUIT BOARD Figure 7 19 2 To disassemble the UP DOWN BOARD 1 Back off the 3 plastic hexagonal head screws b which fix the protective grille using a 7 mm wrench 2 Remove the protective grille 3 Disconnect all the connectors To remove t...

Page 121: ...S CIRCUIT BOARD 1 Back off the 4 hexagonal head screws c using a 7 mm wrench 2 Remove the SERIAL PORTS CIRCUIT BOARD To reassemble the ELECTRONIC CIRCUIT BOARDS carry out the above steps in reverse order After replacing the inverter interface board calibrate the speed as described in paragraph 8 7 ...

Page 122: ...wdriver for the logic signals upper terminal block and a medium flat blade screwdriver for the power signals lower terminal block In order to reach the fixing bolts 3 Disconnect the yellow green earth cable a using a medium Philips screwdriver 4 Back off the nut b using a 10 mm wrench 5 Undo the 2 bolts c using a 4 mm Allen T wrench holding their nuts with a 8 mm wrench Figure 7 20 2 6 Back off th...

Page 123: ...is securely closed 4 Using the large Philips screwdriver back off the 9 self tapping screws a 5 Remove the belt guard b Figure 7 21 2 6 Holding pivot c in place with a 5 mm hex T wrench back off the self locking nut of belt tensioner d using a 17 mm wrench 7 Rotate the belt tensioner to slacken the BELT 8 Remove the BELT from the lower part of the machine When removing the BELT be careful not to r...

Page 124: ... down motor belt up until the slackening of the belt step 7 1 Disconnect the motor supply cable a 2 Disconnect the photocell cable b 3 Using a 10 mm wrench back off the 2 cover fixing screws c on the protective housing of the encoder wheel 4 Open the cover d Figure 7 22 2 5 Using a 10 mm wrench back off screw e 6 Disassemble the encoder wheel f Continued on the following page ...

Page 125: ...ual rev 2 0 Page 7 29 Figure 7 22 3 7 Remove the spacer g Figure 7 22 4 8 Using a rubber hammer and if necessary a pointed tool knock on the motor shaft and remove it from the lower part of the machine Continued on the following page ...

Page 126: ...el in question BONFIGLIOLI motor 10 mm wrench SITI motor 8 mm wrench 11 Back off the 4 fixing screws of the UP DOWN MOTOR using a 4 mm hex T wrench and holding the nut in place with a 10 mm wrench 12 Remove the UP DOWN MOTOR To reassemble the UP DOWN MOTOR carry out the above steps in reverse order After completing the procedure adjust the tension of the up down motor belt as described in paragrap...

Page 127: ...be carried out on all the motor models Carry out the procedures described in paragraphs 7 8 Disassembling the motor guard and 7 10 Disassembling the front plate 1 Manually or using a small flat blade screwdriver unscrew the motor brush cap a 2 Pull out the BRUSHES b To reassemble the BRUSHES carry out the above steps in reverse order ...

Page 128: ... system is installed ensure that the oil reservoir cap is securely closed 4 Back off the two wheel fixing screws a using two 6 mm T wrenches Figure 7 24 2 5 Pull out the wheel b 6 Pull out the wheel shaft c 7 Remove the spacer d 8 Manually unscrew the 2 ELEVATION BARS e to remove them To reassemble the ELEVATION BARS carry out the above steps in reverse order During the reassembly phase lubricate ...

Page 129: ...hand side If the automatic lubrication system is installed ensure that the oil reservoir cap is securely closed 4 Using a large Philips screwdriver back off the 9 self tapping screws a 5 Remove the belt guard b 6 Carry out the procedure described in paragraph 7 24 Disassembling the elevation bars Figure 7 25 2 7 Back off the bearing clamp screw c using a 4 mm hex T wrench 8 Rotate the bearing clam...

Page 130: ...OSWITCH support bracket using a 3 mm hex T wrench 3 Remove the MICROSWITCHES Figure 7 26 2 To remove the LOWER MICROSWITCH from its support bracket 4 Back off the 2 screws c using a 3 mm hex T wrench and holding the nut underneath in place with an 8 mm wrench To reassemble the MICROSWITCHES carry out the above steps in reverse order To reconnect the cables remember that the UPPER MICROSWITCH is co...

Page 131: ...ver c 4 Back off the 2 screws d fixing the PHOTOCELL board to the support using a small Philips screwdriver 5 Remove the PHOTOCELL board There are 2 different photocell versions distinguished by the name of the printed circuit board on which they are mounted Each version requires a specific microcontroller SW version on the up down board circuit board GF920415 requires SW M3S10 circuit board GF970...

Page 132: ...e the right fan downflow fan 1 Back off the 4 screws a using a medium Phillips screwdriver holding the nut in place with a 7 mm wrench To disassemble the left fan air entry fan it is necessary to disassemble the conveyor b Figure 7 28 2 2 Back off the 2 screws c using a 4 mm Allen T wrench 3 Back off the 4 screws d using a medium Phillips screwdriver holding the nut in place with a 7 mm wrench To ...

Page 133: ...rence marks on the tread belt at a distance of exactly 1 meter from each other Figure 8 1 2 3 Lock down the right hand tread belt tensioner screw a until the distance between the reference marks increases by 7 mm 4 Lock down the left hand tread belt tensioner screw until the driven roller is aligned with the crosspiece After completing this procedure any further adjustments should be performed usi...

Page 134: ...e 8 2 2 Use a gauge to measure the distance between the surface of the driven roller and the outer edge of spacer c This procedure is normally carried out after replacing the driving or driven rollers or in those cases where it is necessary to reassemble the used tread belt it is not possible to carry out the procedure as described in 8 1 because the tread belt is not elastic Before disassembling ...

Page 135: ...movement of the tread belt correcting any tendency to shift to the right or left exclusively by adjusting the left tensioning 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 10 mph making any small adjustments which may be necessary until the tread belt is perfectly centered ...

Page 136: ...13 mm screw and holding the screw underneath in place with a 6 mm Allen T wrench Figure 8 4 2 3 Back off the 2 outer nuts b using a 13 mm wrench 4 Use a tension gauge for belts 5 Turn the 2 inner adjusting nuts c using a 13 mm wrench until the instrument measures a tension of 35 kg If a tension gauge is not available the tension of the motor belt is correct when it yields by 0 5 1 cm when pressed ...

Page 137: ...eference rod d rested against the driving roller pulley and make sure that The pulley and flywheel are parallel 1 Repeat steps 3 and 4 2 Make the adjustment by turning the 2 inner adjuster nuts c using a 13 mm wrench The pulley and flywheel are aligned 1 Repeat step 3 2 Make the adjustment by shifting the motor ...

Page 138: ...ne on its maximum elevation position 2 Remove the belt guard The up down motor belt tension is correct when it has a play of approximately 1 5 cm at the point A indicated by the arrow Figure 8 5 2 3 Back off the chain tightener nut a using a 17 mm wrench and holding the pivot in place with a 5 mm Allen T wrench 4 Adjust the chain tightener to obtain the correct belt tension 5 After completing the ...

Page 139: ...eel shaft holes on both bars are aligned 2 Use a gauge to make sure that both elevation bars project by the same distance A from the lead screw nuts If this is not the case turn one of the bars by half a turn at a time and repeat the measurement until perfect alignment is obtained 3 Reassemble the wheel shaft This procedure must be carried out whenever the wheel shaft is reassembled ...

Page 140: ...y should be performed exclusively by a QUALIFIED TECHNICIAN who must ensure that there are no unauthorized persons near the machine 1 Plug the mains lead into the wall outlet 2 Turn on the machine 3 Start the tread belt and set the speed at 12 6 km 4 View the belt motor control frequency on the inverter display 5 Adjust potentiometer PT1 on the inverter interface board using a small flat blade scr...

Page 141: ...crew the 2 fixing screws of the cover of the protective housing of the encoder wheel 2 Open the cover For the BONFIGLIOLI motor 3 Adjust the centering of the encoder photocell by turning the 2 screws a and b so that the photocell is positioned as shown in Figure 8 8 1 Figure 8 8 2 For the SITI motor 4 Adjust the centering of the encoder photocell by turning the 2 screws c and d so that the photoce...

Page 142: ...8 9 1 After the machine has been switched on for at least 1 hour without switching it off 1 Adjust trimmer P1 on the back of the display to obtain the desired level of LCD luminosity This adjustment must be made when the LCD is warmed up the machine must have been switched on for at least 1 hour ...

Page 143: ...anual rev 2 0 Page 8 11 8 10 ADJUSTING THE BUZZER TONE Figure 8 10 1 Turn on the machine and when the buzzer is sounded during the start up procedure 1 Adjust trimmer P2 on the back of the display to obtain the desired buzzer tone ...

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Page 145: ... LANGUAGE CONFIGURATION Dip switches No 2 3 and 4 of the right hand bank at the rear of the CPU board are used for setting the language Right hand bank Dip switch 2 3 4 Language OFF OFF OFF Italian Kcal printouts OFF OFF ON English OFF ON OFF German OFF ON ON French ON OFF OFF Dutch ON ON ON Italian VO2 printouts 9 1 3 EXTERNAL DEVICE INTERFACE CONFIGURATION On the HC1400 machine equipped with SW ...

Page 146: ...2 Dip switch No 2 unit of measurement for speed Left hand bank Dip switch 2 Unit of measurement ON mph OFF Km h Dip switches No 3 and 4 type of protocol used Left hand bank Dip switch 3 4 Protocol OFF OFF Marquette OFF ON TrackMaster ON ON NA ON OFF NA ...

Page 147: ... R O N G 3 To change the current configuration press the number key from 1 to 3 corresponding to the desired choice As soon as the number has been pressed the new configuration becomes operative and the machine reverts to the standby state The procedure can be aborted at any time by pressing the Clear key The above procedure modifies the duration of the lubrication cycle expressed in seconds and t...

Page 148: ...firm 9 3 1 MACHINE UTILIZATION The total hour count of machine on time and the total kilometers covered The following message appears on the LCD T O T A L H O U R S X X X X K m C O V E R E D X X X X After 10 seconds it automatically goes on to the next view The procedure can be aborted at any time by pressing the Clear key 9 3 2 TYPE OF LUBRICATION The type of lubrication setting Weak Medium or St...

Page 149: ...lubrication cycles carried out The following message appears on the LCD N O O F A U T O M A T I C L U B R I C A T I O N S X X After 10 seconds it automatically goes on to the next view 9 3 6 TOTAL LUBRICATION TIME The total lubrication time taking into account both the automatic and manual cycles The following message appears on the display T O T A L L U B R I C A T I O N T I M E X X X s e c After...

Page 150: ...eters covered The following message appears on the LCD T O T A L H O U R S X X X X K m C O V E R E D X X X X After 10 seconds it automatically goes on to the next view The procedure can be aborted at any time by pressing the Clear key 9 4 2 LUBRICATION INTERVAL The number of kilometers the machine must cover between one lubrication cycle and the next The following message appears on the display L ...

Page 151: ...MBER OF AUTOMATIC LUBRICATION CYCLES The number of automatic lubrication cycles carried out The following message appears on the LCD N O O F A U T O M A T I C L U B R I C A T I O N S X X After 10 seconds it automatically goes on to the next view 9 4 7 TOTAL LUBRICATION TIME The total lubrication time taking into account both the automatic and manual lubrication cycles The following message appears...

Page 152: ...xit the procedure at any time The changes made will remain valid 9 5 1 TOTAL HOURS This option is used for entering the desired number of working hours The following message appears on the display T O T A L H O U R S X X X X 0 0 0 0 0 XXXX indicates the value currently in memory while 00000 is the new value to be entered After entering the desired new value using the number keys press ENTER to con...

Page 153: ...ing the duration of an automatic lubrication cycle The following message appears on the LCD L E N G T H O F L U B R I C A T S e c X X X XX indicates the value currently in memory while 000 is the new value to be modified After entering the desired value using the number keys press ENTER to confirm At the end of the procedure the machine reverts to standby mode If the machine is not equipped with a...

Page 154: ...without saving press the FUNC key After this the display will revert to showing the selected main function To display the extended function parameters 1 Press the 1 or 2 keys to display the desired function A b C o H 2 Press the FUNC key to display the code of the extended function for example the display will show A01 3 Press the 1 or 2 key until the desired extended function appears The display ...

Page 155: ...3 Function of terminal 3 setting 12 C13 Condition of terminal 3 setting 01 F02 Acceleration 15 0 F03 Deceleration 5 0 H01 Autotuning mode setting 0 H02 Motor data selection 01 H03 Motor capacity setting 2 2 H04 Motor poles setting 4 H05 Motor constant Kp setting 80 H06 Motor stabilization constant 100 H30 Motor constant R1 Autotuning data 1 124 H31 Motor constant R2 Autotuning data 0 888 H32 Motor...

Page 156: ...mory 7 Check that the machine operates correctly 8 If this is not the case repeat the above procedure otherwise turn off the machine and reassemble the original keyboard If it is necessary to program an inverter that is not mounted on the machine before carrying out the above procedure connect the mains power supply to terminals L1 and N place a jumper between terminals 1 and PV24 place a jumper b...

Page 157: ...he value press the 1 key to increase or the 2 key to decrease 13 To save the modified value press the FUNC key the display will revert to showing the value of the selected extended function 14 Press the FUNC key again to return to the main function menu Incorrect programming of the inverter may result in serious damage to the machine or improper operation potentially hazardous for the user Therefo...

Page 158: ...8 1 A 8 0 A 49 2 A 9 0 A 50 1 A 10 16 A 51 0 A 11 8 A 52 1 A 12 0 A 53 0 A 13 0 A 55 0 A 14 0 A 56 1 A 15 0 A 57 0 A 16 0 A 58 1 A 17 0 A 62 50 A 18 10 0 A 63 106 A 19 10 0 A 64 0 A 20 0 5 A 68 0 5 A 21 0 A 71 0 A 22 0 A 80 127 A 23 100 A 81 132 A 24 1 A 82 1 0 A 26 1 5 A 83 10 0 A 27 106 A 84 0 A 28 0 A 85 1 0 A 29 0 C 0 09 A 30 150 C 1 02 A 31 150 C 2 07 A 32 0 C 3 11 A 33 0 C 4 00 A 34 0 C 10 0...

Page 159: ...n the SH key 2 When the desired parameter is reached press PRG to display its value 3 To modify the value press the or keys to increase or decrease 4 To save the modified value simultaneously press the SH keys and then PRG the display reverts to showing the value of the selected main function Incorrect programming of the inverter may result in serious damage to the machine or improper operation po...

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Page 161: ...TERNAL CLEANING OPERATIONS These operations can be carried out by the owner of the machine and do not require any special skills The external cleaning operations are involve simple cleaning for the purposes of general hygiene These should be performed at least once a week For external cleaning proceeds as follows 10 1 1 SETTING UP THE OPERATION 1 Turn off the machine by placing the switch in the 0...

Page 162: ...n the entire surface between the tread belt and the running track using a cloth Repeat several times if necessary 2 Then lubricate the entire length of the running track and tread belt using Silube spray oil code 0V022 start the machine at a speed of approximately 3 km h 2 mph and walk on it taking care to tread on the entire width of the belt so as to facilitate the distribution of the oil on the...

Page 163: ...adjust the tension 2 With the machine moving at a speed of approximately 10 km h 7 mph check the centering of the tread belt If any anomalies are found call in the authorized Technogym Technical Service or adjust the centering 10 2 6 CHECKING THE EMERGENCY BUTTON 1 With the machine turned on and moving at a speed of approximately 5 km h 3 mph press the emergency button and check that the machine s...

Page 164: ...he machine wheels 2 Check that the machine is connected directly to the wall outlet without any extension cords and that the outlet is correctly earthed 3 Using a multimeter check that the machine earth node is correctly connected to earth 10 3 3 CHECKING THE WIRING AND CONNECTIONS 1 Open all the machine guards 2 Check the condition of all the cables External conditions Possible rusting of the con...

Page 165: ...ed up raise it to its maximum incline 25 2 Turn off the machine by placing the switch in the 0 position OFF 3 Unplug the mains lead from the wall outlet 4 Remove the guard plate of the up down motor drive belt 5 Check the state of wear of the up down motor drive belt Replace if it shows evident signs of wear 6 Check the tension of the up down motor drive belt Adjust the tension if necessary 10 3 1...

Page 166: ...ed strap and wait for the machine to display the measured heart rate At this point using a heart rate frequency simulator check that the machine does not detect its presence and doesn t alter the previously measured heart rate 10 3 13 CHECKING THE OIL LEVEL 1 Where present top up the oil reservoir of the automatic lubrication system ...

Page 167: ...ver shown in the figure below which consists of Figure 11 1 1 an antenna a designated the coil which receives the signal from the transmitter strap worn by the user an integrated circuit b designated the ASIC which has the function of filtering the analog signal and generating a pulse train corresponding to the received heart rate two contacts c parallel to the coil on which a 15 KOhm resistor is ...

Page 168: ...ich may be useful for improving the reception of the cardio signal 11 1 1 TYPE OF ASIC The cardio receivers can be equipped with 3 different types of ASIC models identifiable by the code marked on the component MAS FTC or HRRE These ASICs are characterized by different reception ranges and different levels of immunity to noise Tests have determined that the maximum reception distances are as follo...

Page 169: ...ay it is possible to determine whether there is electromagnetic noise and identify its source The only effective solution in the presence of electromagnetic interference is to reduce the power of the noise source using a trial and error method based principally on Shielding the noise source Increasing the distance between the noise source and the receiver if necessary by changing the position of t...

Page 170: ...el combination of the added resistor and the existing 15 KOhm resistor 11 1 4 MECHANICAL VIBRATIONS Mechanical vibrations may cause slight shifting of the coil giving rise to transient impulses If these transients occur only occasionally they can be easily filtered by SW However if the mechanical vibrations are periodic they can produce periodic pulses which may be interpreted as correct heart rat...

Page 171: ...hown in the figure below Figure 11 1 2 Please note that even small departures from the above specifications may considerably impair the accuracy of reception The optimal configuration is therefore that shown in the figure below Figure 11 1 3 11 1 6 ROUTING OF CABLES Particular care must be taken in the routing of cables to prevent interference with the receiver coil ...

Page 172: ...which stores the working program the output is disconnected E08 Low voltage protection A drop in the input voltage below 150 160 V triggers this error and the output is disconnected E09 CT error When a major noise source is situated near the inverter or there is a malfunction in the internal current transducer circuit the output is disconnected E10 E11 CPU error If a malfunction is detected in the...

Page 173: ... of the machine 11 3 PROCEDURE FOR CLEARING THE ERROR MEMORY ON HITACHI SJ100 INVERTER For all Hitachi SJ100 inverters it is available an easy procedure for clearing the error memory To do this 1 Turn on the machine 2 Configure parameter b84 00 3 Come back to the visualization of the parameter b84 and press simultaneously the keys FUNC 4 Holding down the three keys press also Stop Reset key for ab...

Page 174: ...ss also Stop Reset key for about 1 second and wait for about 3 seconds until the blinking d00 is shown on the display 6 Now release all keys again The initializing phase that now begins will be complete as soon as the display 00 appears The parameters will be reset to the factory setting ...

Page 175: ...isconnected E7 EEPROM error When an error is detected on the EEPROM memory which stores the working program the output is disconnected E8 Low voltage protection A drop in the input voltage below 150 160 V triggers this error and the output is disconnected E9 CT error When a major noise source is situated near the inverter or there is a malfunction in the internal current transducer circuit the out...

Page 176: ...e very careful not to touch any other keys or touch the aforesaid keys at the wrong time as this can seriously damage the inverter programming with consequent malfunctioning of the machine 11 6 PROCEDURE FOR CLEARING THE ERROR MEMORY ON HITACHI J100 INVERTER For all Hitachi J100 inverters starting from and including series E3 there is an easy procedure for clearing the error memory To do this 1 Tu...

Page 177: ...he key until the parameter C67 appears 5 Press the PRG key The display will show 6 Press the key if any error codes are memorized they will be displayed Otherwise the display will continue to show 7 At the end of the procedure press the PRG key and revert to displaying the parameter C50 11 8 DELETING ERRORS ON THE LENZE 644 INVERTER To delete an error 1 Remove the motor guard 2 Turn on the machine...

Page 178: ... code 0C732 The inverter requires a different braking resistor with order code 0WT111 The inverter interface board is different the one for the Hitachi inverter has code 0WQ031 The inverter connecting cables are different supply cable for inverter up down board and power supply cable connecting the inverter to the inverter interface board motor thermal cutout cable and motor cable To facilitate th...

Page 179: ...s in force pending further instructions proceed as follows On the Lambda ZT30 522 power supply eliminate the two capacitors C3 and C4 2200 pF This reduces the leakage of the power supply to approximately 0 µA On the Hitachi E5 inverter eliminate the two capacitors CNX and CPX 10 nF This reduces the leakage of the power supply to approximately 0 µA In place of the Schaffner 350 20 29 filter use the...

Page 180: ...he automatic circuit breaker is connected to only one machine rather than protecting the general circuit of the entire machine line In fact even though the leakage currents of the individual machines are low when many machines are connected to the same circuit the sum of their leakage currents may exceed the capacity of the circuit breaker the automatic circuit breaker is in perfect working order ...

Page 181: ...raph 9 5 0 3 2406 Partial display of working parameters as described in paragraph 9 3 0 3 6144 Complete display of working parameters as described in paragraph 9 4 1 4 7 none Manual lubrication with a duration of 10 seconds Mem prog Enter 1508 Save program in memory Mem prog 0 1508 Delete program from memory Mem prog 8 1508 Delete all programs in memory Runrace Test 0 2406 Automatic incline test 3...

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Page 184: ...0SMM0021 ING TECHNOGYM S p A Via G Perticari 20 47035 Gambettola FC ITALIA Tel 39 0547 650438 Fax 39 0547 650150 e mail service technogym com ...