Operation Manual

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SERVICE & MAINTENANCE MANUAL

REV. 2.0

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Summary of content (184 pages)

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SERVICE & MAINTENANCE MANUAL REV. 2.0 Downloaded from www.Manualslib.
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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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 Contents 1. GENERAL NOTICES............................................................................................................................................1.1 1.1. 1.2. 1.3. INTRODUCTION............................................................................................................................................ 1.1 RECOMMENDATIONS .....................................................................................................
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RUNRACE : Service & Maintenance Manual - rev. 2.0 4.4.1. 4.4.2. RS-232 Port..................................................................................................................................4.4 RS-485 Ports ................................................................................................................................4.4 5. INSTALLATION INSTRUCTIONS ....................................................................................................................5.1 5.1.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.23. 7.24. 7.25. 7.26. 7.27. 7.28. DISASSEMBLING THE UP-DOWN MOTOR BRUSHES ...................................................................................... 7.31 DISASSEMBLING THE ELEVATION BARS ..................................................................................................... 7.32 DISASSEMBLING THE LEAD SCREW NUTS ................................................................................................... 7.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 10.3. 10.2.1. Internal cleaning operations ......................................................................................................10.2 10.2.2. Lubricating the tread belt...........................................................................................................10.2 10.2.3. Lubricating the elevation bars ...................................................................................................10.2 10.2.4.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 1.3. GENERAL RULES FOR REPAIR PROCEDURES 1. Always mark any parts or positions which may be confused with each other at the time of reassembly. 2. Use original Technogym spare parts and lubricants of the recommended brands. 3. Use special tools where specified. 4. Consult the technical circulars, which may contain more up-to-date information on adjustments and maintenance than those contained in this manual. 5.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 2. TECHNICAL CHARACTERISTICS 2.1. MECHANICAL CHARACTERISTICS Width Length Height Weight 90 cm 224 cm 140 cm 270 Kg 2.2. ELECTRICAL CHARACTERISTICS Mains voltage Frequency Consumption Fuse 230 VAC 50 - 60 Hz ~ 2500 Watt - 11 A 5x20 4 A slow-blow 2.3. AMBIENT SPECIFICATIONS Temperature Humidity 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 2.4.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 2.5. WIRING DIAGRAMS Over time, the machine has undergone modifications for component upgrades and improvements. In certain cases, these modification have entailed changes to the wiring diagram. In the interests of simplicity, the following paragraphs give the diagrams for the most important versions. 2.5.1. 220 MODEL CONFORM TO IEC 601 Valid from SN. 03000131. Page 2.2 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 RN-13Q: Emergency button cable CPU – Emergency button – Patch cable Emergency button 1-3 2 4 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 RN-5TQ: Inverter cable Inverter interface board – Inverter – Motor thermal cutout Inverter interf. Board CN1 1 1 2 3 4 5 6 Signal Color Inverter Reference Thermal cutout ref.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 2.5.2. 220 MODEL WITH SJ100 INVERTER Valid from SN. 0200531. Page 2.8 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 RNIMQ-13S: Emergency button cable CPU – Emergency button CPU board CN2 2 3 Signal Color Reference NC contact Brown Blue Emergency button 1 2 RN-5TQ: Inverter cable Inverter interface board – Inverter – Motor thermal cutout Inverter interf.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 2.5.3. 220 MODEL Valid from SN. 5866. The differences between the 220 model and the 220 model with SJ100 inverter are: • • Inverter cable change from RN-5TQ to RN-5T; Low voltage power supply cable change from RX-8Q to RN-8; Page 2.14 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 RN-5T: Inverter cable Inverter interface board – Inverter – Motor thermal cutout Inverter interf.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 2.5.4. 220 MODEL WITH HITACHI E2 INVERTER Valid from SN 2043. Page 2.16 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 2.5.5. 220 MODEL WITH LENZE INVERTER Valid to SN 2042. Page 2.17 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 Page intentionally left blank Page 2.18 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 3. PRINCIPLES OF OPERATION 3.1. BLOCK DIAGRAM The machine block diagram is shown in the figure below: 3.1.1. CARDIO TRANSMITTER It is worn by the person using the machine, and transmits to the cardio receiver one pulse for every heart beat that is detected. Page 3.1 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 3.1.2. CARDIO RECEIVER It is connected to the machine’s CPU board and receives the pulses sent by the transmitter. Its reception area is approximately a circle of 1 meter of radius. If there is electromagnetic noise (produced by high voltage lines, radio transmitters, monitors, motors, etc.) within its reception area, the receiver becomes saturated and stops receiving any signal.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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. 3.1.5.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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: • • Old photocell model: chip version M3S10; New photocell model: chip version RR52V2.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 3.2. TREAD-BELT MOTOR DRIVE 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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 The speed control utilizes the following signals: • Start signal This is the signal generated by the CPU board (pin 8-3 of connector CN1) to enable starting of the motor.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 • Variable frequency VAC signal This is the variable frequency alternating voltage generated by the inverter (pin U-V-W) for supplying the motor. The motor speed increases with increasing frequency. • Thermal cutout signal Each motor phase is equipped with a normally-closed thermal cutout which opens when the temperature exceeds a preset threshold.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 3.3. UP-DOWN MOTOR DRIVE 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 The elevation control utilizes the following signals: • 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 • Limit switch signal This is the signal from the 2 limit switches which determine the machine’s range of up-down motion. The lower microswitch is a NC contact input to the up-down board (pin 4-6 of connector CN3). When this contact opens the circuit board inhibits movement in the down direction. The upper microswitch is a NO contact input to the up-down board (pin 3-6 of connector CN3).
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RUNRACE : Service & Maintenance Manual - rev. 2.0 3.4. AUTOMATIC LUBRICATION SYSTEM Up until serial number 3905, the machine was equipped with an oil reservoir and pump for the automatic lubrication of the tread belt. Starting from serial number 3906, these components have been eliminated, and the automatic tread belt lubrication function is no longer available. However, for reasons of compatibility, the machine configuration SW procedure still retains the parts pertaining to the lubrication system.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 3.4.3.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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 • +12 Vdc signal This is the DC voltage output by the CPU (pin 10-9 of connector CN2) which enters the pump interface board (pin 2-1 of connector K1). This voltage reaches one terminal of the relay which drives the pump.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 thermal cutouts of the tread belt motor and sends it to the LENZE inverter interface board. Page 3.14 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 4.2. CONNECTING TO THE PRINTER The machine provides a printing facility through the RS 232 port on the serial port panel. If the machine is equipped with SW for the Technogym System, the print function is not available.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 4.3. CONNECTING TO AN EXTERNAL DEVICE (ECG AND/OR METABOLIC MONITOR) The medical version of the machine (HC1400) can be connected to an external device (ECG and/or metabolic monitor) for carrying out exertion tests. The connection is made through the machine’s RS-232 serial port.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 4.4. PIN OUT SERIAL PORTS 4.4.1. RS-232 PORT This is a 25 pin female connector. It can be used to connect the printer or an external device. Its pin out is: PIN 1 2 3 4 5 6 7 SIGNAL Shield Tx Rx RTS CTS DSR GND 4.4.2. RS-485 PORTS These connectors are actually not used; however on report the pin out in the next table: PIN 1 3 5 7 Page 4.4 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 5.3. FIRST POWER-ON After completing the installation procedure, the machine is ready to be powered up. To turn on the machine, simply toggle the on/off switch from the 0 position to the 1 position. When the machine is turned on it will perform a power-on test which: • • • sounds the buzzer; lights all the LEDs; resets the elevation. After completing this power-on test the machine enters standby mode, awaiting a keyboard command.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.1. THE DISPLAY DOES NOT ILLUMINATE This error occurs when the supply voltage fails to reach the display. THE DISPLAY DOES NOT ILLUMINATE NO Is the fuse OK? Replace the blown fuse YES NO Is mains lead OK? Replace the mains lead YES NO Does the wall output supply the correct voltage? Connect machine to a suitable electrical output YES 1 Is the mains voltage present at the power supply input? YES A Continued on the following page. Page 6.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.2. THE LCD SHOWS “EMERGENCY PRESSED: EXERCISE INTERRUPTED” The machine displays this message if: • • The emergency button is pressed during a training session. The emergency button is damaged.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.3. THE INVERTER IS OFF This condition is related to emergency button or relay. THE INVERTER IS OFF 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 NO Is the v oltage at the emergency button correct? Replace RN-13Q cable YES 3 Replace emergency button NO Is the v oltage at the CN9 patch connector correct? YES A Continued on the following page.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 (4) As for point (1) but on pin 1 and 2 of the patch connector CN5. (5) As for point (1) but on pin 0 and 1 of the relay. (6) Place the tester probes between pins 6 and 8 of the relay. The measured voltage should be 0 Ohm. (7) Place the tester probes between pins L1 and N of the inverter. The measured voltage should be 220 VAC. Page 6.9 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4. THE LCD SHOWS “BELT MOTOR HALTED” WARNING: Old SW version shows “DAMAGE ON THE BELT MOTOR SYSTEM” instead of this message. The machine displays this message if: • • 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 HITACHI INVERTER BELT MOTOR HALTED NO The inv erter is on? Execute the procedure "The inv erter is of f " 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 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.1. THE INVERTER DISPLAY SHOWS E01, E02, E03, E04 OR E05 These inverter error messages are related to output short-circuit problems.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.2. THE INVERTER DISPLAY SHOWS E6 OR E7 These inverter error messages are related to problems with the inverter braking group or the braking resistor.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.3. THE INVERTER DISPLAY SHOWS E8, E10 OR E11 These inverter error messages are related to HW and SW problems with the inverter. E08 E10 E11 1 Does the error occur f requently ? YES Replace the inv erter NO Does the machine resume correct operation af ter being turned of f f or 1 minute? YES Probable interf erence.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.4. THE INVERTER DISPLAY SHOWS E09 This inverter error message is related to low line voltage problems on the inverter power supply. E09 YES Does the machine resume correct operation af ter being turned of f f or 1 minute? Probable low line v oltage.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 (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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.5. THE INVERTER DISPLAY SHOWS E12 This inverter error message is related to the opening of the motor thermal cutouts. E12 YES Does the machine resume correct operation af ter being turned of f f or 1 hour? Probable ov erheating of the motor.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.6. THE INVERTER DISPLAY SHOWS E14 This inverter error message is related to poor isolation between the motor phases and ground. E14 1 NO Are the motor phases isolated from ground at the inverter output? Replace the inverter YES 2 NO Are the motor phases isolated from ground? Replace the belt motor YES Check and reinstate cable RN-14 Follow the procedure step by step to correctly diagnose the problem.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.7. THE INVERTER DISPLAY SHOWS E15 This inverter error message is caused by high voltage problems on the inverter power supply line. E15 YES Does the machine resume correct operation af ter being switched of f f or 1 minute? Probable high line v oltage.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 (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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.8. THE INVERTER DISPLAY SHOWS E21 This inverter error message is associated with problems of high inverter temperature. E21 NO Replace the inv erter Page 6.22 Downloaded from www.Manualslib.com manuals search engine Does the machine resume correct operation af ter being switched of f f or 1 hour? YES Probable ov erheating of the inv erter. The machine is OK.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.9. THE INVERTER DISPLAY DOES NOT SHOW ANY ERROR This is an anomalous error condition in which the machine display reports an error but the inverter has not generated an error.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.5. THE BELT MOTOR IS JERKING The probable cause of this error is a disconnected phase on the motor or inverter output.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.6. THE BELT MOTOR STARTS WITH DELAY The problem is caused by the inverter failing to receive the enable signal (Start) or the speed signal.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.7. THE DISPLAYED SPEED IS INCORRECT The machine displays this error if: • • the calibration is incorrect; there are HW problems with the CPU board - inverter interface – inverter and motor group.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 A 5 YES Is the inv erter control PWM signal at the input of the inv erter interf ace board correct? Replace the inv erter interf ace board NO 6 NO Replace the CPU board Is the inv erter control PWM signal at the output of the CPU board correct? YES Check and/or replace cables RN-1 and/or RN-2 Follow the procedure step by step to correctly diagnose the problem.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 (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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.8. THE LCD SHOWS “GRADE MOVEMENT OUT OF ORDER” The machine displays this error if it is unable to control the up-down motor.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 A NO Is fuse F1 of the up-down board OK? Replace the fuse YES 6 NO Does the up-down board receive the mains electricity supply? Check and/or replace the cable connecting the up-down board to the filter YES 7 YES Does the voltage at output by the transformer-rectifier reach the up-down board? Replace the up-down board NO 8 YES Is the voltage at the transformer output correct? NO Replace the transformer Continued on the following page. Page 6.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 (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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.9. THE UP-DOWN MOVES IN ONLY ONE DIRECTION The machine displays this error if a microswitch is broken or if it is unable to move the up-down motor.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.10. THE DISPLAYED ELEVATION IS INCORRECT The machine displays this error if there is a mismatch between the photocell model and the SW of the up-down board or there is a bad photocell reading due to incorrect calibration, breakage or disturbances produced by the motor brushes as a result of excessively high currents.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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 the following table: Photocell Siemens SFH910 Optek OPB610 (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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.11. THE LCD SHOWS “WARNING: CHECK BATTERY” The machine displays this error message on power up whenever it finds inconsistent data in the battery-backed memory. In consequence: • • 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 cause of the problem may be: • • Defective battery that fails to charge to 3.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.13. THE LUBRICATION CIRCUIT DOES NOT WORK The machine displays this error if the lubrication system is not working or if the CPU board fails to provide the necessary control signal.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.14. THE MACHINE DOES NOT PRINT The machine displays this error if there are HW errors or if the machine is incorrectly configured. It is in any case recommended to also check whether the printer itself is working correctly.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.15. THERE IS NO HEART RATE SIGNAL The machine displays this error if the receiver is not working or if it is not supplied by the CPU board. THERE IS NO CARDIO SIGNAL 1 YES Is the supply voltage on the receiver connector correct? Replace the receiver NO 2 Is the supply voltage on connector K7 of the CPU board correct.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 6.16. THE HEART RATE SIGNAL IS INCORRECT The machine displays this error if the receiver is disturbed by electromagnetic noise. In some case the machine may show “Err” on the heart rate display. THE HEART RATE SIGNAL IS INCORRECT NO Is the minimum distance between machines OK? Move the machines to the minimum distance: see paragraph 5.1.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 A 2 Is the transmitter in good working order? NO Use a known good transmitter YES Is the transmitter always within a distance of 80 cm from the receiver? NO Keep the transmitter within the minimum reception distance YES Change the receiver Follow the procedure step by step to correctly diagnose the problem.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7. DISASSEMBLY OF COMPONENTS 7.1. DISASSEMBLING THE DISPLAY 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Back off the 2 screws a. 3. Remove guard b. 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.2. DISASSEMBLING THE EPROM 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Back off the 4 screws a using a small Philips screwdriver. 3. Remove guard plate b. Figure 7.2-1 4. Remove the EPROMs c from their socket using an integrated circuit extractor tool Figure 7.2-2 To reassemble each EPROM: 1. Place EPROM A on the upper socket and EPROM B on the lower socket. 2.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.3. DISASSEMBLING THE BACKUP BATTERY 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Back off the 4 screws a using a small Philips screwdriver. 3. Remove guard plate b. Figure 7.3-1 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.4. DISASSEMBLING THE CPU BOARD Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display placed on a work bench: 1. Remove EPROMs guard plate. 2. Back off the 13 screws a, using a small Philips screwdriver. 3. Disconnect the cardio receiver cable from connector b. Figure 7.4-1 4.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7. Separate the CPU board g from the LED board h, turning it over toward the left and being careful with strip i. 8. Using your hands, disconnect strip i from the CPU board side. 9. Remove the circuit boards. Figure 7.4-4 10. To disconnect the LCD from the CPU board, back off the 4 screws l using a small Philips screwdriver or release the 4 spring fasteners. 11. Disconnect or unsolder the cables on the CPU board side. 12. Remove the LCD.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.5. DISASSEMBLING THE KEYBOARD Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display placed on a work bench: 1. Remove EPROMs guard plate. 2. Back off the 13 screws a, using a small Philips screwdriver. 3. Disconnect the cardio receiver cable from connector b. Figure 7.5-1 4.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 To reassemble the new KEYBOARD, with the display placed on a work bench: 1. Remove the backing film from the adhesive side. 2. Apply the adhesive part, starting from the left and working toward the right, being careful not to bend the KEYBOARD. 3. Plug the connector into the CPU board. 4. Remove the protective film. 5. Reassemble the display. When reassembling the KEYBOARD, make sure that none of the keys are bent or remain pushed in.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.6. DISASSEMBLING THE CARDIO RECEIVER 1. Raise the machine to its maximum incline. 2. Turn off the machine and unplug the mains lead from the wall outlet. If the receiver is situated under the display: Figure 7.6-1 3. Detach the sticker. 4. Back off the 2 screws a using a 3-mm hex T wrench. 5. Open the housing b which contains the RECEIVER. If the receiver is situated inside the display: 6.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.7. DISASSEMBLING THE EMERGENCY STOP BUTTON Carry out the procedure described in paragraph 7.1. “Disassembling the display” up until the disconnection of the cables and the disassembly of the right hand side panel which accommodates the EMERGENCY STOP BUTTON. With the side panel on a work bench: 1. Back off the 2 screws a using a 4-mm hex T wrench. 2. With the help of a flat blade screwdriver, open the cover of the side panel from the outer housing.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.8. DISASSEMBLING THE MOTOR GUARD 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Back off the 6 screws a using a large Philips screwdriver. 3. Raise the MOTOR GUARD b. Figure 7.8-1 To retain the MOTOR GUARD in the raised position, use the elastic strap provided inside the guard itself, as shown in figure at left. To reassemble the MOTOR GUARD, carry out the above steps in reverse order. Figure 7.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.9. DISASSEMBLING THE SIDE GUARDS 1. Turn off the machine and unplug the mains lead from the wall outlet. For each SIDE GUARD: 2. Back off the 4 screws a using a large Philips screwdriver. 3. Remove the SIDE GUARD. Figure 7.9-1 4. Pull out cable clamp b and, pulling on cable c, expose the free connectors d CN1-CN2 on the right hand side of the machine, or CN3CN4 and CN5-CN6 on the left hand side of the machine.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.10. DISASSEMBLING THE FRONT PLATE Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard”. 1. Back off the 4 screws a using a 6-mm hex T wrench. 2. Remove the 2 side plugs b. 3. Back off the 4 self-tapping screws c using a large Philips screwdriver. 4. Rotate the FRONT PLATE d downward. Figure 7.10-1 The front plate remains attached to the frame by means of two steel cables.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.11. DISASSEMBLING SHIELD GRID FOR TREAD BELT MOTOR AND INVERTER Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard”. 1. Remove the dust guard a. Figure 7.11-1 2. Back off the screw b using a medium Phillips screwdriver, in the rear part of the shield grid. 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.12. DISASSEMBLING THE REAR ROLLER 1. Lower the machine to its minimum incline position. 2. Turn off the machine and unplug the mains lead from the wall outlet. 3. Back off the 4 screws a using a 6-mm hex T wrench. 4. Remove the rear plugs b on the right and left hand sides. Figure 7.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7. Push the REAR ROLLER forward against the running track. With the rear screw removed, there will be enough space to move REAR ROLLER forward until it comes out of its guide and drops onto the belt. 8. Pull out the REAR ROLLER. To reassemble the REAR ROLLER, carry out the above steps in reverse order. Figure 7.12-4 After completing the procedure, center the belt and adjust its tension as instructed in 8.2. and 8.3. . Page 7.15 Downloaded from www.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.13. DISASSEMBLING THE MOTOR ROLLER 1. Raise the machine to its maximum incline position. 2. Turn off the machine and unplug the mains lead from the wall outlet. To facilitate the subsequent adjustment of the belt tension, after shifting the join to the underside of the machine, measure out a distance of 1 m on the belt and mark its ends with a white marker pen. Figure 7.13-1 3. Carry out the procedure described in the paragraph 7.8.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.14. DISASSEMBLING THE BRUSH 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Overturn the machine on its right side. If the automatic lubrication system is installed, ensure that the oil reservoir cap is securely closed. 3. Slightly shifting the belt, on either end of the BRUSH, back off the 2 knobs a fixing it to the frame. 4. Pull out the BRUSH from the side. Figure 7.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.15. DISASSEMBLING THE TREAD BELT AND RUNNING TRACK Carry out the procedure described in the paragraphs 7.8. “Disassembling the motor guard”, 7.12. “Disassembling the rear roller”, 7.13. “Disassembling the motor roller” and 7.14. “Disassembling the brush”. 1. Overturn the machine on its right side. If the automatic lubrication system is installed, ensure that the oil reservoir cap is securely closed. Figure 7.15-1 2.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 The upper table of the RUNNING TRACK can be inverted by turning it over. To reassemble the TREAD BELT and the RUNNING TRACK, carry out the above steps in reverse order. When reassembling the TREAD BELT, ensure that: • • • the TREAD BELT is oriented as indicated by the arrow on the inner side; the TREAD BELT is correctly centered on the RUNNING TRACK; the TREAD BELT is not pinched in the RUNNING TRACK. Lubricate the RUNNING before reassembling.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.16. DISASSEMBLING THE SHOCK ABSORBERS Carry out the procedure described in paragraph 7.15. “Disassembling the tread belt and running track”. For the new model: 1. On each side of the machine, back off the 2 nuts a using a 13-mm wrench. 2. Pull out the SHOCK ABSORBERS from the top. Figure 7.16-1 Page 7.20 Downloaded from www.Manualslib.com manuals search engine To reassemble the SHOCK ABSORBERS, carry out the above steps in reverse order.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.17. DISASSEMBLING THE TREAD-BELT MOTOR Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard” and 7.11. “Disassembling shield grid for tread belt motor and inverter”. 1. Raise the machine to its maximum incline position. 2. Remove the dust guard a. 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 9. Back off the 4 nuts i (2 are concealed by the motor itself in the figure at left) fixing the tread-belt motor to the machine frame, using a 17-mm wrench and holding the screw underneath in place with a 17-mm wrench. 10. Pull out the TREAD-BELT MOTOR, pushing it first inward and then upward to remove the motor drive-belt. To reassemble the TREAD-BELT MOTOR, carry out the above steps in reverse order.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.18. DISASSEMBLING THE MOTOR DRIVE-BELT Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.13. “Disassembling the motor roller”. 1. Back off the 4 nuts a (2 are concealed by the motor itself in the figure at left) fixing the tread-belt motor to the machine frame, using a 17-mm wrench and holding the screw underneath in place with a 17-mm wrench. 2.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.19. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”. To disassemble the INVERTER INTERFACE BOARD and the POWER SUPPLY: 1. Back off the 4 plastic hexagonal-head screws a which fix the protective grille, using a 7mm wrench. 2. Remove the protective grille. To disassemble each of the 2 circuit boards: Figure 7.19-1 3.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 To disassemble the SERIAL PORTS CIRCUIT BOARD: 1. Back off the 4 hexagonal-head screws c using a 7-mm wrench. 2. Remove the SERIAL PORTS CIRCUIT BOARD. To reassemble the ELECTRONIC CIRCUIT BOARDS, carry out the above steps in reverse order. After replacing the inverter interface board, calibrate the speed as described in paragraph 8.7. . Figure 7.19-3 Page 7.25 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.20. DISASSEMBLING THE INVERTER Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard” and 7.11. “Disassembling shield grid for tread belt motor and inverter”. 1. Remove the cover from the INVERTER, using a small Philips screwdriver to back off the fixing screw, if present. 2.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.21. DISASSEMBLING THE UP-DOWN MOTOR BELT 1. Raise the machine to its maximum incline position. 2. Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”. 3. Overturn the machine on its right side. If the automatic lubrication system is installed, ensure that the oil reservoir cap is securely closed. Figure 7.21-1 4.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.22. DISASSEMBLING THE UP-DOWN MOTOR Carry out the procedure described in paragraph 7.21. “Disassembling the up-down motor belt” up until the slackening of the belt (step 7). 1. Disconnect the motor supply cable a. 2. Disconnect the photocell cable b. 3. Using a 10-mm wrench, back off the 2 cover fixing screws c on the protective housing of the encoder wheel. 4. Open the cover d. Figure 7.22-1 5. Using a 10-mm wrench, back off screw e. 6.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7. Remove the spacer g. Figure 7.22-3 8. Using a rubber hammer and, if necessary, a pointed tool, knock on the motor shaft and remove it from the lower part of the machine. Figure 7.22-4 Continued on the following page → Page 7.29 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 9. Recover the tab h. Figure 7.22-5 10. Disassemble the protective housing of the encoder wheel, using the tool appropriate for the motor model in question: • “BONFIGLIOLI” motor: 10-mm wrench; • “SITI” motor: 8-mm wrench. 11. Back off the 4 fixing screws of the UPDOWN MOTOR using a 4-mm hex T wrench and holding the nut in place with a 10-mm wrench. 12. Remove the UP-DOWN MOTOR. To reassemble the UP-DOWN MOTOR, carry out the above steps in reverse order.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.23. DISASSEMBLING THE UP-DOWN MOTOR BRUSHES This operation cannot be carried out on all the motor models. Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”. 1. Manually, or using a small flat blade screwdriver, unscrew the motor brush cap a. 2. Pull out the BRUSHES b. To reassemble the BRUSHES, carry out the above steps in reverse order. Figure 7.23-1 Page 7.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.24. DISASSEMBLING THE ELEVATION BARS 1. Raise the machine to its maximum incline position. 2. Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”. 3. Overturn the machine on its right side. If the automatic lubrication system is installed, ensure that the oil reservoir cap is securely closed. Figure 7.24-1 4. Back off the two wheel fixing screws a using two 6-mm T wrenches. 5.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.25. DISASSEMBLING THE LEAD SCREW NUTS 1. Raise the machine to its maximum incline position. 2. Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”. 3. Overturn the machine on its right hand side. If the automatic lubrication system is installed, ensure that the oil reservoir cap is securely closed. Figure 7.25-1 4.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.26. DISASSEMBLING THE MICROSWITCHES Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”. 1. Disconnect the cables a. 2. Back off the 2 fixing screws b of the MICROSWITCH support bracket, using a 3mm hex T wrench. 3. Remove the MICROSWITCHES. Figure 7.26-1 To remove the LOWER MICROSWITCH from its support bracket: 4.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.27. DISASSEMBLING THE PHOTOCELL Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”. 1. Disconnect connector a on the PHOTOCELL board. 2. Using a 10-mm wrench, back off the 2 cover fixing screws b on the protective housing of the encoder wheel. 3. Open the cover c. 4. Back off the 2 screws d fixing the PHOTOCELL board to the support, using a small Philips screwdriver. 5.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 7.28. DISASSEMBLING THE FANS Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.11. “Disassembling shield grid for tread belt motor and inverter”. To disassemble the right fan, downflow fan: 1. Back off the 4 screws a using a medium Phillips screwdriver, holding the nut in place with a 7-mm wrench. Figure 7.28-1 To disassemble the left fan, air entry fan, it is necessary to disassemble the conveyor b: 2.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 8. ADJUSTMENTS 8.1. TENSIONING A NEW TREAD BELT 1. After assembling the new tread belt, turn it until the join is underneath and tighten the tread belt until it is just slightly taut. 2. Place a tape measure along the right hand edge of the tread belt, and use a pen make two reference marks on the tread belt at a distance of exactly 1 meter from each other. Figure 8.1-1 3.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 8.2. TENSIONING A USED TREAD BELT 1. After completing reassembly of the used tread belt, lock down the rear right hand screw a until measurement L in Figure 8.2-2 corresponds to the value shown on the red decal b on the inside of the rear right hand cap. 2. Lock down the left hand tread belt tensioning screw until the drive roller is aligned with the crosspiece. Figure 8.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 8.3. CENTERING THE TREAD BELT 1. Start the machine at a speed of 10 km/h (6 mph). 2. Observe the movement of the tread belt, correcting any tendency to shift to the right or left exclusively by adjusting the left tensioning screw a. Locking down this screw favors shifting of the belt to the right and vice versa. Figure 8.3-1 3.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 8.4. ADJUSTING THE TENSION AND ALIGNMENT OF THE TREAD-BELT MOTOR BELT Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”. 1. Remove the dust guard. 2. Back off the 4 nuts a (2 are concealed by the motor in the figure at left) fixing the belt motor to the machine frame, using a 13-mm screw and holding the screw underneath in place with a 6-mm Allen T-wrench. Figure 8.4-1 3.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 To adjust the alignment, use a straight-line reference rod d, rested against the driving roller pulley, and make sure that: • The pulley and flywheel are parallel. 1. Repeat steps 3 and 4. 2. Make the adjustment by turning the 2 inner adjuster nuts c using a 13-mm wrench. • Figure 8.4-3 The pulley and flywheel are aligned. 1. Repeat step 3. 2. Make the adjustment by shifting the motor. Page 8.5 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 8.5. TENSIONING THE UP-DOWN MOTOR BELT Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”. 1. Place the machine on its maximum elevation position. 2. Remove the belt guard. The up-down motor belt tension is correct when it has a play of approximately 1.5 cm at the point A indicated by the arrow. Figure 8.5-1 3.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 8.6. ALIGNING THE ELEVATION BARS 1. With the machine turned over on one side, turn one of the elevation bars until the wheel shaft holes on both bars are aligned. 2. Use a gauge to make sure that both elevation bars project by the same distance A from the lead screw nuts. If this is not the case, turn one of the bars by half a turn at a time and repeat the measurement until perfect alignment is obtained. 3. Reassemble the wheel shaft.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 8.7. CALIBRATING THE TREAD BELT SPEED Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard”. The operations described below must be carried out with the machine powered up; they should be performed exclusively by a QUALIFIED TECHNICIAN who must ensure that there are no unauthorized persons near the machine. 1. Plug the mains lead into the wall outlet. 2. Turn on the machine. Figure 8.7-1 Page 8.8 Downloaded from www.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 8.8. CENTERING THE PHOTOCELL Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” e 7.10. “Disassembling the front plate”. 1. Using a 10-mm wrench, unscrew the 2 fixing screws of the cover of the protective housing of the encoder wheel. 2. Open the cover. For the “BONFIGLIOLI” motor: Figure 8.8-1 3.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 8.9. ADJUSTING THE LCD BACKLIGHTING After the machine has been switched on for at least 1 hour, without switching it off: 1. Adjust trimmer P1 on the back of the display to obtain the desired level of LCD luminosity. This adjustment must be made when the LCD is warmed up: the machine must have been switched on for at least 1 hour. Figure 8.9-1 Page 8.10 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 8.10. ADJUSTING THE BUZZER TONE Turn on the machine and, when the buzzer is sounded during the start-up procedure: 1. Adjust trimmer P2 on the back of the display to obtain the desired buzzer tone. Figure 8.10-1 Page 8.11 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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: 9.1.1. ENABLE USE OF EXTERNAL DEVICE Using dip-switch No.1 of the right hand bank at the rear of the CPU board, select the type of external connection: Right hand bank Dip-switch 1 Connection ON Printer None (HC1200) OFF External device (HC1400) 9.1.2.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 • Dip-switch No. 2: unit of measurement for speed: Left hand bank Dip-switch 2 Unit of measurement ON mph OFF Km/h • Dip-switches No. 3 and 4: type of protocol used: Left hand bank Dip-switch Protocol 3 4 OFF OFF Marquette OFF ON TrackMaster ON ON NA ON OFF NA Page 9.2 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 9.2. CONFIGURATION OF SW PARAMETERS The only configurable parameters are those for the machine lubrication. To change these values, simultaneously press the when the 01 keys when the machine is in standby mode. The following message will appear on the LCD: 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 9.3. PARTIAL DISPLAY OF WORKING PARAMETERS In order to check the state of wear of the machine and correctly carry out routine machine maintenance, a special procedure is provided for viewing the values of the working parameters. This is a “partial” procedure in that the lubrication parameters shown are only those pertaining to the type. To access this procedure, simultaneously press the 03 keys when the machine is in standby mode.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 9.3.4. NUMBER OF MANUAL LUBRICATION CYCLES The total number of manual lubrication cycles carried out. The following message appears on the LCD: N O . O F MA N U A L L U B R I C A T I O N S = X X After 10 seconds, it automatically goes on to the next view. 9.3.5. NUMBER OF AUTOMATIC LUBRICATION CYCLES The total number of automatic lubrication cycles carried out. The following message appears on the LCD: N O .
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RUNRACE : Service & Maintenance Manual - rev. 2.0 9.4. COMPLETE DISPLAY OF WORKING PARAMETERS In order to check the state of wear of the machine and correctly carry out routine maintenance, a special procedure is provided for viewing the working parameters. This is a “complete” procedure in that the lubrication parameters shown are those pertaining to the duration and frequency. To access this procedure, simultaneously press the 03 keys when the machine is in standby mode.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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. 9.4.5. NUMBER OF MANUAL LUBRICATION CYCLES The total number of manual lubrication cycles carried out. The following message appears on the display: N O . O F MA N U A L L U B R I C A T I O N S = X X After 10 seconds, it automatically goes on to the next view. 9.4.6.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 9.5. MODIFYING THE WORKING PARAMETERS The procedure for setting the values of the machine’s working parameters (for example, after having replaced the CPU board) is accessed by simultaneously pressing the 01 keys when the machine is in standby mode. The following message appears on the LCD: 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 “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. 9.5.4. LUBRICATION DURATION This option is used for configuring the duration of an automatic lubrication cycle. The following message appears on the LCD: L E N G T H O F S e c . = X X X L U B R I C A T .
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RUNRACE : Service & Maintenance Manual - rev. 2.0 9.6. PROGRAMMING THE HITACHI SJ100 INVERTER The inverter can be programmed using the special keypad installed on board the machine. It is necessary to correctly configure the values of the main functions labeled with an F, and those of the extended functions labeled with A, b, C and H.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 9.6.1.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 9.7. PROGRAMMING THE HITACHI J100 INVERTER 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: 1. Turn off the machine. 2. Disassemble the inverter keyboard, by unscrewing the fixing screw with a medium Phillips screwdriver. 3. Connect the external keyboard DRW 100 EA. 4.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 To display the parameters of the extended functions: 8. Press the FUNC key until function F 14 appears. 9. Press the 1 key to display the code of the extended function: for example the display will show 0 to indicate A 0. When the value . 0 appears it means that the type C extended functions are available. 10. Press the FUNC key to access the extended function: the display will show A 0. 11.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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 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 Page 9.14 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 9.8. PROGRAMMING THE LENZE 644 INVERTER The LENZE inverter can be programmed only by using the keypad eventually installed on-board the machine. 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 10. SCHEDULED MAINTENANCE To keep the machine in perfect working order and prevent the risk of malfunction, it is necessary to perform the scheduled maintenance operations set out in the table below. There are 3 basic types of maintenance operations: • • • External cleaning operations; Routine maintenance operations; Special maintenance operations.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 10.2. ROUTINE MAINTENANCE OPERATIONS 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 10.2.5. CHECKING AND CENTERING THE TREAD BELT 1. With the machine stopped, check the tension of the entire surface of the tread belt, turning it by hand. If any anomalies are found, call in the authorized Technogym Technical Service or adjust the tension. 2. With the machine moving at a speed of approximately 10 km/h (7 mph), check the centering of the tread belt.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 10.3. SPECIAL MAINTENANCE OPERATIONS 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 4. Check the state of wear of the motor roller. Replace if it shows evident signs of wear. 10.3.6. CHECKING THE WEAR OF THE REAR ROLLER 1. Turn off the machine by placing the switch in the 0 position (OFF). 2. Unplug the mains lead from the wall outlet. 3. Check the state of wear of the rear roller. Replace if it shows evident signs of wear. 10.3.7. CHECKING THE WEAR OF THE RUBBER HANDLEBAR COVERS 1.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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. 10.3.13. CHECKING THE OIL LEVEL 1. Where present, top up the oil reservoir of the automatic lubrication system. Page 10.6 Downloaded from www.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 There are 3 types of problems which can typically occur on the heart rate signal: • • • interference caused by disturbances from sources of electromagnetic noise. These problems cause the heart rate signal to deviate from the rear value, typically making it higher; saturation caused by disturbances from sources of electromagnetic noise.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 • 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 11.1.6.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 11.2. HITACHI SJ100 INVERTER ERROR CODES The inverter memorizes all the errors detected during operation, in the form of a code which indicates the cause of the error. The table below lists the error codes and their meaning, as referred to in chapter 6. DESCRIPTION CAUSES Power circuits protection A short-circuit on an inverter output or a motor block causes a high current to flow, generating this error.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 2. Turn on the machine. 3. Repeatedly press the “1” or “2” key on the inverter keypad until the display shows “d08”. 4. Press the “FUNC” key to display the last error which occurred. The following will sequentially appear: • • • • 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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 Downloaded from www.Manualslib.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 11.5. HITACHI J100 INVERTER ERROR CODES The inverter memorizes all the errors detected during operation, in the form of a code which indicates the cause of the error. The table below lists the error codes and their meaning, as referred to in chapter 6. DESCRIPTION CAUSES Power circuits protection A short-circuit on an inverter output or a motor block causes a high current to flow, generating this error.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 • 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 11.7. LENZE 644 INVERTER ERROR CODES The inverter memorizes all the errors detected during operation, in the form of a code which indicates the cause of the error.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 11.9.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 11.10. LEAKAGE CURRENT PROBLEMS WITH HITACHI E5 INVERTER The introduction of Hitachi inverter version E5 on the machine has given rise to problems with increased earth leakage currents, which result in non-conformance to the relevant regulations for electromedical equipment.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 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.
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RUNRACE : Service & Maintenance Manual - rev. 2.0 11.11. SPECIAL FUNCTIONS AND PASSWORD The table below details the special functions and passwords available on the machine: Keys 0-1 0-1 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.
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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 Downloaded from www.Manualslib.