Technogym Vario Excite + 700LED User manual

V
VA AR RI IO O
E X C I T E +
REV.4.2

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.
CAREFULLY READ THE INFORMATION CONTAINED IN
THIS MANUAL BEFORE PERFORMING ANY MAINTENANCE
PROCEDURES ON THE MACHINE
DANGEROUS VOLTAGES
PRESENT
NOTE
The information contained in this document is subject to change without notice.
Technogym does not guarantee this documentation in any way. Technogym shall not be held
responsible for any errors contained in this manual and declines all liability for accidents or
damages resulting from the supply, characteristics or use of this manual.
This document contains proprietary information that is protected by copyright. All rights reserved.
No part of this document may be photocopied, reproduced or translated into another language
without the prior written consent of Technogym.
The Technogym™ trademark is property of Technogym S.p.A.
The VARIO Excite +™ trademark is property of Technogym S.p.A.

VARIO Excite +: Service & maintenance manual- rev. 4.2
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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 SPECIFICATIONS.........................................................................................................................2.1
2.1. PRODUCT CODES ................................................................................................................................................2.1
2.2. SERIAL NUMBER STRUCTURE .............................................................................................................................2.3
2.3. COLOUR OPTIONS ...............................................................................................................................................2.3
2.4. PRODUCT CHARACTERISTICS ..............................................................................................................................2.4
2.5. MECHANICAL CHARACTERISTICS .......................................................................................................................2.5
2.5.1. Overall dimensions.................................................................................................................................2.5
2.5.2. European and overseas packing dimensions..........................................................................................2.6
2.6. AMBIENT SPECIFICATIONS..................................................................................................................................2.7
2.7. CONFORMITY TO REGULATIONS..........................................................................................................................2.7
2.8. WIRING DIAGRAMS .............................................................................................................................................2.8
2.8.1. 500LED model (ARM Board).................................................................................................................2.8
2.8.2. 500SP model (ARM Board)....................................................................................................................2.9
2.8.3. 700LED model (ARM Board)...............................................................................................................2.10
2.8.4. 700SP model (ARM Board)..................................................................................................................2.11
2.8.5. 700VISIO model (CPU Board).............................................................................................................2.12
2.9. CABLES ............................................................................................................................................................2.13
2.9.1. CBQ cables...........................................................................................................................................2.13
2.9.2. CU Cables ............................................................................................................................................2.14
3. PRINCIPLES OF OPERATION............................................................................................................................3.1
3.1. BLOCK DIAGRAM ................................................................................................................................................3.1
3.2. LED DISPLAY BOARDS.......................................................................................................................................3.2
3.2.1. ARM Board: 500 and 500SP models......................................................................................................3.2
3.2.2. ARM Board: 700 and 700SP models......................................................................................................3.3
3.2.3. C-Safe board ..........................................................................................................................................3.3
3.2.4. Dual TGS reader....................................................................................................................................3.3
3.3. VISIO DISPLAY BOARD .....................................................................................................................................3.4
3.3.1. CPU Board: 700VISIO model................................................................................................................3.4
3.3.1.1. Back-Up battery........................................................................................................................................................... 3.4
3.3.2. LCD inverter ..........................................................................................................................................3.5
3.3.3. Digital/Analogue tuner board................................................................................................................3.5
3.3.4. Integrated LAN network board (Wired) .................................................................................................3.5
3.3.5. Wireless network board (without cables)...............................................................................................3.6
3.3.6. Audio/Video external device connector board.......................................................................................3.7
3.3.7. Headphone jack......................................................................................................................................3.7
3.3.8. C-Safe board (integrated) ......................................................................................................................3.7
3.3.9. Service USB port (integrated)................................................................................................................3.7
3.3.10.Optional Accessories..............................................................................................................................3.8
3.3.10.1. iPod docking station ....................................................................................................................................................3.8
3.3.10.2. Client USB port ........................................................................................................................................................... 3.8
3.3.10.3. Dual TGS reader .......................................................................................................................................................... 3.8
3.4. CARDIO RECEIVER BOARD...................................................................................................................................3.9
3.4.1. HR/HS (Chest belt/Hand Sensor)...........................................................................................................3.9
3.4.2. HR (Chest Belt) ....................................................................................................................................3.10
3.5. BRAKE BOARD .................................................................................................................................................3.11
3.6. ELECTROMAGNETIC BRAKE ..............................................................................................................................3.12
3.7. MAGNETIC BRAKE ............................................................................................................................................3.12

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3.8. SPEED SENSOR..................................................................................................................................................3.13
3.9. POWER ENTRY MODULE....................................................................................................................................3.13
3.10.ALTERNATOR ...................................................................................................................................................3.13
3.11.BATTERY..........................................................................................................................................................3.14
3.12.EXTERNAL POWER SUPPLY INPUT .....................................................................................................................3.14
3.13.BRAKE CONTROL..............................................................................................................................................3.15
3.13.1.Mechanics ............................................................................................................................................3.15
3.13.2.Control 3.15
3.13.2.1. ELECTROMAGNETIC Brake...................................................................................................................................3.15
3.13.2.2. MAGNETIC Brake ....................................................................................................................................................3.17
3.13.3.The signals involved.............................................................................................................................3.18
4. ACCESSORIES........................................................................................................................................................4.1
4.1. CARDIO THEATER CONNECTION..........................................................................................................................4.1
4.2. PC LINK FOR PROGRAMMING ..............................................................................................................................4.2
4.3. MONITOR PLUG FOR C-SAFE PORT......................................................................................................................4.3
4.4. VISIOWEB UPGRADE.......................................................................................................................................4.3
4.4.1. VISIO vs VISIOWEB ..............................................................................................................................4.3
4.4.2. VISIOWEB upgrade for VISIO models...................................................................................................4.3
4.4.3. UpGrade from LED to VisioWEB ..........................................................................................................4.4
4.5. ACCESSORISE .....................................................................................................................................................4.4
5. INSTALLATION INSTRUCTIONS......................................................................................................................5.1
5.1. SPECIFICATIONS AND REQUIREMENTS.................................................................................................................5.1
5.2. EQUIPEMENT MOVING.........................................................................................................................................5.2
5.2.1. Spostamento a mano ..............................................................................................................................5.2
5.2.2. Moving with hand-trolley.......................................................................................................................5.3
5.3. RECOMMENDED ANTENNA SIGNAL REQUIREMENTS............................................................................................5.4
5.4. INSTALLATION ....................................................................................................................................................5.5
5.5. FIRST POWER-ON ................................................................................................................................................5.5
6. TROUBLESHOOTING...........................................................................................................................................6.1
6.1. TROUBLESHOOTING MENU:LED MODELS ..........................................................................................................6.2
6.1.1. Accessing configuration of 500 models..................................................................................................6.2
6.1.2. Accessing configuration of 700 models..................................................................................................6.2
6.1.3. Automatic Test........................................................................................................................................6.3
6.1.3.1. I2C Devices Test..........................................................................................................................................................6.3
6.1.3.2. LED Test...................................................................................................................................................................... 6.4
6.1.3.3. Serial Ports Test........................................................................................................................................................... 6.4
6.1.4. Manual Test............................................................................................................................................6.4
6.1.4.1. Man. Keyboard Test.....................................................................................................................................................6.4
6.2. TROUBLESHOOTING MENU:VISIO MODEL .........................................................................................................6.5
6.3. THE DISPLAY FAILS TO ILLUMINATE ....................................................................................................................6.6
6.3.1. LED models............................................................................................................................................6.6
6.3.2. SP models...............................................................................................................................................6.8
6.3.2.1. The Display does not illuminate...................................................................................................................................6.8
6.3.2.2. The Display doesn’t remain on when stopping the execution of the exercise............................................................ 6.10
6.3.3. VISIO models .......................................................................................................................................6.12
6.4. THE TOUCH SCREEN DOES NOT WORK /IT’S NOT CALIBRATED ..........................................................................6.16
6.5. NO AUDIO SOUND .............................................................................................................................................6.16
6.6. NO TV PICTURE................................................................................................................................................6.16
6.7. THE RADIO DOES NOT PLAY ..............................................................................................................................6.16
6.8. THE IPOD DOES NOT WORK...............................................................................................................................6.17
6.9. MESSAGE ON DISPLAY “THE EQUIPMENT IS LOCKED (COM)”.................................................................6.19
6.10.THERE IS NO RESISTANCE.................................................................................................................................6.20
6.11.THE RESISTANCE IS INCORRECT........................................................................................................................6.22
6.12.THE SPEED SIGNAL IS INCORRECT .....................................................................................................................6.24
6.13.THE MACHINE DOES NOT READ THE TGS..........................................................................................................6.26
6.14.THERE IS NO HEART RATE SIGNAL.....................................................................................................................6.28
6.14.1.HR/HS RECEIVER (Hand Sensor).......................................................................................................6.28

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6.14.2.HR/HS Receiver (Chest Belt)................................................................................................................6.32
6.14.3.HR RECEIVER (Chest Belt).................................................................................................................6.35
6.15.THE TELEMETRIC HEART RATE SIGNAL IS INCORRECT.......................................................................................6.37
6.15.1.Chest Belt .............................................................................................................................................6.37
6.15.2.Hand Sensor.........................................................................................................................................6.41
7. DISASSEMBLY OF COMPONENTS...................................................................................................................7.1
7.1. DISASSEMBLING THE DISPLAY ............................................................................................................................7.1
7.1.1. 500 and 500SP version...........................................................................................................................7.1
7.1.2. 700 and 700SP version...........................................................................................................................7.2
7.1.3. VISIO versions........................................................................................................................................7.3
7.2. DISASSEMBLING BOARDS AND COMPONENTS......................................................................................................7.4
7.2.1. LED Display (ARM Board)....................................................................................................................7.4
7.2.1.1. ARM board (A)............................................................................................................................................................7.5
7.2.1.2. C-Safe board (B).......................................................................................................................................................... 7.6
7.2.2. VISIO Display 15” (CPU Board)...........................................................................................................7.7
7.2.2.1. Wireless board (A)....................................................................................................................................................... 7.8
7.2.2.2. Tuner DVB-T board (B).............................................................................................................................................7.10
7.2.2.3. Tuner board ATSC (B1) and ISDB-T (B2)................................................................................................................7.11
7.2.2.4. LCD Inverter (C)........................................................................................................................................................7.12
7.2.2.5. CPU board (D)........................................................................................................................................................... 7.13
7.2.2.6. LCD (E) + Touch Screen ...........................................................................................................................................7.14
7.2.2.7. Headphone Jack (F) ...................................................................................................................................................7.15
7.2.2.8. Dual TGS reader + USB port (G)............................................................................................................................... 7.16
7.2.2.9. iPod Docking Station (H)...........................................................................................................................................7.17
7.2.2.10. Frontal plugs TGS + USB and cover.......................................................................................................................... 7.18
7.3. DISASSEMBLING THE KEYBOARD /TOUCH SCREEN ..........................................................................................7.19
7.3.1. LED Keyboard......................................................................................................................................7.19
7.3.2. VISIO version.......................................................................................................................................7.21
7.4. DISASSEMBLING THE CARDIO RECEIVER...........................................................................................................7.22
7.4.1. HS/HR Receiver (Chest Belt/Hand Sensor)..........................................................................................7.22
7.4.2. HR Receiver (Chest Belt)......................................................................................................................7.23
7.5. DISASSEMBLING THE HAND SENSOR (FIXED HANDGRIPS)..............................................................7.24
7.6. DISASSEMBLING THE HAND SENSORS (MOVING LEVERS)...................................................................................7.25
7.7. DISASSEMBLING THE GUARDS...........................................................................................................................7.26
7.7.1. Disassembling the centre guard...........................................................................................................7.26
7.7.2. Disassembling the side guards.............................................................................................................7.27
7.7.3. Disassembling the bottom centre guard...............................................................................................7.29
7.7.4. Swivel belt connector guard.................................................................................................................7.30
7.8. DISASSEMBLING THE FOOTBOARDS ...................................................................................................................7.32
7.8.1. Disassembling rear footboard..............................................................................................................7.32
7.8.2. Disassembling front footboard.............................................................................................................7.33
7.8.3. Disassembling the lever footboard.......................................................................................................7.34
7.9. DISASSEMBLING THE LEVER .............................................................................................................................7.35
7.9.1. Disassembling the footboard lever.......................................................................................................7.35
7.9.2. Disassembling the upper lever .............................................................................................................7.37
7.10.DISASSEMBLING THE FIXED HANDGRIPS............................................................................................................7.40
7.11.DISASSEMBLING THE LEVER HANDLEBARS .......................................................................................................7.41
7.12.DISASSEMBLING THE ELECTROMAGNETIC BRAKE BOARD .................................................................................7.43
7.13.DISASSEMBLING THE ELECTROMAGNETIC BRAKE .............................................................................................7.44
7.14.DISASSEMBLING THE LOWER TRANSMISSION (FLYWHEEL –DRIVEN PULLEY –PRIMARY UNIT) .........................7.45
7.14.1.Disassembling th flywheel (A)..............................................................................................................7.46
7.14.2.Disassembling the driven pulley (B).....................................................................................................7.48
7.14.3.Disassembling the primary unit (C) .....................................................................................................7.49
7.15.DISASSEMBLING THE UPPER TRANSMISSION (FLYWHEEL –COGGED BELT –MAGNETIC BRAKE) ..................7.51
7.16.DISASSEMBLING THE BELTS AND MAGNET........................................................................................................7.55
7.16.1.Short belt disassembling.......................................................................................................................7.55
7.16.2.Disassembling the magnet (Anti bottom dead point)............................................................................7.57
7.16.3.Disassembling the long belt .................................................................................................................7.58
7.16.4.Pin with snap-rings (A) ........................................................................................................................7.60
7.16.5.Pin with eccentrics (B) .........................................................................................................................7.60

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7.17.DOUBLE PULLEYS ASSEMBLY DISASSEMBLING .................................................................................................7.62
7.18.DISASSEMBLING THE SPEED SENSOR.................................................................................................................7.63
7.19.DISASSEMBLING THE RIGID STOP AND THE LEVER SHOCK ABSORBER................................................................7.64
7.20.DISASSEMBLING THE BATTERY.........................................................................................................................7.65
7.21.DISASSEMBLING THE FLYWHEEL AND STATOR GROUP......................................................................................7.66
8. ADJUSTMENTS......................................................................................................................................................8.1
8.1. BELT TENSION ....................................................................................................................................................8.1
8.2. ADJUSTING THE SHORT BELT ..............................................................................................................................8.2
8.3. ADJUSTING THE LONG BELT ................................................................................................................................8.3
8.3.1. Machines with slotted pulley..................................................................................................................8.3
8.3.2. Machines without slotted pulley.............................................................................................................8.6
8.4. POSITIONING THE ELECTROMAGNETIC BRAKE WINDING......................................................................................8.8
8.5. GREASE ON LONG AND SHORT BELTS..................................................................................................................8.9
8.6. THE MACHINE IS NOT FLAT ...............................................................................................................................8.10
9. MACHINE CONFIGURATION ............................................................................................................................9.1
9.1. USER MENU CONFIGURATION:500LED MODELS ................................................................................................9.1
9.1.1. Language................................................................................................................................................9.2
9.1.2. Units of measurement.............................................................................................................................9.2
9.1.3. Maximum exercise time..........................................................................................................................9.2
9.1.4. Pause time..............................................................................................................................................9.3
9.1.5. Cooldown time........................................................................................................................................9.3
9.1.6. Default age.............................................................................................................................................9.3
9.1.7. Default weight........................................................................................................................................9.4
9.1.8. Default duration.....................................................................................................................................9.4
9.1.9. Default calories......................................................................................................................................9.4
9.1.10.Default distance......................................................................................................................................9.5
9.1.11.Enable TGS ............................................................................................................................................9.5
9.1.12.Enable keyboard.....................................................................................................................................9.5
9.1.13.Modifiable target frequencies ................................................................................................................9.6
9.1.14.Enable custom messages........................................................................................................................9.6
9.1.15.Resetting parameters to default values...................................................................................................9.6
9.1.16.Format P&P key.....................................................................................................................................9.7
9.1.17.SN 9.7
9.2. USER MENU CONFIGURATION:700LED MODELS ................................................................................................9.8
9.2.1. Language................................................................................................................................................9.9
9.2.2. Distance..................................................................................................................................................9.9
9.2.3. Maximum excercise time ........................................................................................................................9.9
9.2.4. Pause time..............................................................................................................................................9.9
9.2.5. Cooldown time......................................................................................................................................9.10
9.2.6. Enable TGS ..........................................................................................................................................9.10
9.2.7. Enable keyboard...................................................................................................................................9.10
9.2.8. Modifiable target heart rate.................................................................................................................9.11
9.2.9. Enable custom messages......................................................................................................................9.11
9.2.10.Edit custom messages...........................................................................................................................9.11
9.2.11.Change messagges languages..............................................................................................................9.11
9.2.12.Enable multi-language mode ...............................................................................................................9.12
9.2.13.Resetting parameters to default values.................................................................................................9.12
9.2.14.Format P&P.........................................................................................................................................9.12
9.2.15.SN 9.12
9.3. SERVICE MENU CONFIGURATION:LED MODELS ...............................................................................................9.13
9.3.1. Accessing configuration of 500 models................................................................................................9.13
9.3.2. Accessing configuration of 700 models................................................................................................9.13
9.3.3. Low kit parameter ................................................................................................................................9.15
9.3.3.1. Read from low kit ......................................................................................................................................................9.15
9.3.3.2. Write to low kit..........................................................................................................................................................9.15
9.3.3.3. Default Setting........................................................................................................................................................... 9.16
9.3.3.4. Table of configuration parameters: ............................................................................................................................ 9.16

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9.3.4. Operating data .....................................................................................................................................9.17
9.3.4.1. Read from low kit ......................................................................................................................................................9.17
9.3.4.2. Write to low kit..........................................................................................................................................................9.18
9.3.4.3. Machine usage data....................................................................................................................................................9.18
9.3.5. Errors log.............................................................................................................................................9.19
9.3.5.1. Read from low kit ......................................................................................................................................................9.19
9.3.5.2. Reset Errors................................................................................................................................................................9.19
9.3.5.3. COM.Fault.................................................................................................................................................................9.20
9.3.5.4. View Errors................................................................................................................................................................9.20
9.3.6. Standard settings..................................................................................................................................9.21
9.3.7. Low kit menu ........................................................................................................................................9.21
9.3.7.1. Low kit version ..........................................................................................................................................................9.21
9.3.7.2. Low Kit fault code ..................................................................................................................................................... 9.22
9.3.8. High kit version....................................................................................................................................9.22
9.3.9. BOOT version.......................................................................................................................................9.22
9.3.10.Key Reader Version..............................................................................................................................9.22
9.4. CONFIG.: VISIO -VISIOWEB USER MENÙ...................................................................................................9.23
9.5. SERVICE MENU CONFIG.: VISIO -VISIOWEB.........................................................................................9.24
9.5.1.1. Table of configuration parameters .............................................................................................................................9.25
10.UPDATING THE SW............................................................................................................................................10.1
11.FUNCTIONAL TEST MD MODELS..................................................................................................................11.1
11.1.ELECTRICAL SAFETY TEST................................................................................................................................11.1
11.2.TEST MECCANICI DI SICUREZZA ........................................................................................................................11.3
11.2.1.Checking the assembly of the transmission and levers systems............................................................11.3
11.2.2.Checking the assembly of the guards ...................................................................................................11.3
11.3.START-UP CHECK..............................................................................................................................................11.3
OLIST OF CRITICAL SPARE PARTS.........................................................................................................................11.4
12.SCHEDULED MAINTENANCE .........................................................................................................................12.1
12.1.ORDINARY MAINTENANCE OPERATION..........................................................................................................12.2
12.1.1.Setting up the operation (Daily)...........................................................................................................12.2
12.1.2.External cleaning operations (Daily)...................................................................................................12.2
12.1.3.Internal cleaning operations (Monthly) ...............................................................................................12.2
12.1.4.Complete operation (six-menthly)........................................................................................................12.2
12.2.EXTRA-ORDINARY MAINTENANCE OPERATIONS.............................................................................................12.3
12.2.1.Checking the working conditions.........................................................................................................12.3
12.2.2.Checking the operation of the cardiotester receiver............................................................................12.3
12.2.3.Checking the operation of the hand sensor..........................................................................................12.3
12.2.4.Checking the state of wear of the pedal lever belt................................................................................12.3
12.2.5.Checking the amount of play on the ball joints....................................................................................12.3
12.2.6.Checking the wear of rubber parts.......................................................................................................12.3
12.2.7.Checking the belts ................................................................................................................................12.3
12.2.8.Checking the play of the lever and pedal group...................................................................................12.3
12.2.9.Checking the display ............................................................................................................................12.4
12.2.10. Checking the wiring and connections ....................................................................................12.4
13.APPENDIX.............................................................................................................................................................13.1
13.1.PASSWORD MENUTABLE...................................................................................................................................13.1
13.2.REQUIRED TOOLS..............................................................................................................................................13.2

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