Professional Documents
Culture Documents
REV. 2.0
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.
Contents
1. GENERAL NOTICES............................................................................................................................................1.1
1.1. INTRODUCTION............................................................................................................................................ 1.1
1.2. RECOMMENDATIONS ................................................................................................................................... 1.1
1.3. GENERAL RULES FOR REPAIR PROCEDURES ................................................................................................. 1.2
2. TECHNICAL CHARACTERISTICS ..................................................................................................................2.1
2.1. MECHANICAL CHARACTERISTICS................................................................................................................. 2.1
2.2. ELECTRICAL CHARACTERISTICS................................................................................................................... 2.1
2.3. AMBIENT SPECIFICATIONS ........................................................................................................................... 2.1
2.4. CONFORMITY TO REGULATIONS................................................................................................................... 2.1
2.5. WIRING DIAGRAMS ...................................................................................................................................... 2.2
2.5.1. 220 model conform to IEC 601.....................................................................................................2.2
2.5.2. 220 model with SJ100 inverter.....................................................................................................2.8
2.5.3. 220 model...................................................................................................................................2.14
2.5.4. 220 model with HITACHI E2 inverter........................................................................................2.16
2.5.5. 220 model with LENZE inverter.................................................................................................2.17
3. PRINCIPLES OF OPERATION ..........................................................................................................................3.1
3.1. BLOCK DIAGRAM ......................................................................................................................................... 3.1
3.1.1. Cardio transmitter........................................................................................................................3.1
3.1.2. Cardio 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 ............................................................................................................................. 3.8
3.3.1. Mechanics ....................................................................................................................................3.8
3.3.2. Controls........................................................................................................................................3.8
3.3.3. The signals involved .....................................................................................................................3.8
3.4. AUTOMATIC LUBRICATION SYSTEM ........................................................................................................... 3.11
3.4.1. Mechanical components.............................................................................................................3.11
3.4.2. Control signals ...........................................................................................................................3.11
3.4.3. The signals .................................................................................................................................3.12
4. ACCESSORIES......................................................................................................................................................4.1
4.1. CONNECTING TO THE TGS ............................................................................................................................ 4.1
4.1.1. Non TGS-adapted machines.........................................................................................................4.1
4.1.2. TGS-adapted machines ................................................................................................................4.1
4.2. CONNECTING TO THE PRINTER ..................................................................................................................... 4.2
4.3. CONNECTING TO AN EXTERNAL DEVICE (ECG AND/OR METABOLIC MONITOR) ........................................... 4.3
4.4. PIN OUT SERIAL PORTS ............................................................................................................................... 4.4
Page i
Page ii
Page iii
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:
1.2. RECOMMENDATIONS
Technogym recommends the following steps for planning repair procedures:
• Carefully evaluate the customer’s description of the machine malfunction and ask all the
necessary questions to clarify the symptoms of the problem.
• Clearly diagnose the causes of the problem. This manual provides the fundamental theoretical
basis, which must then be integrated by personal experience and attendance at the training
courses periodically offered by Technogym.
• Rationally plan the repair procedure so as to minimize the downtime necessary for procuring
spare parts, preparing tools, etc.
• Access the component to be repaired, avoiding any unnecessary operations. In this regard it will
be useful to refer to the disassembly sequence described in this manual.
Page 1.1
2. Use original Technogym spare parts and lubricants of the recommended brands.
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 tool sizes quoted in this manual are expressed in mm.
Page 1.2
2. TECHNICAL CHARACTERISTICS
Europe
EMI EN 60601-1-2
EN 60601-1
Safety
EN 957-1
73/23/CEE
Directive 93/68/CEE
89/336/CEE
Page 2.1
Page 2.2
CONNECTORS
• CPU board
• Power supply
• Up-down board
• Patch cables
Page 2.3
WIRING
Page 2.4
Page 2.5
Page 2.6
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
• Power supply
• Up-down board
• Patch cables
Page 2.9
WIRING
Page 2.10
Page 2.11
Page 2.12
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
Page 2.15
Page 2.16
Page 2.17
Page 2.18
3. PRINCIPLES OF OPERATION
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 (user’s 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.
• 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.
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.
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.
The 2 photocells are mechanically interchangeable but functionally distinct — each one requires its
own specific SW version on the up-down board.
Page 3.3
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.
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.
• 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.
The button, which has a NC contact, is connected both to the CPU board and to a relay which
enables the inverter power supply. Once the button has been pressed, the relay shuts off the power
supply to the inverter and the motor stops. At the same time, the CPU board also detects that the
button was pressed, interrupts the exercise and shows a message on the display. To resume using the
machine, it is necessary to wait at least 5-10 seconds before returning the emergency button to the
working position.
Page 3.4
3.2.1. MECHANICS
The tread belt is actuated by the motor through a linkage consisting of the motor pulley, the driving
roller and the belt which connects them. In this way, a given belt motor speed corresponds to a
predetermined linear tread belt speed. The belt motor is controlled by the inverter which generates a
variable-frequency sine wave signal: variations in frequency cause the motor speed and hence the
tread belt speed to vary.
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
Inverter interface
board
5-6 2-1 CN1 3-4
Inverter
3-PV24
U-V-W
VAC
Variable frequency Thermal
protection
• 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
3.3.1. MECHANICS
The elevation of the machine is varied by the up-down motor which, by means of a timing belt,
turns the lead screw nuts on the 2 elevation bars. The motor has an integral encoder wheel which, by
means of a photocell, provides the motor motion control signal: each motor revolution corresponds
to a predetermined number of pulses and to a predetermined displacement on the elevation bars.
The direction of rotation of the motor determines whether the treadmill moves upward or
downward.
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.
CPU board
13-15 14-15 CN1 12-15
Up Down Status
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 up-
down 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 up-
down 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
The principal reasons for the elimination of the automatic lubrication pump are:
• 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 self-
lubricating tread belts.
Resetting the pump enable signal opens the relay contact, switching off the pump.
The reservoir incorporates a float for monitoring the oil level. When the oil level falls below the
minimum mark, a signal is transmitted to the CPU board causing it to display the message “BELT
LUBRICANT OUT: REFILL” or “BELT LUBRICANT OUT, ACT NOW”, depending on the SW
release installed, on the LCD at each power-up.
WARNING: This message is ambiguous and may be misinterpreted. In fact it does not
mean that the oil is finished, but only that the oil level is low. When this message first
appears the lubrication can continue to function for at least another 2-3 cycles.
Page 3.11
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
Pump interface
board
1-2-3/KR6 4-5/KR6
Pump
WARNING: The pump interface board also functions as a distribution board for the
220 VAC mains voltage. Depending on the machine version, the pump interface
board supplies the voltage to the up-down board, the inverter, the power supply, the
pump and the cooling fans of the motor and motor guard. What’s more, in the
machine version with LENZE inverter, this board also receives the input from the
Page 3.13
thermal cutouts of the tread belt motor and sends it to the LENZE inverter interface
board.
Page 3.14
4. ACCESSORIES
The CPU board is connected to the serial connector via the cable described below, which is supplied
together with the upgrade kit.
For additional information, including troubleshooting, refer to the manual “Technogym System:
Installation Guide”.
Page 4.1
If the machine is equipped with SW for the Technogym System, the print function is not
available.
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. .
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.
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:
(*) 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
PIN SIGNAL
1 Shield
2 Tx
3 Rx
4 RTS
5 CTS
6 DSR
7 GND
PIN SIGNAL
1 A-BUS
3 GND
5 B-BUS
7 Shield
Page 4.4
5. INSTALLATION INSTRUCTIONS
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.
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.
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
THE DISPLAY
DOES NOT
ILLUMINATE
NO
Is the fuse OK?
Replace the blown fuse
YES
YES
NO Connect machine to a
Does the wall output supply the
suitable
correct voltage?
electrical output
YES
NO
Is the mains voltage present at
the power supply input?
B
YES
Page 6.2
YES
YES
Do all DC v oltages reach the Replace the display
display ? CPU board
NO
4
YES
5
YES
YES NO
Replace cable RN-1 Are all DC v oltages present at the
Replace cable RN-2
f ree connector CN2?
Page 6.3
YES
8
YES
9
YES
10
YES
11
NO
Is the mains voltage present at Replace the filter
the output of the filter?
YES
12
Page 6.4
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.
(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.
(12) Using the tester probes, check the continuity of the fuse holder by measuring its resistance.
This is correct if the measured value is less than a few Ohms.
Page 6.5
EMERGENCY PRESSED,
EXERCISE INTERRUPTED
YES
Did the user press the emergency
button during the training session or Correct operation
at the start?
NO
1
YES
Is the v oltage at the emergency Replace the emergency
button terminals correct? button
NO
2
YES NO
Is the v oltage at the output of the CPU
Replace cable RN-13Q board correct? 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
Is the v oltage at the output of the CPU
board correct? Replace the CPU board
YES
2
YES
NO YES
Replace emergency Is the v oltage at the CN9 patch
button connector correct? A
Page 6.7
NO
Is the v oltage at the CN5 patch
connector correct? Replace RN-3Q cable
YES
5
YES
6
NO
Is the relay contact close? Replace the relay
YES
7
NO YES
Check the mains cables Is the v oltage at the input of the
inv erter correct? Replace the inv erter
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.
(2) As for point (1) but on pin 1 and 4 of the emergency button.
Page 6.8
(4) As for point (1) but on pin 1 and 2 of the patch connector CN5.
(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
NO
The inv erter is on? Execute the procedure
"The inv erter is of f "
YES
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.
NO
Are the belt and the deck Replace the belt and the
lubricated and in good state? deck and/or lubricate
YES
NO
Are the roller bearings in
good state? Replace the rollers
YES
YES
NO Replace the belt motor
2 3
YES
Is there a short-circuit on the Is the belt motor short-
motor cable terminals? circuited?
NO YES
Does the machine resume Probable interf erence. The
Replace the inv erter
correct operation af ter being machine is OK
turned of f f or 1 minute?
Page 6.12
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
E06 E07
YES
1
NO
Is the v alue of the braking Replace the braking
resistance correct? resistor
YES
YES
NO Does the machine resume
Replace the inv erter correct operation af ter being Probable interf erence. The
turned of f f or 1 minute? 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) 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:
by increasing its value. This adjustment enables the inverter to increase the use of the
braking resistance.
Page 6.14
1
YES
Does the error occur
f requently ? Replace the inv erter
NO
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) 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
E09
NO
1
YES
Is the power supply at the Replace the inv erter
inv erter input OK?
NO
2
Check and reinstate the
NO wiring between the power
Is the supply v oltage at the
input socket, automatic
f ilter input correct?
circuit breaker and f ilter
YES
3
NO
Is the supply v oltage at the Replace the f ilter
f ilter output correct?
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
E12
YES
Does the machine resume
correct operation af ter being Probable ov erheating of the
turned of f f or 1 hour? motor. The machine is OK
NO
1
NO
Is the thermal cutout on the Replace the belt motor
motor OK?
YES
2
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 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
E14
YES
2
NO
Are the motor phases Replace the belt motor
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
E15
NO
1
YES
Is the supply v oltage at the Replace the inv erter
input to the inv erter correct?
NO
2
NO Check and reinstate cable
Is the supply v oltage at the between the circuit breaker
input to the f ilter correct? and 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) 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
E21
Page 6.22
None
1
NO YES
Is LED DL2 on the inv erter Is the alarm signal present
interf ace board illuminated? at the inv erter output? Replace the inv erter
YES NO
3 NO
YES
Is the alarm present at the Replace the inv erter
output of the interf ace board? interf ace board
NO
4
YES
Is the alarm present at the Check and/or replace cable
f ree connector CN1? RN-2
NO
5
YES
Is the alarm present at the Check and/or replace cable
input to the display ? RN-1
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
YES
Are the belt motor windings short-
Replace the belt motor
circuited or open-circuited?
NO
2
NO
Does the inv erter generate a
balanced v oltage on all phases? Replace the inv erter
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 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
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) 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
YES
Is the relationship between the The machine is operating
display ed speed and the inv erter correctly
f requency correct?
NO
3
YES
Is the inv erter control v oltage correct? Replace the inv erter
NO
4
Is the inv erter control v oltage at the YES Check and/or replace
output of the inv erter interf ace board cable RN-5TQ between
correct? the inv erter interf ace
board and the inv erter
NO
Page 6.28
NO
NO YES
Is the inv erter control PWM signal at
Replace the CPU board Check and/or replace
the output of the CPU board correct? 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.
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
YES
Are 2 LEDs on the up-down A
board both OFF?
NO
2
NO
3
YES
4
NO
Does the free connector CN1 Check and/or replace
receive the correct control signal? cable RN-1
YES
5
YES NO
Replace the up-down Does the up-down board receive Check and/or replace
board the correct control signal? cable RN-2
Page 6.31
NO
Is fuse F1 of the up-down board
Replace the fuse
OK?
YES
6
NO Check and/or replace the
Does the up-down board receive cable connecting the
the mains electricity supply? up-down board to the
filter
YES
7
YES
Does the voltage at output by the
Replace the up-down
transformer-rectifier reach the
board
up-down board?
NO
8
YES
Is the voltage at the transformer Replace the rectifier
output correct? bridge
NO
Page 6.32
B NO
Lubricate the elevation
bars
9
NO
Is the up-down motor current Are the elevation bars lubricated?
correct?
YES
Replace the up-down
motor
10 YES
NO
Is the pulse signal at the
photocell output correct? Replace the photocell
YES
11
NO
Does the up-down board output
Replace the up-down board
the status signal?
YES
12
NO
Does the free connector CN1 Check and/or replace cable RN-2
receive the Status signal?
YES
13
NO
Does the status signal reach Check and/or replace cable RN-1
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 up-
down. 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 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 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
THE UP-DOWN
MOVES IN ONLY
ONE DIRECTION
YES
Are 2 LEDs on the up-down board
both illuminated?
NO
1
NO
Is the machine in one of the 2 travel
limit positions? A
YES
YES
Does the up-down board receive the
correct control signal in the inactive Replace the up-down
direction? board
NO
NO
Page 6.36
5
YES
Is the limit switch associated with the Check the position and/or
non-illuminated LED tripped? replace the limit switch
NO
6
NO
NO
NO
Does the CPU board send the YES
correct control signal in the inactive Check and/or replace
Replace the CPU board cable RN-1
direction?
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
THE DISPLAYED
ELEVATION IS INCORRECT
NO
Is the SW of the up-down board
matching the photocell model? Install the proper v ersion
YES
NO
Is the position of the limit switch Regolare la posizione dei
correct? microswitch
NO
Lubricate the elev ation
YES bars
NO
Is the up-down motor current correct? Are the elev ation bars lubricated?
YES
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:
(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 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.
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 lubrication can continue to operate for at least another 2-3 cycles.
If this message appears even though the oil level is above the minimum mark, the oil-low sensor is
probably damaged and it is necessary to replace the pump.
If a machine not provided with the automatic lubrication system shows this error, the
short between pins 9 and 11 of the patch connector CN4 can be opened.
Page 6.41
Check whether the relay of the YES Disconnect the distributor and
pump interface board is check whether the oil comes
working out from the pump
NO
3
YES
Check whether the pump
command signal at the free Replace cable RN-4
connector CN3 is correct
NO
4
YES
Check whether the pump
command signal at the output Replace cable RN-3
of the CPU board is correct
NO
Page 6.42
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
THE MACHINE
DOES NOT
PRINT
NO
Is the machine correctly configured Correctly configure the
for printing? machine
YES
2
NO
NO YES
Replace or rewire the printer Is the printer cable OK? Replace the CPU board
cable
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. .
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
THERE IS NO
CARDIO SIGNAL
1
YES
Is the supply voltage on the
receiver connector correct? Replace the receiver
NO
2
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
YES
YES
YES
1
Move the machine away
Are there sources of YES from the electromagnetic
electromagnetic noise near source or attenuate the
the receiver? power of the noise: see
paragraph 11.1.
NO
Page 6.47
NO
Is the transmitter in good Use a known good
working order? transmitter
YES
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.
Page 6.48
7. DISASSEMBLY OF COMPONENTS
Figure 7.1-1
4. Back off the 4 screws c using a 4-mm hex T
wrench.
Page 7.1
Figure 7.2-1
Figure 7.2-2
To reassemble each EPROM:
Page 7.2
Figure 7.3-1
4. Disconnect connector c.
5. Remove the BACKUP BATTERY d.
Figure 7.3-2
Page 7.3
Figure 7.4-1
Figure 7.4-2
5. Disconnect connectors e.
6. Unscrew the 6 studs f using a 7-mm wrench.
Figure 7.4-3
Continued on the following page →
Page 7.4
Page 7.5
Figure 7.5-1
Figure 7.5-2
Page 7.6
Page 7.7
Figure 7.6-2
Figure 7.6-3
Page 7.8
Figure 7.7-1
Figure 7.7-2
Page 7.9
Figure 7.8-1
Figure 7.8-2
The MOTOR GUARD can also be removed
completely, in order to work more freely inside
the machine:
Page 7.10
Figure 7.9-1
Figure 7.9-2
Page 7.11
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.
Page 7.13
Figure 7.12-1
Figure 7.12-2
Page 7.14
Page 7.15
Page 7.16
Page 7.17
Page 7.18
Page 7.19
Page 7.20
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 7.17-3
Continued on the following page →
Page 7.21
Page 7.22
Page 7.23
Page 7.24
Figure 7.19-3
Page 7.25
Figure 7.20-2
Page 7.26
Figure 7.21-2
After completing the procedure, adjust
the tension of the UP-DOWN MOTOR
BELT as indicated in paragraph 8.5. .
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
Figure 7.22-6
Page 7.30
Figure 7.23-1
Page 7.31
Page 7.32
Figure 7.25-2
Page 7.33
Figure 7.26-1
To remove the LOWER MICROSWITCH from
its support bracket:
Page 7.34
Page 7.35
Figure 7.28-2
Page 7.36
8. ADJUSTMENTS
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.
Page 8.1
Figure 8.2-1
Page 8.2
Page 8.3
Page 8.4
1. Repeat step 3.
2. Make the adjustment by shifting the
Figure 8.4-3 motor.
Page 8.5
Figure 8.5-2
Page 8.6
Page 8.7
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
Page 9.1
Page 9.2
P A S S WO R D = 0 0 0 0
T H E N E N T E R O R 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 Duration Frequency
Sec Km covered
Light 30 400
Medium 30 300
Heavy 15 100
If the machine is not equipped with the automatic lubrication system, the above
configuration parameters are ignored.
Page 9.3
To access this procedure, simultaneously press the 03 keys when the machine is in standby mode.
The following message will appear on the LED matrix display:
P A S S WO R D = 0 0 0 0
T H E N E N T E R O R C L E A R
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
The procedure can be aborted at any time by pressing the “Clear” key.
L U B R I C A T I O N :
X X X X X X
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
Page 9.4
N O . O F MA N U A L
L U B R I C A T I O N S = X X
N O . O F A U T OMA T I C
L U B R I C A T I O N S = X X
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 .
If the machine is not equipped with the automatic lubrication system, the values of the
lubrication parameters are not significant.
Page 9.5
To access this procedure, simultaneously press the 03 keys when the machine is in standby mode.
The following message appears on the LED matrix:
P A S S WO R D = 0 0 0 0
T H E N E N T E R O R C L E A R
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
The procedure can be aborted at any time by pressing the “Clear” key.
L U B R I C A T I O N T I M E .
K m . = X X X
L E N G T H O F L U B R I C A T .
S e c . = X X X
Page 9.6
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
N O . O F MA N U A L
L U B R I C A T I O N S = X X
N O . O F A U T OMA T I C
L U B R I C A T I O N S = X X
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 .
If the machine is not equipped with an automatic lubrication system, the lubrication
parameters are not significant.
Page 9.7
P A S S WO R D = 0 0 0 0
T H E N E N T E R O R 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.
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 confirm.
K m . C O V E R E D =
X X X X - > 0 0 0 0 0
“XXXX” indicates the value currently in memory, while “00000” 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 I O N T I M E .
K m . = X X X - > 0 0 0
Page 9.8
“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 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.
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. Press the “1” or “2” key until the desired main function appears.
2. Press the “FUNC” key once to display the value of the parameter.
3. To modify the value, press the “1” key to increase or the “2” key to decrease.
4. To exit and save the modified value, press the “STR” key; to exit without saving press the
“FUNC” key. After this, the display will revert to showing the selected main function.
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 of the extended
function parameters is cyclical, and after scrolling the type A parameters it goes on to type b and
so on.
4. Press the “FUNC” key once to display the value of the parameter.
5. To modify the value, press the “1” key to increase or the “2” key to decrease.
6. To exit and save the modified value, press the “STR” key; to exit without saving press the
“FUNC” key. After this the display reverts to showing the selected extended function.
7. To exit extended function menu, press the “FUNC” key until it shows A--, b--, C-- o H--.
Incorrect programming of the inverter may result in serious damage to the machine or
improper operation potentially hazardous for the user. Therefore, carry out this
operation only if certain of being able to perform the procedure correctly.
WARNING: when the programming has been completed, remember to set displayed the
value of the parameter d01 (motor frequency).
Page 9.10
Before modifying the value of function C0, modify the value of function C13.
Page 9.11
9.7.1. VERSION E2
Version E2 of the HITACHI J100 inverter can be programmed only by using the special external
keyboard DRW 100 EA to copy the correct version of the EPROM program supplied by the
manufacturer. To carry out this operation:
Incorrect programming of the inverter may result in serious damage to the machine or
improper operation potentially hazardous to the user. Therefore, carry out this
operation only if certain of being able to perform the procedure with the updated SW
version.
With the inverter powered up, the display shows the parameters for function F 1. To display the
parameters of another main function:
5. Press the FUNC key until the desired main function appears.
6. Press the 1 key once to display the value of the parameter.
7. To modify the value, press the 1 key to increase or the 2 key to decrease.
8. To save the modified value, press the FUNC key: the display reverts to showing the selected
main function.
Page 9.12
Incorrect programming of the inverter may result in serious damage to the machine or
improper operation potentially hazardous for the user. Therefore, carry out this
operation only if certain of being able to perform the procedure correctly.
The tables below show the values of the function parameters, and indicate which of those
parameters take on a different value from the inverter default.
MAIN FUNCTIONS
FUNCTION Value Default
F1 - ✓
F2 2.5
F4 F ✓
F5 __
F6 15
F7 5.0
F8 40
F9 03 ✓
F 10 72 ✓
F 11 220 ✓
F 14 0 ✓
Page 9.13
EXTENDED FUNCTIONS
FUNCTION Value Default FUNCTION Value Default
A0 2 A 37 220 ✓
A1 1.5 A 38 5 ✓
A2 4 ✓ A 39 100 ✓
A3 0.0 ✓ A 40 100 ✓
A4 1.5 ✓ A 41 1 ✓
A5 0 ✓ A 42 0
A6 0 ✓ A 43 0 ✓
A7 0 ✓ A 48 1
A8 0 ✓ A 49 2 ✓
A9 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 ✓ C0 09
A 30 150 ✓ C1 02 ✓
A 31 150 ✓ C2 07 ✓
A 32 0 ✓ C3 11 ✓
A 33 0 ✓ C4 00 ✓
A 34 0 ✓ C 10 00 ✓
A 35 0 ✓ C 20 01
A 36 0 ✓ C 21 03 ✓
Page 9.14
With the inverter powered up, the display shows the parameters for function C50 (work frequency).
To display the other parameters:
1. Press the “^” or “∨” keys to increase or decrease the number of the displayed parameter. To
increase the scrolling speed, also hold down 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 potentially hazardous for the user. Therefore, carry out this
operation only if certain of being able to perform the procedure correctly.
MAIN PARAMETERS
Parameter Value
C10 0
C11 110
C15 50
C16 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.
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.
Page 10.1
These operations can be carried out by the owner of the machine and do not require any
special skills.
The routine maintenance operations involve simple cleaning, lubrication and checking the state of
wear and emergency operation, in order to ensure the correct and safe operation of the machine. It is
recommended to perform these operations at least once a month.
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 10.2
Page 10.3
These operations can only be carried out by a qualified technician specifically trained by
Technogym and authorized to carry out machine installation and adjustments, as well as
special maintenance operations or repairs which require special knowledge of the
machine, its operation, safety systems and working procedures.
The special maintenance operations involve checking the operation, wear and tension of the
mechanical components so as to ensure perfect and safe operation of the machine. It is
recommended to carry out these operations at least once every 6 months.
• External conditions;
• Possible rusting of the connectors;
• Electrical continuity of the individual wires;
• Isolation of the individual wires toward ground.
Page 10.4
4. Check the state of wear of the motor roller. Replace if it shows evident signs of wear.
WARNING: this must be done with the machine opened and powered up.
Page 10.5
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 doesn’t alter the
previously measured heart rate.
Page 10.6
11. APPENDIX
• 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 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.
ASIC DISTANCE
(cm)
MAS 90
FTC 100
HRRE 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 DISTANCE
(Ohm) (cm)
15K 89
13K 88
11K 87
9K1 85
6K8 84
5K1 81
3K 74
2K 69
1K 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.
To eliminate or reduce the effects of vibration, house the receiver between the foam pads in such a
way that any vibrations are correctly damped.
WARNING: when securing the foam pads and the receiver with a strap, be careful not
to overtighten the strap as this may reduce the damping capacity of the foam pad.
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.
Figure 11.1-3
Page 11.5
To display the inverter error codes, follow the instructions below or refer to pages 8-2 of the inverter
manual:
Page 11.6
• error code;
• output frequency when the error occurred;
• motor current when the error occurred;
• motor voltage when the error occurred;
5. To view the last 2 logged errors in inverse chronological order, display the function “d09”and
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.
Page 11.7
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
To display the inverter error codes, follow the instructions below or refer to pages 8-14 of the
inverter manual:
Page 11.9
• 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.
WARNING: set the A57 parameter back to 0 in order to continue logging future errors.
Page 11.10
ERROR DESCRIPTION
OC1 Short Circuit - Overcurrent
OC2 Isolation fault
OC3 Overcurrent during acceleration
OC4 Overcurrent during deceleration
U15 Problem on ± 15 Volt power supply
OH Overtemperature
CCr Inverter CPU error
This function is available only if the inverter is equipped with the special keypad.
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
In fact, in order to keep the emissions within the limits set down by the regulations for light
industry, this inverter version has a capacitive filter to ground on the supply conductors, which
increases the current in the earth conductor up to 1200 µA.
The leakage currents for the individual machine components are detailed in the table below:
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 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 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 µA.
• 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 µA,
bringing it within the 500 µA 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
Page 11.15
Page 11.16
0SMM0021-ING