Technogym Wellness Expert User manual

SERVICE & MAINTENANCE MANUAL
REV. 1.1

The information in this manual is intended for a QUALIFIED TECHNICIAN, specifically trained
by TECHNOGYM and authorized to set and start the machine, as well as to carry out special
maintenance or repairs that require complete familiarity with the machine, its operation, safety
devices, and intervention procedures.
READ THE INFORMATION IN THIS MANUAL CAREFULLY BEFORE PERFORMING
ANY SERVICE OPERATIONS ON THE MACHINE
DANGEROUS VOLTAGES
ARE PRESENT EVEN WHEN
THE MACHINE IS SHUT OFF
NOTICE
The information in this manual is subject to change without notice.
Technogym does not guarantee this material in any way. Technogym may not be held liable for any
errors contained herein, or for accidental damages or those caused by the provision and use of this
material.
This document contains proprietary information covered by copyright. All rights reserved. No part
of this document may be photocopied, reproduced or translated into another language without prior
written consent by Technogym.
Technogym™ is a registered trademark of Technogym S.p.A.
New Wellness Expert™ is a registered trademark of Technogym S.p.A.

New Wellness Expert: Service & Maintenance manual - rev. 1.1
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
1.4. GENERAL RECOMMENDATIONS FOR THE PREVENTION OF ELECTROSTATIC DISCHARGE DAMAGE ...........1.2
1.4.1. ESD wrist straps..................................................................................................................................1.2
1.4.2. ESD static mats for work benches .......................................................................................................1.2
1.4.3. ESD isolation gloves............................................................................................................................1.3
1.4.4. ESD static shoes ..................................................................................................................................1.3
2. TECHNICAL CHARACTERISTICS..................................................................................................................2.1
2.1. MECHANICAL CHARACTERISTICS .....................................................................................................................2.1
2.2. ELECTRICAL CHARACTERISTICS .......................................................................................................................2.1
2.3. AMBIENT SPECIFICATIONS................................................................................................................................2.1
2.4. CONFORMITY TO REGULATIONS........................................................................................................................2.1
2.5. WIRING DIAGRAM ............................................................................................................................................2.2
2.6. WIRING ............................................................................................................................................................2.3
3. PRINCIPLES OF OPERATION..........................................................................................................................3.1
3.1. BLOCK DIAGRAM..............................................................................................................................................3.1
3.1.1. Display board......................................................................................................................................3.2
3.1.2. LCD inverter........................................................................................................................................3.2
3.1.3. LCD display.........................................................................................................................................3.3
3.1.4. Touch screen interface board..............................................................................................................3.3
3.1.5. TGS reader ..........................................................................................................................................3.3
3.1.6. Fan.......................................................................................................................................................3.3
3.1.7. Power supply .......................................................................................................................................3.3
3.1.8. AUX input board..................................................................................................................................3.3
3.1.9. Power entry module.............................................................................................................................3.3
4. ACCESSORIES.....................................................................................................................................................4.1
5. INSTALLATION INSTRUCTIONS....................................................................................................................5.1
5.1. SPECIFICATIONS AND REQUIREMENTS ..............................................................................................................5.1
5.2. INSTALLATION..................................................................................................................................................5.1
5.3. FIRST POWER-ON ..............................................................................................................................................5.2
6. TROUBLESHOOTING........................................................................................................................................6.1
6.1. THE MACHINE DOES NOT ILLUMINATE ..............................................................................................................6.2
6.2. THE MACHINE DOES NOT READ THE TGS ...........................................................................................................6.6
6.3. SW ERRORS .....................................................................................................................................................6.8
6.3.1. The operating system doesn’t work .....................................................................................................6.8
6.4. UPDATING SW .................................................................................................................................................6.9
6.4.1. Formatting procedure........................................................................................................................6.10
6.4.2. System restore from Hard Disk..........................................................................................................6.11
6.4.3. System restore from USB key.............................................................................................................6.11
6.5. UPDATING WELLNESS EXPERT AND WELLNESS EXPERT VIDEO SW..............................................................6.13
6.5.1. Network installation...........................................................................................................................6.13
6.5.2. Installation from external USB key....................................................................................................6.13
6.5.3. Installation from external CD-ROM drive.........................................................................................6.14
7. DISASSEMBLY OF COMPONENTS.................................................................................................................7.1
7.1. DISASSEMBLING THE LOWER ELECTRONIC........................................................................................................7.1
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7.2. DISASSEMBLING THE DISPLAY BOARD ..............................................................................................................7.3
7.2.1. DISPLAY before the changes to fix the malfunctioning with appearance of a blue screen” ..............7.3
7.2.2. DISPLAY after the changes to fix the malfunctioning with appearance of a blue screen”.................7.6
7.3. DISASSEMBLING THE FOOTBOARD..................................................................................................................7.10
8. ADJUSTMENTS....................................................................................................................................................8.1
8.1. TOUCH SCREEN CALIBRATION ..........................................................................................................................8.1
8.1.1. Touch screen first model “SEMTECH” ..............................................................................................8.2
8.1.2. Touch screen second model “HAMPSHIRE” .....................................................................................8.3
8.2. DISPLAY COLORS CALIBRATION.......................................................................................................................8.6
9. MACHINE CONFIGURATION..........................................................................................................................9.1
9.1. CONFIGURING THE “CONSOLE.INI” FILE............................................................................................................9.1
9.1.1. Language.............................................................................................................................................9.1
9.1.2. IdCen and IdCat ..................................................................................................................................9.2
9.1.3. Using the printer..................................................................................................................................9.2
9.1.4. Enabling messages ..............................................................................................................................9.2
9.1.5. Unit of measure ...................................................................................................................................9.3
9.1.6. Date format..........................................................................................................................................9.3
10.SCHEDULED MAINTENANCE.......................................................................................................................10.1
10.1.DAILY MAINTENANCE OPERATIONS................................................................................................................10.1
10.1.1. Setting up the operation.....................................................................................................................10.1
10.1.2. External cleaning operations.............................................................................................................10.1
10.2.TWICE-YEARLY MAINTENANCE OPERATIONS..................................................................................................10.2
10.2.1. Setting up the operation.....................................................................................................................10.2
10.2.2. Checking the wiring and connections................................................................................................10.2

New Wellness Expert: Service & Maintenance manual - rev. 1.1
1. GENERAL NOTICES
1.1. INTRODUCTION
This document is reserved for Technogym Service technicians, and is intended to provide
authorized personnel with the necessary information to correctly carry out repairs and maintenance.
A thorough knowledge of the technical information contained in this manual is essential for
completing the professional training of the operator.
In order to facilitate consultation, the paragraphs are accompanied by schematic drawings which
illustrate the procedure being described.
This manual contains notices and symbols which have a specific meanings:
WARNING: non observance may result in accident or injury.
ATTENTION: non observance may cause damage to the machine.
Information about the operation in progress.
OBSERVE: observation about the operation in progress.
1.2. RECOMMENDATIONS
Technogym recommends the following steps for planning repair procedures:
• Carefully evaluate the customer’s description of the machine malfunction and ask all the
necessary questions to clarify the symptoms of the problem.
• Clearly diagnose the causes of the problem. This manual provides the fundamental theoretical
basis, which must then be integrated by personal experience and attendance at the training
courses periodically offered by Technogym.
• Rationally plan the repair procedure so as to minimize the downtime necessary for procuring
spare parts, preparing tools, etc.
• Access the component to be repaired, avoiding any unnecessary operations. In this regard it
will be useful to refer to the disassembly sequence described in this manual.
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Page 1.2
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. Before starting the repair procedure, make sure that the recommended tools are available and in
good condition.
6. For the procedures described in this manual, use only the specified tools.
OBSERVE: The tool sizes quoted in this manual are expressed in mm.
1.4. GENERAL RECOMMENDATIONS FOR THE PREVENTION
OF ELECTROSTATIC DISCHARGE DAMAGE
When performing any operations on the electronic
components of the machine, always pay special attention
to the control of electrostatic discharges. These can in
most cases damage the electronic components, so it is
necessary to adopt the special preventive measures and
procedures described below.
1.4.1. ESD WRIST STRAPS
These are grounded conductive straps worn on the wrist that continually channel any static
electricity build-up to ground. The elastic strap fits snugly on the wrist and has a clip connecting it
to a grounding cable that reaches the user from the ceiling or work bench, depending on the
situation.
ESD straps must always be worn before: removing electronic components from a bag,
pre-assembling an electronic circuit board or unit on a work bench, assembling an
electronic circuit board or unit on a machine, performing repairs or maintenance on a
machine, being handed a circuit board by another operator.
1.4.2. ESD STATIC MATS FOR WORK BENCHES
These ESD bench mats, like the wrist straps, continually dissipate any charge build-up to ground.
All electronic units or circuit boards must be placed on an ESD mat for any pre-assembly or
software download operations. No pre-assembly work should be carried out on electronic units that
have not first been placed on these ESD protection mats.

New Wellness Expert: Service & Maintenance manual - rev. 1.1
NEVER place electronic units on bubble wrap or polystyrene (white or light blue), as
these materials are highly charged with electrostatic particles. Packing materials of
this type must be categorically kept away from work benches, as they must never come
into contact with the electronic circuit boards.
1.4.3. ESD ISOLATION GLOVES
These are gloves which in practice isolate a charged wearer from the electronic circuit boards but
do not allow the built-up charge to dissipate to ground, so that they do not afford optimal protection
unless used in conjunction with ESD dissipative wrist straps or conductive shoes. For example, if
the gloves tear and the operator inadvertently touches the circuit board through the hole, there is the
risk of damaging the electronic components.
Always request immediate replacement of gloves that have become ripped, damaged or
torn.
1.4.4. ESD STATIC SHOES
These are worn by all operators working both on the line and outside the line. They are the standard
shoes worn every day, and have a moderately conductive sole.
They afford adequate protection if used on a cement floor or on anti-static mats, but
are useless on wooden floors such as those of the production lines, or on carpeted or
plastic-laminate floors such as those of gyms.
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New Wellness Expert: Service & Maintenance manual - rev. 1.1
2. TECHNICAL CHARACTERISTICS
2.1. MECHANICAL CHARACTERISTICS
Footboard diameter 43 cm 17 inch
Height 115 cm 46 inch
Weight 25 Kg 55 lb
2.2. ELECTRICAL CHARACTERISTICS
US version European version
Line voltage 100 - 240 VAC
Frequency 50-60 Hz
Consumption ~ 800 Watt – 7.5 A ~ 800 Watt – 3.5 A
2.3. AMBIENT SPECIFICATIONS
Operating from 10° to 25° C
Temperature Storage from 10° to 25° C
Operating from 30% to 80% non-condensing
Humidity Storage from 20% to 90% non-condensing
2.4. CONFORMITY TO REGULATIONS
The equipment conforms to the following directives:
Europe USA
EMI
EN 55022
EN 55024
EN 61000-3-2
EN 61000-3-3
Safety EN 60950
Directive 73/23/CEE
89/336/CEE
UL 60950
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New Wellness Expert: Service & Maintenance manual - rev. 1.1
Page 2.2
2.5. WIRING DIAGRAM
DISPLAY
LCD
BASE BOARD
CBQ-32
HARD DISK
J12
J2
TGS
READER
CN1
J5
J10U10
INVERTER
CN03
CN02
CN1J8
ETX BOARD
RAM MEMORY
U7
LVDS
BOARD
CN1CN1
J9
POWER
ENTRY
MODULE
VAC POWER SUPPLY
CN1
CN2
WE-1
WE-2
AUX INPUT BOARD
TOUCH SCREEN
INTERFACE
BOARD
TOUCH
SCREEN
CN5
CN1
Keyboard
JS1 Ethernet J3 USB 0-1 CN1 USB 2-3 CN2
J2
Ethernet
GND
J4
J1
USB 0-3
Keyboard
GND
H1
FAN
J4
CPU
J3
WE-4
WE-7
WE-6
WE-5
WE-3

New Wellness Expert: Service & Maintenance manual - rev. 1.1
2.6. WIRING
WE-1: High voltage cable
Power entry module – Power supply
Power entry
module Signal Color Power supply CN1
2 Line Blue 1
1 Neutral Brown 3
faston Earth Yellow/Green 5
WE-2: Cable connecting upper and lower assemblies
Power supply – Base board
Power supply
CN2 Signal Color Base Board
J5
1 +5 Vdc Red 1
2 +5 Vdc Red 2
6 Gnd Black 3
7 Gnd Black 4
8 Gnd Black 5
9 Gnd Black 6
11 +12 Vdc Orange 7
12 +12 Vdc Orange 8
WE-3: Keybord/USB cable
AUX input board – Base board
AUX input board
J1
Signal Color Base board
J2
1 VCC White 1
2 USB 0 Brown 2
3 USB 1 Black 3
4 USB 2 Grey 4
5 USB 3 White 5
6 GND White 6
7 GND Blue 7
8 VCC Pink 8
9 USB 0# White 9
10 USB 1# White 10
11 USB 2# Yellow 11
12 USB 3# Green 12
13 KBCLK White 13
14 KBDAT Grey 14
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Page 2.4
WE-5: LCD cable
LVDS board – Base board
LVDS board
CN1
Signal Color Base board
J9
1 GND 1
2 TXCLKOUT+ 2
3 TXCLKOUT- 3
4 TXOUT2+ 4
5 TXOUT2- 5
6 TXOUT1+ 6
7 TXOUT1- 7
8 TXOUT0+ 8
9 TXOUT0- 9
10 VCC LCD 10
11 VCC LCD 11
12 GND 12
13 (not used) 13
14 (not used) 14
WE-6: Touch screen interface cable
Touch screen interface board – Base board
Touch screen
interface board
CN5
Signal Color Base Board
J10
1 +5 Vdc 1
8 MS-DATA 2
9 MS-CLOCK 3
10 GND 4
WE-7: LCD inverter power supply cable
Main board – LCD inverter
Main board
J8 Signal Color LCD inverter CN1
1 +12 Vdc power supply Black 1
2 Reference Black 3
3 +3.3 Vdc power supply Black 5
4 Reference Black 4
5 Lamp failure detector: • 0 Vdc = standard condition
• 5 Vdc = error condition Black 6

New Wellness Expert: Service & Maintenance manual - rev. 1.1
TRM-32: TGS Cable
Main Board – TGS reader
Main Board
J12 Signal Color TGS CN1
1 +12 Vdc power supply Yellow 1
3 Rx White 8
5 Tx Green 7
9 Gnd Brown 3
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New Wellness Expert: Service & Maintenance manual - rev. 1.1
3. PRINCIPLES OF OPERATION
3.1. BLOCK DIAGRAM
The figure below shows the block diagram for the machine:
POWER
ENTRY
MODULE
DISPLAY
DISPLAY BOARD
TGS READER
POWER SUPPLY
VAC
AUX INPUT BOARD
NET
FAN
USB
Keyboard
TOUCH SCREEN
LCD DISPLAY
LCD INVERTER
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New Wellness Expert: Service & Maintenance manual - rev. 1.1
Page 3.2
3.1.1. DISPLAY BOARD
• ETX board
This is the circuit board that houses the microprocessor, which runs a dedicated version of the
Windows XP Embedded operating system and the "Wellness Expert" application, and the
system RAM (512 MB), placed on a bank.
• Base board
This board acts as the interconnection hub for all the components of the display, and serves as
the point of connection with the power supply. It includes connectors for the following:
> Hard disk;
> ETX board;
> TGS reader;
> LVDS board;
> Touch screen interface board;
> LCD power supply inverter;
> AUX input board;
> Power supply;
> PC fan.
It has a connector linking it to the CPU board, for transferring the collected signals.
The board also includes an indicator LED:
LED name Color Description
D3 green
POW LED: if ON the +12 Vdc power supply
provided by the brake board, correctly reaches
the board.
and one Faston:
Name Description
H1 GND: denotes a ground node on the circuit board, where the
cable coming from the AUX input board is connected.
The principal functions of the board are:
> Distributes the voltages received from the brake board to the display;
> Manages the display of images on the LCD;
> Enable the fan to cool down the PC.
3.1.2. LCD INVERTER
This device powers the LCD display segments. It receives DC power supplies (12 Vdc supply and
3.3 Vdc enable signal) from the main board, and generates the AC voltages 380 Vac and 190 Vac
needed to power the LCD.

New Wellness Expert: Service & Maintenance manual - rev. 1.1
3.1.3. LCD DISPLAY
The component used is a colour TFT-LCD unit with 800x3x600 resolution and 262144 colors. It is
provided with a touch screen to facilitate interaction with the user.
3.1.4. TOUCH SCREEN INTERFACE BOARD
This is the board that controls the 4-wire resistive touch screen and interfaces the touch screen to
the CPU board.
3.1.5. TGS READER
This device enables the machine to read the user's TGS key for performing workouts programmed
with the Wellness System.
On the key reader there are 2 LEDs: a green one that lights if the device is powered, and a red one
that lights if read/write operations are in progress.
3.1.6. FAN
There are 2 fans powered with 12 Vdc used to cool down the PC.
3.1.7. POWER SUPPLY
Receives the incoming line voltage and outputs the direct currents +12 Vdc and +5 Vdc to power all
the electronic boards and the devices of the machine.
3.1.8. AUX INPUT BOARD
This is a circuit board situated on the base of the machine, that makes available 4 USB ports, one
PS/2 port and an Ethernet network cable input for connecting any keyboards, computer mice or
memory keys.
3.1.9. POWER ENTRY MODULE
This is a block consisting of:
• power inlet socket;
• power outlet socket;
• fuse-holder for protecting line voltage and neutral with two 4A slow-blow fuses.
Situated on the side of the rear platform.
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