Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
MAINTENANCE MANUAL
REV. 2.0
The information contained in this manual is intended for QUALIFIED TECHNICIANS who have
completed a specific TECHNOGYM training course and are authorized to perform machine start-up
and adjustment procedures as well as extraordinary maintenance or repairs which require a thorough
knowledge of the machine, its operation, its safety devices and working procedures.
DANGEROUS VOLTAGES
PRESENT EVEN WHEN 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 proprietary information that is protected by copyright. All rights reserved.
No part of this document may be photocopied, reproduced or translated into another language
without the prior written consent of Technogym.
The Technogym trademark is property of Technogym S.p.A.
The Runrace trademark is property of Technogym S.p.A.
Contents
1. GENERAL NOTICES............................................................................................................................................1.1
1.1.
1.2.
1.3.
INTRODUCTION............................................................................................................................................ 1.1
RECOMMENDATIONS ................................................................................................................................... 1.1
GENERAL RULES FOR REPAIR PROCEDURES ................................................................................................. 1.2
3.2.
3.3.
3.4.
4. ACCESSORIES......................................................................................................................................................4.1
4.1.
4.2.
4.3.
4.4.
Page i
4.4.1.
4.4.2.
RS-232 Port..................................................................................................................................4.4
RS-485 Ports ................................................................................................................................4.4
6. TROUBLESHOOTING.........................................................................................................................................6.1
6.1.
6.2.
6.3.
6.4.
6.5.
6.6.
6.7.
6.8.
6.9.
6.10.
6.11.
6.12.
6.13.
6.14.
6.15.
6.16.
Page ii
7.23.
7.24.
7.25.
7.26.
7.27.
7.28.
8. ADJUSTMENTS ....................................................................................................................................................8.1
8.1.
8.2.
8.3.
8.4.
8.5.
8.6.
8.7.
8.8.
8.9.
8.10.
9. MACHINE CONFIGURATION...........................................................................................................................9.1
9.1.
9.2.
9.3.
9.4.
9.5.
9.6.
9.7.
9.8.
Page iii
10.3.
11.2.
11.3.
11.4.
11.5.
11.6.
11.7.
11.8.
11.9.
11.10.
11.11.
Page iv
1. GENERAL NOTICES
1.1. INTRODUCTION
This document is reserved for Technogym Service technicians, and is intended to provide
authorized personnel with the necessary information to correctly carry out repairs and maintenance.
A thorough knowledge of the technical information contained in this manual is essential for
completing the professional training of the operator.
In order to facilitate consultation, the paragraphs are accompanied by schematic drawings which
illustrate the procedure being described.
This manual contains notices and symbols which have specific meanings:
WARNING: non observance may result in accident or injury.
ATTENTION: non observance may cause damage to the machine.
Information about the operation in progress.
OBSERVE: observation about the operation in progress.
1.2. RECOMMENDATIONS
Technogym recommends the following steps for planning repair procedures:
Carefully evaluate the customers description of the machine malfunction and ask all the
necessary questions to clarify the symptoms of the problem.
Clearly diagnose the causes of the problem. This manual provides the fundamental theoretical
basis, which must then be integrated by personal experience and attendance at the training
courses periodically offered by Technogym.
Rationally plan the repair procedure so as to minimize the downtime necessary for procuring
spare parts, preparing tools, etc.
Access the component to be repaired, avoiding any unnecessary operations. In this regard it will
be useful to refer to the disassembly sequence described in this manual.
Page 1.1
Page 1.2
2. TECHNICAL CHARACTERISTICS
2.1. MECHANICAL CHARACTERISTICS
Width
Length
Height
Weight
90 cm
224 cm
140 cm
270 Kg
230 VAC
50 - 60 Hz
~ 2500 Watt - 11 A
5x20 4 A slow-blow
Operating
Storage
Operating
Storage
from 5 to 35 C
from -20 to 55 C
from 30% to 80% non-condensing
from 5% to 85% non-condensing
Europe
EMI
Safety
Directive
EN 60601-1-2
EN 60601-1
EN 957-1
73/23/CEE
93/68/CEE
89/336/CEE
Page 2.1
Page 2.2
CONNECTORS
CPU board
Name
CN1
CN2
CN3
CN5
CN6
K7
Type of connector
AMP MATE-N-LOCK 15-pin F
AMP MATE-N-LOCK 12-pin F
AMP MODU II 6-pin M
AMP MODU II 2-pin M
AMP MODU II 8-pin M
AMP MODU II 4-pin M
Power supply
Name Type of connector
CN1
PANDUIT 6-pin
CN2
PANDUIT 6-pin
Type of connector
AMP MATE-N-LOCK 6-pin F
AMP MATE-N-LOCK 12-pin F
AMP MOD I 4-pin M
Connection
To inverter
To CPU board
To power supply
Up-down board
Name
CN1
CN2
CN3
CN4
CN5
CN6
Connection
To mains electricity supply
To inverter interface board
Connection
To up-down and inverter interface boards
To serial ports
To emergency button
To back up battery
To TGS interface
To cardio receiver
Type of connector
AMP MOD II 4-pin M
AMP MATE-N-LOCK 4-pin F
AMP MATE-N-LOCK 6-pin F
AMP MATE-N-LOCK 2-pin F
Sauro 2-pin
Sauro 2-pin
Connection
To photocell
To CPU board
To up-down motor and microswitches
To mains electricity supply
To transformer
To rectifier bridge
Patch cables
Name
CN1
CN2
CN3
CN4
CN5
CN6
CN7
CN8
CN9
Type of connector
AMP MATE-N-LOCK 15-pin M
AMP MATE-N-LOCK 15-poli F
AMP MATE-N-LOCK 12-poli M
AMP MATE-N-LOCK 12-poli F
AMP MATE-N-LOCK 2-poli M
AMP MATE-N-LOCK 2-poli F
AMP MATE-N-LOCK 2-poli M
AMP MATE-N-LOCK 2-poli F
2 fastons
Connection
To CPU board
To up-down and inverter interface boards
To CPU board
To serial ports
To emergency button
To relay
To mains electricity supply
To up-down board / fan
To patch cable CN5
Page 2.3
WIRING
Signal
Color
+12 V
+5V
Ground
Ground
-12 V
Not used
Not used
Start
Inverter alarm
Tread belt speed reference (PWM)
Not used
Status
Up
Down
Ground
Blue 1
Brown 1
Gray 1
White 1
Violet 1
Red 1
Black
Orange
Brown 2
Pink
Blue 2
Red 2
Gray 2
White 2
Violet 2
Patch cable
CN1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Page 2.4
Signal
+12 V
+5V
Ground
Ground
-12 V
Not used
Not used
Start
Inverter alarm
Tread belt speed
reference (PWM)
Not used
Status
Up
Down
Ground
Color
Blue 1
Brown 1
Gray 1
White 1
Violet 1
Red 1
Black
Orange
Brown 2
Pink
Inverter interf.
board
CN2
1
2
3
4
5
6
7
8
9
10
Up-down
board
CN2
-
Blue 2
Red 2
Gray 2
White 2
Violet 2
11
-
1
2
3
4
Signal
Color
CTS
DSR
RX
RTS
TX
GND
BUS A
BUS B
GND
Not used
Level of the oil tank
Not used
Signal
Blue 1
Brown 1
Gray1
White
Violet
Red
Black
Orange
Brown 2
Pink
Blue 2
Grey2
Color
+12 Vdc
NC contact on button
Blue
Brown
Patch cable
CN3
1
2
3
4
5
6
7
8
9
10
11
12
Patch cable
CN5
1
2
Signal
CTS
DSR
RX
RTS
TX
GND
BUS A
BUS B
GND
Level of the oil tank
Color
Blue 1
Brown 1
Gray1
White
Violet
Red
Black
Orange
Brown 2
Blue 2
Serial ports
CN1
1
2
3
4
5
6
7
8
Short
Signal
Color
Receiver
+5 V
Pulse per beat
ground
Red
Blue
Black
1
2
3
Page 2.5
Signal
Color
Reference
NC contact (5 Vdc)
NC contact
+ 12 Vdc
Black
Red
Green
White
CPU board
CN3
2
3
1
Patch cable
CN9
Red faston
Red faston
Signal
Color
Inverter
Reference
Thermal cutout ref.
NC thermal cutout
Start
NC Alarm
Alarm reference
Vref (0-10 Vdc)
Vref reference
White
Red
Red
Gray
Violet
Red
Brown
Black
PV24
3
1
AL1
AL0
0
L
Motor thermal
cutout
1
2
-
Signal
Phase U
Phase V
Phase W
ground
Color
Blue
Black
Brown
Yellow-Green
Belt motor
U
V
W
Casing
Page 2.6
Signal
Color
Brown
Blue
White
Violet
Black
Up-down
motor
1
2
-
Upper Lower
LS
LS
3
2
1
1
Signal
Color
Rectifier bridge
48 VAC
Ground
Red
Black
Signal
Color
Photocell
+ 5 Vdc
Clock
Direction
Ground
Red
Orange
Blue
Black
1
2
3
4
Signal
Color
1
3
4
6
+ 12 V
+5V
Ground
- 12 V
Red
Yellow
Black
Blue
Inverter interf.
board
CN4
2
4
3
1
The high voltage power supply cables and the ground connections are not described here, in that
they can be easily determined from the wiring diagram above.
Page 2.7
Page 2.8
CONNECTORS
CPU board
Name
CN1
CN2
CN3
CN5
CN6
K7
Type of connector
AMP MATE-N-LOCK 15-pin F
AMP MATE-N-LOCK 12-pin F
AMP MODU II 6-pin M
AMP MODU II 2-pin M
AMP MODU II 8-pin M
AMP MODU II 4-pin M
Power supply
Name Type of connector
CN1
PANDUIT 6-pin
CN2
PANDUIT 8-pin
Type of connector
AMP MATE-N-LOCK 6-pin F
AMP MATE-N-LOCK 12-pin F
AMP MOD I 4-pin M
Connection
To inverter
To CPU board
To power supply
Up-down board
Name
CN1
CN2
CN3
CN4
CN5
CN6
Connection
To mains electricity supply
To inverter interface board
Connection
To up-down and inverter interface boards
To serial ports
To emergency button
To back up battery
To TGS interface
To cardio receiver
Type of connector
AMP MOD II 4-pin M
AMP MATE-N-LOCK 4-pin F
AMP MATE-N-LOCK 6-pin F
AMP MATE-N-LOCK 2-pin F
Sauro 2-pin
Sauro 2-pin
Connection
To photocell
To CPU board
To up-down motor and microswitches
To mains electricity supply
To transformer
To rectifier bridge
Patch cables
Name
CN1
CN2
CN3
CN4
Type of connector
AMP MATE-N-LOCK 15-pin M
AMP MATE-N-LOCK 15-poli F
AMP MATE-N-LOCK 12-poli M
AMP MATE-N-LOCK 12-poli F
Connection
To CPU board
To up-down and inverter interface boards
To CPU board
To serial ports
Page 2.9
WIRING
Signal
Color
+12 V
+5V
Ground
Ground
-12 V
Not used
Not used
Start
Inverter alarm
Tread belt speed reference (PWM)
Not used
Status
Up
Down
Ground
Blue 1
Brown 1
Gray 1
White 1
Violet 1
Red 1
Black
Orange
Brown 2
Pink
Blue 2
Red 2
Gray 2
White 2
Violet 2
Patch cable
CN1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Page 2.10
Signal
+12 V
+5V
Ground
Ground
-12 V
Not used
Not used
Start
Inverter alarm
Tread belt speed
reference (PWM)
Not used
Status
Up
Down
Ground
Color
Blue 1
Brown 1
Gray 1
White 1
Violet 1
Red 1
Black
Orange
Brown 2
Pink
Inverter interf.
board
CN2
1
2
3
4
5
6
7
8
9
10
Up-down
board
CN2
-
Blue 2
Red 2
Gray 2
White 2
Violet 2
11
-
1
2
3
4
Signal
CTS
DSR
RX
RTS
TX
GND
BUS A
BUS B
GND
Level of the oil tank
Color
Blue 1
Brown 1
Gray
White
Violet
Red
Black
Orange
Brown 2
Blue 2
Patch cable
CN3
1
2
3
4
5
6
7
8
9
11
Signal
CTS
DSR
RX
RTS
TX
GND
BUS A
BUS B
GND
Level of the oil tank
Color
Blue 1
Brown 1
Gray
White
Violet
Red
Black
Orange
Brown 2
Blue 2
Serial ports
CN1
1
2
3
4
5
6
7
8
Short
Signal
Color
Receiver
+5 V
Pulse per beat
ground
Red
Blue
Black
1
2
3
Page 2.11
Signal
Color
Reference
NC contact
Brown
Blue
Emergency
button
1
2
Signal
Color
Inverter
Motor thermal
cutout
Reference
Thermal
cutout
reference
NC thermal cutout
Start
NC Alarm
Alarm reference
Vref (0-10 Vdc)
Vref reference
White
Red
PV24
-
Red
Gray
Violet
Red
Brown
Black
3
1
AL1
AL0
0
L
2
-
Signal
Phase U
Phase V
Phase W
ground
Color
Blue
Black
Brown
Yellow-Green
Belt motor
U
V
W
Casing
Page 2.12
Signal
Color
Brown
Blue
White
Violet
Black
Up-down
motor
1
2
-
Upper Lower
LS
LS
3
2
1
1
Signal
Color
Rectifier bridge
48 VAC
Ground
Red
Black
Signal
Color
Photocell
+ 5 Vdc
Clock
Direction
ground
Red
Orange
Blue
Black
1
2
3
4
Signal
Color
3
4
1
6
+5V
Ground
+ 12 V
- 12 V
Yellow
Black
Red
Blue
Inverter interf.
board
CN4
4
3
2
1
The high voltage power supply cables and the ground connections are not described here, in that
they can be easily determined from the wiring diagram above.
Page 2.13
The differences between the 220 model and the 220 model with SJ100 inverter are:
Page 2.14
Signal
Color
Inverter
Motor thermal
cutout
Reference
Thermal
cutout
reference
NC thermal cutout
Start
NC Alarm
Alarm reference
Vref (0-10 Vdc)
Vref reference
White
Red
PV24
PV24
Red
Gray
Violet
Red
Brown
Black
1
FW
AL1
AL0
0
L
2
-
Signal
Color
1
2-4-5
3
6
+5V
Ground
+ 12 V
- 12 V
Yellow
Black
Red
Blue
Inverter interf.
board
CN4
4
3
2
1
Page 2.15
Page 2.16
Page 2.17
Page 2.18
3. PRINCIPLES OF OPERATION
3.1. BLOCK DIAGRAM
The machine block diagram is shown in the figure below:
Page 3.1
3.1.3. DISPLAY
This is the heart of the machine, which controls all the machine functions by executing the program
stored in EPROM. It receives information from the user (age, weight, etc.) during set-up of the
training session, from the cardio receiver (users heart rate), from the inverter interface board and
from the up-down interface board. It controls the speed selected with the + keys and the
elevation selected with the keys or according to the chosen training program. It receives the
error signal from the inverter interface board and the status signal from the up-down interface board.
It consists of 2 circuit boards:
CPU board: contains the microprocessor, 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 inverter interface board. Variations in this voltage cause corresponding variations in the
operating frequency of the sinusoidal wave provided by the inverter to the motor phases, and hence
change the speed of the tread belt. It handles motor drive errors and, in the event of an error, shuts
down the power supply to the motor and sends an alarm signal through the interface board to the
display. The event which caused the error is memorized as an error code.
The inverter power supply is enabled by the relay activated by the emergency button. When the
button is pressed, the relay contact opens, the power to the inverter goes off and hence the belt
motor stops.
The following inverter models are used on these machines:
Each inverter model requires its own special interface board, designated as follows:
Page 3.2
Regardless of whether the Lenze or Hitachi model is used, the inverter and interface board group
has the function of driving the tread belt motor at the desired speed, in accordance with the data
programmed on the machine CPU board and on the basis of the program saved on the inverter itself.
The inverter has a power of 2.2 KW.
3.1.8. PHOTOCELL
This is the device which provides feedback on the motion of the up-down motor. It transmits one
pulse for each tooth detected on the encoder wheel which is fixed to the gearmotor, and a signal
indicating the direction of movement.
Two different types of photocells are used on these machines:
The 2 photocells are mechanically interchangeable but functionally distinct each one requires its
own specific SW version on the up-down board.
a transformer and rectifier bridge. Determines the motor position, and hence the treadmill elevation,
by means of the photocell. Generates and sends to the display a motion status signal at every 0.5%
variation in the elevation.
It is necessary to use the appropriate SW version for the photocell model, as identified by the label
on the chip:
It checks the lower and upper travel limits by means of 2 limit switches. The board includes 2 LEDs
associated to the limit switches, which are normally illuminated:
3.1.10. MICROSWITCHES
There are 2 limit switches which control the range of motion of the elevation mechanism. These
switches are positioned at the travel limits of the elevation bars, and change state when pressed
and/or released. The lower limit switch is NC, while the upper one is NO.
PRINTER: RS-232 port for connecting the machine to a printer or other external device, such
as an ECG or metabolic monitor;
IN: RS-485 input port, not used;
OUT: RS-485 output port, not used.
3.2.2. CONTROLS
To start the motor, the CPU board sends the inverter a Start signal through the inverter interface
board, enabling the inverter to drive the motor. After outputting this enable signal, the CPU board
sets the motor speed by sending a PWM signal to the inverter interface board, which the inverter
interface board converts 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 signal
to the CPU board, which displays the error message BELT MOTOR HALTED.
To protect the motor from overheating, each motor phase has a thermal cutout connected in series. If
the temperature exceeds the threshold value, the thermal cutout opens and interrupts the circuit. The
inverter detects this condition as the opening of a NC external contact. In such a case the inverter
halts the motor and outputs an alarm signal to the CPU board, which displays the error message
cited above.
Page 3.5
CPU board
10-3 8-3
CN1
PWM
9-3
Alarm
Start
10-3
8-3
CN2
9-3
Inverter interface
board
5-6
2-1
CN1
Vref
3-4
Alarm
Start
O-L
1-PV24
AL1-AL0
Inverter
3-PV24
U-V-W
VAC
Variable frequency
Thermal
protection
M
Start signal
This is the signal generated by the CPU board (pin 8-3 of connector CN1) to enable starting of
the motor. When the tread belt is stopped this signal is at logic level low (0 Vdc), whereas
immediately after the Start button on the display is pressed it goes high (4.5 Vdc).
The signal enters the inverter interface board (pin 8-3 of connector CN2), is processed and sent
out (pin 2-1 of connector CN1) to the inverter. In the belt-stopped condition it is -24.7 Vdc,
while immediately after pressing the Start button on the display it is -2.7 Vdc.
Page 3.6
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 conditions, 10 Vdc under alarm conditions.
The signal is then sent from the inverter interface board (pins 9-3 of connector CN2) to the CPU
board (pins 9-3 of connector CN1) and is 5 Vdc under normal conditions, 0 Vdc under alarm
conditions. When this alarm signal switches to 0 Vdc, the CPU disables the Start signal, resets
the PWM signal and shows the BELT MOTOR HALTED error message on the display.
Page 3.7
3.3.2. CONTROLS
To vary the incline, the CPU board sends the up-down board an Up signal (move motor in the up
direction to increase the elevation) or a Down signal (move motor in the down direction to decrease
the elevation). The up-down board accordingly actuates the motor the appropriate 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
received. When this value corresponds to the desired incline, it resets the Up or Down signal which
produced the movement.
If during the power-up reset, after having asserted the Up or Down signal, the CPU board does not
receive any Status signal within a few seconds, it resets the asserted signal and displays error
message GRADE MOVEMENT OUT OF ORDER to indicate absence of movement.
14-15
Up
CN1
12-15
Down
2-4
3-4
1-4
Up-down
board
3-6
4-6
CN2
Status
CN3
2-4/CN1
1-2
Vdc
Pulses
Switch
M
Photocell
Page 3.8
Up signal
This is the signal generated by the CPU board (pins 13-15 of connector CN1) to enable
movement of the up-down motor in the upward direction. Under normal conditions the signal is
at logic level low (-0.4 Vdc), and it goes high (4.0 Vdc) to actuate the motor. The signal remains
high for the entire duration of the movement.
The signal enters the up-down board (pin 2-4 of connector CN2) and enables movement of the
motor in the desired direction.
Down signal
This is the signal generated by the CPU board (pin 14-15 of connector CN1) to enable
movement of the up-down motor in the downward direction. Under normal conditions the signal
is at logic level low (-0.8 Vdc), and it goes high (4.0 Vdc) to actuate the motor. The signal
remains high for the entire duration of the movement.
The signal enters the up-down board (pin 3-4 of connector CN2) and enables movement of the
motor in the desired direction.
Pulse 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 updown board for controlling the movement.
The photocell also outputs a direction signal, which varies from logic level high (5 Vdc) to low
(0 Vdc) depending on whether the motor is moving in a clockwise or anticlockwise direction.
This signal is input to the up-down board (pin 3-4 of connector CN1).
To operate correctly, the photocell requires a 5 Vdc supply voltage which is provided by the updown board (pins 1-4 of connector CN1).
Status signal
This is the square wave signal generated by the up-down board (pin 1-4 of connector CN2) that
changes its logic level (level low 0 Vdc and level high 5 Vdc) whenever the up-down board
receives from the photocell a number of pulses corresponding to an 0.5% variation in the
elevation.
This signal provides the CPU board (pin 12-15 of connector CN1) with an indication of the
change in machine incline. By counting the number of transitions, the CPU determines the
current elevation and, comparing it with the desired value, determines whether to continue
asserting the Up or Down signal to continue the movement, or whether on the other hand the
desired elevation has been reached, and the Up or Down signal can be reset.
Page 3.9
Page 3.10
Difficulty in finding the right compromise between the quantity of oil and the interval between
successive lubrication cycles, as these are considerably influenced by the working conditions:
how much the machine is used, the average speed, weight of the users, ambient temperature
conditions etc Incorrect values of these parameters have in fact caused problems of both
excessive and insufficient lubrication.
Technological advances have made available new materials for the manufacture of selflubricating tread belts.
Signal
Color
CTS
DSR
RX
RTS
TX
GND
BUS A
BUS B
GND
+12 Vdc
Oil reservoir level
Start pump command
Blue 1
Brown 1
Gray
White
Violet
Red
Black
Orange
Brown 2
Blue 2
Free
CN3
1
2
3
4
5
6
7
8
9
10
11
12
Signal
CTS
DSR
RX
RTS
TX
GND
BUS A
BUS B
GND
+12 Vdc
Oil reservoir level
Start pump command
Color
Serial ports
CN1
Blue 1
Brown 1
Gray
White
Violet
Red
Black
Orange
Brown 2
1
2
3
4
5
6
7
8
-
Blue 2
Pump inter.
board
K1
1
2
3
4
The machine controls the lubrication via the CPU board, the power distribution board and the oil
pump as shown in the figure below:
Page 3.12
CPU board
12-9
+12 Vdc
Enable
4-1
11-9
CN2
10-9
2-1
K1
Oil Low
3-1
Pump interface
board
1-2-3/KR6
4-5/KR6
Oil Low
220 VAC
Pump
Page 3.13
thermal cutouts of the tread belt motor and sends it to the LENZE inverter interface
board.
Page 3.14
4. ACCESSORIES
4.1. CONNECTING TO THE TGS
The machine can be connected to the Technogym System by installing a special upgrade kit, which
involves the following:
Installation of a special SW;
Installation of special cables, for providing through a 9-pin D-connector at the back of the
display the half duplex RS 485 serial port for connecting to the TGS system.
The CPU board is connected to the serial connector via the cable described below, which is supplied
together with the upgrade kit.
Free
15 pin
1
2
3
4 15
-
Signal
12 pin
16
7
8
9 12
+12 V
GND
+Serial
-Serial
-
Color
DB9 male
Yellow
Green
Brown
White
-
8
6
1
2
-
Signal
Color
DB9 male
+12 V
GND
-Serial
+Serial
Yellow
Green
Brown
White
1
5
3
2
For additional information, including troubleshooting, refer to the manual Technogym System:
Installation Guide.
Page 4.1
Signal
Screen
Tx
Rx (not used)
DTR
Gnd
Color
Printer
1
3
2
20
7
Page 4.2
The machine SW is configured for interfacing with an external device using the dip-switches on the
CPU board, as indicated in paragraph 9.1.1. and using a specific cable for each model.
Contact Technogym Technical Service to obtain the diagram of the cable.
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
Marquette
Marquette
Cardio Control (*)
Schiller
Schiller
Esaote (**)
Esaote (**)
Esaote (**)
MedGraphics
Cosmed
Cosmed
Mortara Instrument
(*)
MODEL
TYPE
Max-1
ECG
Max-personal
ECG
Cardio Perfect
ECG
CS-100
ECG
AT-60
ECG
Actavis
ECG
Formula
ECG
Lap Top 210
ECG
CardiO2
Metabolic monitor
K4b2
Metabolic monitor
Quark b2
Metabolic monitor
X/Scribe
ECG
PROTOCOL
USED
Marquette
Marquette
Marquette
TrackMaster
TrackMaster
TrackMaster
TrackMaster
TrackMaster
TrackMaster
Marquette
Marquette
TrackMaster
In this SW version, the Select Treadmill menu includes the item Technogym Run Race
protocol. Choose this option.
(**) These Esaote models must have the Stress program installed, which interfaces the ECG to
treadmills. To check whether this program is installed, after switching on the ECG press the
FUNC key on the keypad.
For other ECGs with compatible characteristics, we always recommended contacting Technogym to
ascertain their effective compatibility.
Page 4.3
SIGNAL
Shield
Tx
Rx
RTS
CTS
DSR
GND
Page 4.4
SIGNAL
A-BUS
GND
B-BUS
Shield
5. INSTALLATION INSTRUCTIONS
5.1. SPECIFICATIONS AND REQUIREMENTS
For correct machine installation, make sure that:
1. The machine is installed on a level surface that is free of vibrations and has sufficient carrying
capacity for the combined weight of the machine and user.
2. The environment is dust or sand free.
3. The environment meets the operating temperature and humidity conditions specified in
paragraph 2.3. .
4. The machine is not positioned close to sources of heat, sources of electromagnetic noise
(television sets, electric motors, antennas, high voltage lines, appliances etc) or medical
equipment.
5. To eliminate any interference with the cardio receiver, there should not be any transmitters at a
distance of 100 cm from the display.
6. The mains voltage must match the value specified on the machine rating plate.
7. The electrical system must be provided with an efficient ground connection.
8. The wall outlet used should be reserved for the machine and have a rating of 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 paragraph
5.1. ).
2. Remove the machine from its packing materials: one carton fixed to a wooden pallet for
overseas shipment, one nylon bag for Italy. For machines shipped in cartons, the side uprights
and handles are disassembled and placed on the tread belt.
3. Position the machine as specified above, on a level surface that is free of vibrations and has
sufficient carrying capacity for the combined weight of the machine and the user.
4. For machines which shipped in a carton, it is necessary to reassemble the components that were
disassembled for transport. For assembling follow the procedure described in the Operating and
service instructions supplied with each machine.
5. Connect the mains lead to the inlet socket on the machine.
6. Place the on/off switch in the 0 position.
7. Plug the mains lead into the electrical outlet.
Page 5.1
After completing this power-on test the machine enters standby mode, awaiting a keyboard
command.
To check the correct operation of the machine:
Page 5.2
6. TROUBLESHOOTING
The troubleshooting procedures are shown in the form of flow charts. In order to facilitate
consultation, the following standard box shapes are used.
This type of box is the START point of the troubleshooting procedure. It
typically contains a description of the problem or malfunction.
This type of box represents a decision point in the troubleshooting procedure.
It typically contains a description of the DECISION to be made, with an
outcome that can be either a positive (YES) or negative (NO) response.
This 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 was carried out.
A circled number (such as that shown on the left) next to a box of the
troubleshooting procedure indicates that detailed instructions for performing
that particular check or action are provided below the flowchart.
A circled letter (such as that shown on the left) is used to highlight a point in
the procedure. Typically, this indicator is used in page changes.
Page 6.1
NO
YES
NO
YES
NO
Connect machine to a
suitable
electrical output
YES
1
Is the mains voltage present at
the power supply input?
YES
A
NO
2
NO
YES
3
YES
NO
4
NO
YES
5
NO
YES
6
YES
Replace cable RN-1
NO
Are all DC v oltages present at the
f ree connector CN2?
Page 6.3
B
7
NO
YES
8
NO
YES
9
Is the mains voltage present at
the output of the automatic
circuit breaker?
YES
NO
NO
10
YES
11
NO
Is the mains voltage present at
the output of the filter?
YES
12
Replace the wiring
between the filter - fuse
holder - power supply
Page 6.4
YES
NO
Is the fuse holder continuity OK?
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:
WARNING: Carry out these checks with the machine powered up.
(1)
Slightly lift connector CN1 on the power supply. Place the tester probes between pins 4 and 6
on that connector. The measured voltage should be approximately 220 VAC.
(2)
Slightly lift connector CN2 on the power supply in order to access the pins with the tester
probes. Check that all the output voltages of the power supply are correct by referring to
paragraph 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)
(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 measured voltage should be approximately
220 VAC.
(8)
As for point (6) but on the input of the automatic circuit breaker.
(9)
As for point (6) but on the output of the automatic circuit breaker.
Page 6.5
YES
Correct operation
NO
1
YES
NO
2
YES
Replace cable RN-13Q
NO
Replace the CPU board
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 button. When the button is
pressed the measured voltage should be +5Vdc, when it is released it should be 0 Vdc.
(2)
Place the tester probes between pins 2 and 3 of connector CN3 of the CPU board. The
measured voltage should be +5Vdc.
Page 6.6
YES
Is the emergency button pressed?
Correct operation
NO
1
NO
YES
2
NO
YES
3
Replace emergency
button
NO
YES
A
Page 6.7
4
NO
YES
5
NO
Is the v oltage at the relay correct?
YES
6
NO
Is the relay contact close?
YES
7
NO
YES
Replace 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.
(2)
(3)
Page 6.8
(4)
As for point (1) but on pin 1 and 2 of the patch connector CN5.
(5)
(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 6.9
it has detected a failure to actuate movement of the belt motor at the start of the training session;
the movement of the belt motor is interrupted during the training session.
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.
LENZE INVERTER
In our experience, when machines with the Lenze inverter display this error message, it is necessary
to replace the inverter. In any case, before doing this ensure that the motor is in good condition by
checking that:
Page 6.10
HITACHI INVERTER
BELT MOTOR HALTED
NO
The inv erter is on?
YES
Check the error message
display ed and/or
memorized by the inv erter
E01-E02-E03-E04-E05
E06-E07
E08-E10-E11-E22
E09
E12
E14
E15
E21
None
The paragraphs below illustrate the troubleshooting procedures for each individual error code.
Page 6.11
6.4.1. THE INVERTER DISPLAY SHOWS E01, E02, E03, E04 OR E05
These inverter error messages are related to output short-circuit problems.
E01
E02
E03
E04
E05
NO
YES
NO
YES
1
YES
YES
NO
3
YES
NO
NO
NO
Replace the inv erter
Page 6.12
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 cable from the inverter and place the tester probes between its terminals
U-V, U-W and V-W. The measured 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 Ohm.
(3)
Disconnect the motor cable from the motor and place a tester between its terminals U-V, U-W
and V-W. The measured resistance should be 1.7 Ohm.
Page 6.13
E07
NO
YES
1
Is the v alue of the braking
resistance correct?
NO
Replace the braking
resistor
YES
YES
NO
Follow the procedure step by step to correctly diagnose the problem. Take particular care with the
checks highlighted by circled numbers, which are described in detail below:
(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 measured resistance should be 150
Ohm.
To reduce the occurrences of error E06, it is possible to adjust the following inverter
parameter:
On model J100:
On model SJ100:
A38;
b90;
by increasing its value. This adjustment enables the inverter to increase the use of the
braking resistance.
Page 6.14
E10
E11
1
Does the error occur
f requently ?
YES
Replace the inv erter
NO
YES
NO
NO
Replace the inv erter
YES
Programming correct. The
machine is OK
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 frequent if it occurs 2 or
3 times a day.
WARNING: incorrect programming of the inverter can cause serious damage to the
machine or malfunctioning that is potentially hazardous to the user. Therefore, attempt
this operation only if certain of being able to carry out the procedure with the latest SW
version.
Page 6.15
YES
NO
1
YES
NO
2
NO
YES
3
Is the supply v oltage at the
f ilter output correct?
NO
Replace the f ilter
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)
Place the tester probes between terminals L1 and N of the inverter. The measured voltage
should be 220 VAC.
Page 6.16
(2)
Disconnect the filter power supply cables and place the tester probes on the terminals. The
measured voltage should be 220 VAC.
(3)
Disconnect the filter output 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 divided by 1.41.
Page 6.17
YES
Does the machine resume
correct operation af ter being
turned of f f or 1 hour?
NO
1
NO
Is the thermal cutout on the
motor OK?
YES
2
Is the wiring between the
motor thermal cutout and the
inv erter correct?
NO
Replace cable RN-5TQ
YES
YES
Replace the inv erter
NO
Programming error.
Reprogram 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)
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 Ohm.
In some cases the value may be higher due to oxidation of the contacts. To reinstate
correct operation, it is necessary to perform a special operation which will be described
to you on contacting the Technogym Service.
(2)
Disconnect the motor thermal cutout cables on both the motor and inverter sides, and place
the tester probes at either end of each wire. The measured resistance should be 0 Ohm.
Page 6.18
1
NO
YES
2
NO
Are the motor phases
isolated from ground?
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 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)
Disconnect the motor cable from the motor and place the tester probes between its terminals
U, V and W and ground. The measured resistance should be MOhm or higher.
Page 6.19
YES
NO
1
YES
Is the supply v oltage at the
input to the inv erter correct?
NO
2
NO
Is the supply v oltage at the
input to the f ilter correct?
YES
3
Check and reinstate cable
between the f ilter and the
inv eter
YES
NO
Is the supply v oltage at the
output of the f ilter correct?
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)
Insert the tester probes between terminals L1 and N of the inverter. The measured voltage
should be 220 VAC.
(2)
Disconnect the supply cables from the filter and place the tester probes across them. The
measured voltage should be 220 VAC.
Page 6.20
(3)
Disconnect the filter output 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 divided by 1.41.
Page 6.21
NO
Replace the inv erter
Page 6.22
YES
1
NO
YES
YES
NO
2
Is the alarm signal present
at the input to the inv erter
interf ace board?
YES
Check and/or replace cable
RN-5TQ
NO
3
YES
NO
4
YES
Check and/or replace cable
RN-2
NO
5
YES
Is the alarm present at the
input to the display ?
NO
Page 6.23
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 terminals AL0 and AL1 of the inverter. Under an alarm
condition the measured voltage should 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 between pins 9 (signal) and 1 (ground) of free connector CN1.
(5)
As for point (4) but between pins 9 (signal) and 3 (ground) of connector CN1 on the CPU
board.
Page 6.24
1
YES
Are the belt motor windings shortcircuited or open-circuited?
NO
2
Does the inv erter generate a
balanced v oltage on all phases?
NO
Replace the inv erter
YES
Check and/or replace
cable RN-17Q connecting
the inv erter to 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 should be approximately 1.7 Ohm.
(2)
Run the machine at 12.6 Km/h and place a tester across its terminals U-V, U-W and V-W.
The measured voltage should be 220 VAC.
Page 6.25
1
NO
YES
2
YES
Replace the inverter
NO
Replace the inverter
interface board
Follow the procedure step by step to correctly diagnose the problem. Take particular care with the
checks highlighted by circled numbers, which are described in detail below:
(1)
To check the Start signal, place a tester between pins 8 (signal) and 3 (ground) of connector
CN1 on the CPU board. When the belt is halted the measured voltage should be 0 Vdc,
whereas immediately after pressing the Start key on the display the 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 the signal must be accompanied by a corresponding variation in the tread belt
speed: see Table 6.7-1.
(2)
To check the Start signal, place a tester between pins 2 (signal) and 1 (ground) of connector
CN1 on the inverter interface board. When the belt is halted the reading should be -24.7 Vdc,
whereas immediately after pressing the Start key on the display the measured value should
be -2.7 Vdc.
To check the analog speed reference signal, place a tester between pins 5 (signal) and 6
(ground) of connector CN1 on the inverter interface board. When the belt is halted the
measured value should be 0 Vdc, whereas immediately after pressing the Start key on the
display the reading should rapidly increase to reach a fixed value corresponding to the selected
Page 6.26
speed. The variation of the signal must be accompanied by a corresponding variation in the
belt speed: see Table 6.7-1.
Page 6.27
1
Check the inv erter
parameters setting and
regulate the speed
2
YES
NO
3
YES
Is the inv erter control v oltage correct?
NO
4
Is the inv erter control v oltage at the
output of the inv erter interf ace board
correct?
NO
A
Page 6.28
YES
5
YES
NO
6
NO
Replace the CPU board
YES
Check and/or replace
cables RN-1 and/or RN-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)
See paragraph 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
PWM SIGNAL
ANALOG SIGNAL
FREQUENCY
(Km/h)
(Vdc)
(Vdc)
(Hz)
CPU BOARD
INVERTER
INVERTER
INTERFACE BOARD
DISPLAY
10-3/CN1
10-3/CN2
5-6/CN1
L-0
DISPLAY
2.0
4.66
4.66
0.772
0.772
7.9
6.0
3.91
3.91
2.15
2.15
23.9
12.6
2.68
2.68
4.50
4.50
50.0
20.0
1.30
1.30
7.14
7.14
79.6
25.00
0.36
0.36
8.93
8.93
99.5
Table 6.7-1
Obviously, the voltages and frequencies quoted above are nominal values.
For the Hitachi J100 inverter, the data given in the above tables will be slightly
different, but still comparable.
Page 6.29
(3)
Place the tester probes between the terminals 0 (signal) and L (ground) of the inverter. Check
that during machine operation the speed shown on the display and the voltage measured on
the inverter correspond to the values shown in Table 6.7-1.
(4)
Place the tester probes between pins 5 (signal) and 6 (ground) of connector CN1 on 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.
(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 probes between pins 10 (signal) and 3 (ground) of connector CN1 on the CPU
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.
Page 6.30
NO
2
YES
NO
3
NO
YES
4
NO
YES
5
YES
NO
NO
Is fuse F1 of the up-down board
OK?
YES
6
NO
Does the up-down board receive
the mains electricity supply?
YES
7
YES
NO
8
YES
Is the voltage at the transformer
output correct?
NO
Page 6.32
NO
Lubricate the elevation
bars
9
NO
Is the up-down motor current
correct?
YES
10
YES
NO
Is the pulse signal at the
photocell output correct?
YES
11
NO
Does the up-down board output
the status signal?
YES
12
NO
Does the free connector CN1
receive the Status signal?
YES
13
NO
Does the status signal reach
the CPU board?
YES
Page 6.33
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:
Execute the following troubleshooting procedure when the machine does the reset at the
start up.
If the motor momentarily starts and stops immediately afterward, there is probably a
problem with the photocell or its cable.
(1)
Each LED corresponds to a limit switch. DL1 turns off when the upper limit switch is tripped,
while DL3/DL2 turns off when the lower limit switch is tripped. If neither of the 2 limit
switches is tripped and one of the 2 LEDs is off, refer to paragraph 6.9. The up-down moves
in only one direction.
If the machine is locked in one of its travel limit positions, the corresponding limit switch
will be tripped, and therefore the machine will be able to move in only one direction. If
movement in this direction is impeded due to a problem, the message GRADE
MOVEMENT OUT OF ORDER may appear on the display.
(2)
Place the tester probes between pins 1 and 2 of connector CN3 on the up-down board. When
the or key is pressed the measured value should be approximately 48 Vdc.
(3)
Place the tester 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 connector CN1.
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 the free connector CN1. When the
key is pressed the measured voltage should be approximately 4 Vdc.
(5)
Place the tester probes between pins 4 (ground) and 3 (signal) of connector CN2 on the updown. board. When the key is pressed the measured voltage should be approximately 4
Vdc. Place the tester probes between pins 4 (ground) and 2 (signal) of connector CN2 on the
up-down board. When the key is pressed the measured voltage should be approximately 4
Vdc.
(6)
Place the tester probes between pins 1 and 2 of connector CN4 on the up-down board. The
measured voltage should be approximately 220 VAC.
(7)
Place the tester probes between pins 1 and 2 of connector CN6 on the up-down board. The
measured voltage should be approximately 50 Vdc.
(8)
Disconnect the yellow transformer cables on the rectifier bridge and place the tester probes
across the 2 terminals. The measured voltage should be 38 VAC.
Page 6.34
(9)
Place the tester probes in series with the motor cable. When the or key is pressed the
measured steady-state current should be less than 6 A.
(10) Slightly lift the connector on the photocell and place the tester probes between pins 4 (ground)
and 2 (signal). 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 updown. 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 for step (11), but with the tester probes between pins 15 (ground) and 12 (signal) of
connector CN1 on the CPU board.
Page 6.35
YES
Are 2 LEDs on the up-down board
both illuminated?
NO
1
NO
YES
2
YES
NO
3
Does the free connector CN1 receive
the correct control signal in the
inactive direction?
NO
B
YES
5
YES
Is the limit switch associated with the
non-illuminated LED tripped?
NO
6
YES
NO
7
YES
NO
4
NO
Replace the CPU board
YES
Page 6.37
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)
The machine is considered to have reached a travel limit when the corresponding limit switch
is tripped. The lower limit switch is tripped when its lever is pressed, while the upper limit
switch is tripped when its lever is released.
(2)
If the machine fails to move downward, place the tester probes between pins 4 (ground) and 3
(signal) of connector CN2 on the up-down board: the measured voltage should be
approximately 4 Vdc. If the machine fails to move upward, place the tester probes between
pins 4 (ground) and 2 (signal) of connector CN2 on the up-down board: the measured voltage
should be approximately 4 Vdc.
(3)
If the machine fails to move downward, place the tester probes between pins 15 (ground) and
14 (signal) of the free connector CN1: the measured voltage should be 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 fails to move upward, place the tester probes between
pins 15 (ground) and 13 (signal) of connector CN1 on the CPU board: the measured voltage
should be approximately 4 Vdc.
(5)
DL1 corresponds to the upper limit switch, while DL2 on SMD board / DL3 on traditional
board corresponds to the lower limit switch.
(6)
Disconnect the 2 connecting cables of the relevant limit switch and place the tester probes
across them: the measured voltage should be approximately 12 Vdc.
(7)
To check the upper limit switch, place the tester probes between pins 6 (ground) and 3 (signal)
of connector CN3 on the up-down board: the measured voltage should be 12 Vdc. To check
the lower limit switch, place the tester probes between pins 6 (ground) and 4 (signal) of
connector CN3 on the up-down board: the measured voltage should be 12 Vdc.
Page 6.38
1
NO
Is the SW of the up-down board
matching the photocell model?
YES
NO
Is the position of the limit switch
correct?
NO
YES
2
NO
Is the up-down motor current correct?
YES
YES
NO
YES
Replace the photocell and
cable RN-12Q connecting
the up-down board and
the photocell
Page 6.39
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)
(2)
Photocell board
GF92015-B
GF970711
SW
M3S10
RR52V2
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 6.40
It is normal for the machine to show this message on the first power up after replacing the
display;
It indicates a problem if the message appears at other times.
Page 6.41
1
YES
NO
NO
2
YES
NO
3
YES
NO
4
Check whether the pump
command signal at the output
of the CPU board is correct
NO
Page 6.42
YES
Replace cable RN-3
WARNING: Run the following checks during a manual lubrication cycle, initiated by
simultaneously pressing the 1, 4 and 7 keys.
Follow the procedure below to correctly diagnose the problem. Take particular care with the steps
highlighted by circled numbers, which are described in detail below:
(1)
If the relay is switching, the sound of the contacts closing should be audible.
(2)
Place the tester probes between pins 1 (ground) and 2 (signal) of connector K1 on the pump
interface board. The measured voltage should be +12 Vdc. Place the tester probes between
pins 1 (ground) 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 probes between pins 9 (ground) and 10 (signal) of connector CN2 on the CPU
board. The measured voltage should be +12 Vdc. Place the tester probes between pins 9
(ground) and 12 (signal) of connector CN2 on the CPU board. During lubrication the
measured voltage should be +5 Vdc.
WARNING: When installing a new pump, before connecting the distribution tube, run a
few manual lubrication cycles until the oil that comes out is clean.
Page 6.43
1
NO
YES
2
YES
NO
3
NO
Replace or rewire the printer
cable
YES
Is the printer cable OK?
Follow the procedure step by step to correctly diagnose the problem. Take particular care with the
checks highlighted by the circled numbers, which are described in detail below:
(1)
Open the display and configure the dip-switches as detailed in paragraph 9.1. .
(2)
Page 6.44
Connect the tester on the output connector printer cable A434, while 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 6.45
1
YES
NO
2
Is the supply voltage on
connector K7 of the CPU board
correct.
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)
Place the tester probes between pins 1 (signal) and 3 (ground) (corresponding to the red and
black wires) of connector K7 on the CPU board of the display: the measured voltage should
be +5Vdc.
Page 6.46
NO
YES
NO
YES
NO
YES
1
Are there sources of
electromagnetic noise near
the receiver?
YES
NO
A
Page 6.47
2
Is the transmitter in good
working order?
NO
YES
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)
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 if possible. Otherwise use a receiver or another
reference machine to check operation up to a distance of about 80 cm from the receiver.
ATTENTION: Consult paragraph 11.1. Technical notes on cardio receivers in the
Appendix.
Page 6.48
7. DISASSEMBLY OF COMPONENTS
7.1. DISASSEMBLING THE DISPLAY
Figure 7.1-1
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.
Figure 7.1-2
Page 7.1
Figure 7.2-2
To reassemble 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 into the socket.
Figure 7.2-3
Page 7.2
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.
Figure 7.3-2
Page 7.3
Figure 7.4-2
Figure 7.4-3
Continued on the following page
Page 7.4
Figure 7.4-4
Page 7.5
Figure 7.5-2
Rest the keyboards electronic circuit boards
group on the work bench:
5. Disconnect the connector from the keyboard.
6. Use a sharp tool to lift up a corner of the
KEYBOARD and detach it.
Figure 7.5-3
Continued on the following page
Page 7.6
Page 7.7
Figure 7.6-1
Page 7.8
Figure 7.7-2
Page 7.9
Figure 7.8-2
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 3mm hex T wrench.
2. Back off screw d with an 8-mm hex T
wrench.
3. Remove the bar guard by lifting it upward.
4. Lift up the MOTOR GUARD.
Figure 7.8-3
Page 7.10
Figure 7.9-1
Page 7.11
Figure 7.10-1
Page 7.12
Figure 7.11-1
Figure 7.11-2
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.
Figure 7.11-3
Page 7.13
Figure 7.12-3
Continued on the following page
Page 7.14
Figure 7.12-4
Page 7.15
Figure 7.13-1
Figure 7.13-2
Page 7.16
Page 7.17
Figure 7.15-1
Figure 7.15-2
Page 7.18
TRACK
Page 7.19
Page 7.20
Figure 7.17-1
3. Back off the 4 screws b on the TREADBELT MOTOR cover using a large Philips
screwdriver.
4. Back off the cable clamp c.
5. Open the cover
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.
Figure 7.17-2
Figure 7.17-3
Continued on the following page
Page 7.21
Page 7.22
Page 7.23
Figure 7.19-1
Figure 7.19-2
Page 7.24
Figure 7.19-3
Page 7.25
Figure 7.20-1
Page 7.26
Figure 7.21-1
Figure 7.21-2
Page 7.27
Figure 7.22-2
Continued on the following page
Page 7.28
Figure 7.22-3
Figure 7.22-4
Continued on the following page
Page 7.29
Figure 7.22-5
Page 7.30
Page 7.31
Figure 7.24-1
5.
6.
7.
8.
Page 7.32
Figure 7.25-1
7. Back off the bearing clamp screw c using a 4mm hex T wrench.
8. Rotate the bearing clamp d.
9. Remove the LEAD SCREW NUT GROUP.
To reassemble the LEAD SCREW NUT
GROUP, carry out the above steps in reverse
order.
Figure 7.25-2
Page 7.33
Figure 7.26-1
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.
Figure 7.26-2
Page 7.34
Page 7.35
Figure 7.28-2
Page 7.36
8. ADJUSTMENTS
8.1. TENSIONING A NEW TREAD BELT
Figure 8.1-1
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 using only the left-hand
tensioning screw.
Figure 8.1-2
Page 8.1
Figure 8.2-2
Page 8.2
Figure 8.3-1
Page 8.3
Figure 8.4-2
Page 8.4
Figure 8.4-3
Page 8.5
3. Back off the chain tightener nut a using a 17mm 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 adjustment, lock down
the chain tightener nut.
Figure 8.5-2
Page 8.6
Page 8.7
Figure 8.7-1
Page 8.8
Figure 8.8-2
Page 8.9
Page 8.10
Figure 8.10-1
Page 8.11
Page 8.12
9. MACHINE CONFIGURATION
9.1. HW MACHINE CONFIGURATION
The HW machine configuration is done via the 2 banks of 4 dip-switches at the rear of the CPU
board, proceeding as follows:
Page 9.2
C L E A R
Type in the password 6144 and ENTER to confirm. The following message will appear on the
LCD:
L U B R I C A T I O N :
W E A K = 1
M E D I UM = 2
S T R O NG = 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 the
frequency of lubrication expressed in km covered by the machine, according to the table below:
LUBRICATION
Type
Light
Medium
Heavy
Duration
Sec
30
30
15
Frequency
Km covered
400
300
100
If the machine is not equipped with the automatic lubrication system, the above
configuration parameters are ignored.
Page 9.3
C L E A R
=
=
X X X X
X X X X
Page 9.4
X X
X X
Page 9.5
C L E A R
=
=
X X X X
X X X X
T I M E .
L U B R I C A T .
K m .
C O V E R E D
F R OM
L A S T
L U B R I C A T . =
X X X X
After 10 seconds, it automatically goes on to the next view.
X X
X X
Page 9.7
C L E A R
Type in the password 2406 and press ENTER to confirm. This accesses the configuration procedure
for sequentially modifying the following parameters.
This procedure can be used on machines equipped with the automatic lubrication
system, for fine tuning the parameters which determine the frequency and duration of
the lubrication cycle.
Press the Clear key to exit the procedure at any time. The changes made will remain
valid.
H O U R S
=
- >
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 confirm.
Page 9.8
T I M E .
0 0 0
XXX 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.
L U B R I C A T .
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 an automatic lubrication cycle, the lubrication
parameters are not significant.
Page 9.9
When the inverter is energized, function parameter d01 appears on the display: this is the inverter
output frequency toward the motor.
To display the inverter monitor parameters (d type) or those of another main function:
1.
2.
3.
4.
Page 9.10
Description
Base frequency
Maximum frequency setting
External frequency setting start
External frequency setting end
Control method setting
Frequency upper limit setting
Selection of AVR function
Selection of voltage of AVR function for the motor
Level of electronic thermal setting
Selection of electronic thermal characteristic
Level of overload restriction setting
Carrier frequency setting (KHz)
Dynamic braking usage ratio
Function of terminal 3 setting
Condition of terminal 3 setting
Acceleration
Deceleration
Autotuning mode setting
Motor data selection
Motor capacity setting
Motor poles setting
Motor constant Kp setting
Motor stabilization constant
Motor constant R1 (Autotuning data)
Motor constant R2 (Autotuning data)
Motor constant L (Autotuning data)
Motor constant Io (Autotuning data)
Motor constant J (Autotuning data)
Value
50
110
0.8
110
02
0
01
240
11.00
01
16.50
16.0
10
12
01
15.0
5.0
0
01
2.2
4
80
100
1.124
0.888
7.79
5.25
20.0
Before modifying the value of function C0, modify the value of function C13.
Description
Motor output frequency
Motor current draw
Direction of movement
Status monitor of intelligent terminal input signals
Status monitor of intelligent terminal output signals
Converted motor output frequency
Monitor of last alarm condition
List of the last error conditions
Page 9.11
Press the FUNC key until the desired main function appears.
Press the 1 key once to display the value of the parameter.
To modify the value, press the 1 key to increase or the 2 key to decrease.
To save the modified value, press the FUNC key: the display reverts to showing the selected
main function.
Page 9.12
MAIN FUNCTIONS
FUNCTION
F1
F2
F4
F5
F6
F7
F8
F9
F 10
F 11
F 14
Value
2.5
F
__
15
5.0
40
03
72
220
0
Default
Page 9.13
EXTENDED FUNCTIONS
FUNCTION
A0
A1
A2
A3
A4
A5
A6
A7
A8
A9
A 10
A 11
A 12
A 13
A 14
A 15
A 16
A 17
A 18
A 19
A 20
A 21
A 22
A 23
A 24
A 26
A 27
A 28
A 29
A 30
A 31
A 32
A 33
A 34
A 35
A 36
Page 9.14
Value
2
1.5
4
0.0
1.5
0
0
0
0
0
16
8
0
0
0
0
0
0
10.0
10.0
0.5
0
0
100
1
1.5
106
0
0
150
150
0
0
0
0
0
Default
FUNCTION
A 37
A 38
A 39
A 40
A 41
A 42
A 43
A 48
A 49
A 50
A 51
A 52
A 53
A 55
A 56
A 57
A 58
A 62
A 63
A 64
A 68
A 71
A 80
A 81
A 82
A 83
A 84
A 85
C0
C1
C2
C3
C4
C 10
C 20
C 21
Value
220
5
100
100
1
0
0
1
2
1
0
1
0
0
1
0
1
50
106
0
0.5
0
127
132
1.0
10.0
0
1.0
09
02
07
11
00
00
01
03
Default
MAIN PARAMETERS
Parameter
C10
C11
C15
C16
Value
0
110
50
9
Page 9.15
Page 9.16
The prescribed frequency differs for each type of operation, as does the required level of operator
qualification. The following paragraphs detail the recommended procedures.
Page 10.1
Turn off the machine by placing the switch in the 0 position (OFF).
Unplug the mains lead from the wall outlet.
Open the motor guard.
Use a vacuum cleaner to clean the interior, paying particular attention to the tread belt motor, the
inverter and the electronic circuit boards.
WARNING: when carrying out these operations, be careful not to damage the cables.
5. Pull out the dust filter and clean it using compressed air or a vacuum cleaner.
6. Move the machine and clean the floor underneath using a vacuum cleaner.
Page 10.3
External conditions;
Possible rusting of the connectors;
Electrical continuity of the individual wires;
Isolation of the individual wires toward ground.
4. Check the state of wear of the motor roller. Replace if it shows evident signs of wear.
Turn off the machine by placing the switch in the 0 position (OFF).
Unplug the mains lead from the wall outlet.
Open the motor guard.
Check the state of wear of the tread motor drive-belt, turning it by hand using the motor
flywheel. Replace if it shows evident signs of wear.
5. Check the tension of the motor drive-belt. Adjust the tension if necessary.
3. If the machine is equipped with a coded receiver (PCD technology), put on the coded 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 doesnt alter the
previously measured heart rate.
Page 10.6
11. APPENDIX
11.1. TECHNICAL NOTES ON CARDIO RECEIVERS
Technogym utilizes Polar technology for measuring the heart rate frequency of the person training
on the machine. The Polar system consists of:
a transmitter, worn by the person training on the machine, which uses 2 electrodes to detect the
electrical activity of the heart and transmits the measured heart rate by sending an
electromagnetic signal at a frequency of 5 kHz.
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 sometimes mounted.
The receiver is connected to the CPU board by means of 3 wires for:
+5 Vdc power supply;
Output signal (heart rate);
ground.
The output is a digital signal that is normally at 5 Vdc and goes to 0 Vdc for a few msec when a
heart beat is detected, as shown in the figure below.
Page 11.1
There are 3 types of problems which can typically occur on the heart rate signal:
The following paragraphs contain various suggestions which may be useful for improving the
reception of the cardio signal.
DISTANCE
(cm)
90
100
85
As regards sensitivity to noise, the best ASIC is the HRRE model. This ASIC is also the one
recommended by the manufacturer.
Page 11.2
of the receiver (detected by the coil) whereas they have no effect on digital components such as the
CPU receiver connecting cable.
Electromagnetic interference can take different forms: on the one hand, the receiver may detect and
hence generate spurious transients or periodic noise pulse, or on the other hand the receiver may
become saturated. The presence of transients is generally accompanied by irregular blinking of the
heart rate LED on the display, but does not affect the value shown which is processed by special SW
filters. The presence of periodic noise pulse effect the heart rate signal. Saturation of the receiver,
on the other hand, is a phenomenon which, depending on its intensity, can reduce the maximum
reception distance until it becomes completely impossible to receive a signal.
In the presence of electromagnetic noise, use the frequency signal monitor shown in the schematic
below to determine the presence, intensity and effect of the fields.
This circuit causes the LED to light for every heart beat and/or transient detected: in this way 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:
Please note that these are merely some possible suggestions, and that the effectiveness of the
chosen solution must be verified in practice.
presence of electromagnetic fields which interfere with reception or saturate the receiver;
problems due to interaction between the receiver on one machine and the signal transmitted by a
user training on another machine that is too close and cannot be moved farther away.
Page 11.3
Sensitivity is reduced by soldering a resistor in parallel with the coil. Normally, the receiver already
has a 15 KOhm resistor mounted in parallel with the coil, however it is advisable to check for its
presence.
The following table shows the nominal values of reception distance based on the value of the
resistor soldered on the coil:
RESISTANCE
(Ohm)
15K
13K
11K
9K1
6K8
5K1
3K
2K
1K
DISTANCE
(cm)
89
88
87
85
84
81
74
69
57
Please note that these are only nominal values. The actual reduction in sensitivity must be verified
experimentally, taking great care not to excessively reduce the reception distance.
WARNING: if there is already a 15 KOhm resistor mounted in parallel with the coil,
note that adding another resistor in parallel will produce a total resistance value
equivalent to the parallel combination of the added resistor and the existing 15 KOhm
resistor.
Page 11.4
the receiver must be directed in such a way that its axis of reception is parallel to that of the
transmitter, as shown 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
Page 11.5
DESCRIPTION CAUSES
Power circuits
protection
Constant
speed
Deceler.
Acceler.
Stop
Overload protection When the internal thermostat of the inverter detects a motor
overload, the output is disconnected.
Braking resistor
When the external resistor is used too frequently, and an
overload
overvoltage is detected caused by interruption of the BRD function,
the output is disconnected.
Overvoltage
When the voltage exceeds a preset threshold, due to motor
protection
regeneration phenomena, this safety is tripped and the output is
disconnected.
EEPROM error
When an error is detected on the EEPROM memory which stores
the working program, the output is disconnected.
Low voltage
A drop in the input voltage below 150-160 V triggers this error, and
protection
the output is disconnected.
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.
CPU error
If a malfunction is detected in the internal CPU, the output is
disconnected.
External shutdown One of the motor thermal cutouts has opened, the inverter has
detected it and disconnected the output.
USP error
Appears if the inverter is turned on with the start key pressed (non
in use on RunXTPRO).
Ground short circuit If one of the inverter phases has a leak or short-circuit to ground,
protection
the output is disconnected.
Overvoltage
If the input voltage increases more than 10% above its nominal
protection
value for at least 100 seconds, this safety is tripped and the output
is disconnected.
Thermal cutout
If the temperature sensor inside the inverter detects an
overtemperature condition, the output is disconnected. In this
condition, the dissipator reading is 80 C.
PTC error
Problem with the PTC sensor (not used on Forma).
ERR.
E01
E02
E03
E04
E05
E06
E07
E08
E09
E10
E11
E22
E12
E13
E14
E15
E21
E35
To display the inverter error codes, follow the instructions below or refer to pages 8-2 of the inverter
manual:
1. Remove the motor guard.
Page 11.6
error code;
output frequency when the error occurred;
motor current when the error occurred;
motor voltage when the error occurred;
To advance to the next value, press the FUNC key.
5. To view the last 2 logged errors in inverse chronological order, display the function d09and
press the FUNC key. Each time this key is pressed the inverter memory goes back one error.
ATTENTION: Be very careful not to touch any other keys, or to touch the aforesaid
keys at the wrong time, as this can seriously damage the inverter configuration, leading
to malfunctioning of the machine.
5. Holding down the three keys, press 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 11.8
DESCRIPTION CAUSES
Power circuits
protection
ERR.
Constant
speed
Deceler.
Acceler.
Stop
Overload protection When the internal thermostat of the inverter detects a motor
overload, the output is disconnected.
Braking resistor
When the external resistor is used too frequently, and an
overload
overvoltage is detected caused by interruption of the BRD function,
the output is disconnected.
Overvoltage
When the voltage exceeds a preset threshold, due to motor
protection
regeneration phenomena, this safety is tripped and the output is
disconnected.
EEPROM error
When an error is detected on the EEPROM memory which stores
the working program, the output is disconnected.
Low voltage
A drop in the input voltage below 150-160 V triggers this error, and
protection
the output is disconnected.
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.
CPU error
If a malfunction is detected in the internal CPU, the output is
disconnected.
External shutdown One of the motor thermal cutouts has opened, the inverter has
detected it and disconnected the output.
USP error
Appears if the inverter is turned on with the start key pressed (non
in use on Runrace).
Ground short circuit If one of the inverter phases has a leak or short-circuit to ground,
protection
the output is disconnected.
E1
E2
E3
E4
E5
E6
E7
E8
E9
E10
E11
E12
E13
E14
To display the inverter error codes, follow the instructions below or refer to pages 8-14 of the
inverter manual:
6.
7.
8.
9.
Voltage at the time of the error (this is the DC voltage internal to the inverter; to obtain the
actual mains voltage simply divide this value by 0.14).
10. To proceed to display all the errors in reverse chronological order, simply press the 1 key
while the error code is being displayed. Each time this key is pressed, the display will go back
by one error in the inverter memory.
ATTENTION: Be 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.
Page 11.10
ERROR
OC1
OC2
OC3
OC4
U15
OH
CCr
DESCRIPTION
Short Circuit - Overcurrent
Isolation fault
Overcurrent during acceleration
Overcurrent during deceleration
Problem on 15 Volt power supply
Overtemperature
Inverter CPU error
This function is available only if the inverter is equipped with the special keypad.
1.
2.
3.
4.
5.
6.
Page 11.11
The Hitachi inverter is smaller, and therefore an adapter plate must be used to mount it on the
supports of the Lenze inverter; this mounting plate has order 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 the upgrade, in addition to the inverter itself, which has order code 0WR014, it is
necessary to order:
Page 11.12
Model
Hitachi J100 E5
Lambda ZT30-522
Schaffner FN350-20-29
Schaffner FS5458-20-29
with FN350 filter
with FS5458 filter
Ileakage
1200 A
300 A
4900 A
350 A
5400 A
1850
A
To ensure conformance to the values prescribed by the regulations 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 A.
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 A.
In place of the Schaffner 350/20/29 filter, use the Schaffner FS5458-20-29 filter specially
manufactured for Technogym, which has order code 0WB018. This filter is installed as standard
on machines with SN 6000120008, or raise the filter off the ground.
Suspend the Schaffner 350-20-29 filter using insulating spacers and plastic screws. This reduces
the leakage of the filter to approximately 0 A.
Replace the Schaffner 660-3/06 filter with the Schaffner 610B-3/06 filter with order code
0WB016.
Replace the Schaffner 660-10/06 filter with the Schaffner 610B-10/06 filter with order code
0WB015.
Always obtain authorization from the Technogym Service Center before carrying out
this operation.
With these modifications, the machine leakage current is reduced to approximately 400 A,
bringing it within the 500 A limit prescribed by the regulations.
Page 11.13
WARNING: The above modifications do not significantly influence the tripping of the
automatic circuit breakers, as these are normally calibrated for residual currents of 30
mA, well above the leakage current of the machine under normal conditions. In this case
it may be useful to check that:
the 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, and in particular that the
50 Hz lowpass filter, installed to eliminate high frequency disturbances caused by the
inverter, is operating correctly.
Page 11.14
Password Function
6144
Configuration of SW parameters as described in paragraph 9.2.
2406
Modifying the working parameters as described in paragraph 9.5.
Partial display of working parameters as described in paragraph
0-3
2406
9.3.
Complete display of working parameters as described in paragraph
0-3
6144
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.
Automatic incline test: 3% up and 2% down up to the maximum
Runrace Test-0
2406
incline, then 3% down and 2% up, and so on. To abort press the
CLEAR key.
Medical Tests
2512
Maximal tests.
Page 11.15
Page 11.16
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
0SMM0021-ING