Technogym Run XT User manual

SERVICE & MAINTENANCE MANUAL
PRELIMINARY

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 EVEN WHEN THE
MACHINE IS TURNED OFF
NOTE
The information contained in this document is subject to change without notice.
Technogym does not guarantee this documentation in any way. Technogym shall not be held
responsible for any errors contained in this manual and declines all liability for accidents or damages
resulting from the supply, characteristics or use of this manual.
This document contains proprietary information that is protected by copyright. All rights reserved.
No part of this document may be photocopied, reproduced or translated into another language
without the prior written consent of Technogym.
The Technogym™ trademark is property of Technogym S.r.l.
The Run XT™ trademark is property of Technogym S.r.l.

RUN XT: Service & Maintenance Manual - rev. 2.0
Page i
Contents
1. GENERAL NOTICES.......................................................................................................................................1.1
1.1. INTRODUCTION ............................................................................................................................................1.1
1.2. RECOMMENDATIONS.....................................................................................................................................1.1
1.3. GENERAL RULES FOR REPAIR PROCEDURES.....................................................................................................1.2
2. TECHNICAL CHARACTERISTICS...............................................................................................................2.1
2.1. MECHANICAL CHARACTERISTICS...................................................................................................................2.1
2.2. ELECTRICAL CHARACTERISTICS.....................................................................................................................2.1
2.3. AMBIENT SPECIFICATIONS.............................................................................................................................2.1
2.4. CONFORMITY TO REGULATIONS.....................................................................................................................2.1
2.5. WIRING DIAGRAM FOR THE 220 MODEL........................................................................................................2.2
2.5.1. Connectors.......................................................................................................................................2.2
2.5.2. Wiring..............................................................................................................................................2.3
2.6. WIRING DIAGRAM FOR THE 220 USA MODEL.................................................................................................2.6
2.7. WIRING DIAGRAM FOR THE 110 MODEL........................................................................................................2.8
3. PRINCIPLES OF OPERATION ......................................................................................................................3.1
3.1. BLOCK DIAGRAM..........................................................................................................................................3.1
3.2. TREAD-BELT MOTOR DRIVE...........................................................................................................................3.4
3.3. UP-DOWN MOTOR DRIVE...............................................................................................................................3.6
4. ACCESSORIES.................................................................................................................................................4.1
4.1. CONNECTING TO THE TGS .............................................................................................................................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 DISPLAY DOES NOT ILLUMINATE.............................................................................................................6.2
6.2. THE DISPLAY SHOWS “E1” OR “E2”...............................................................................................................6.6
6.3. THE DISPLAY SHOWS “E3” OR “E4”...............................................................................................................6.8
6.3.1. The inverter display shows E1, E2, E3, E4 or E5..............................................................................6.9
6.3.2. The inverter display shows E6 or E7...............................................................................................6.11
6.3.3. The inverter display shows E8, E10 or E11.....................................................................................6.12
6.3.4. The inverter display shows E9 ........................................................................................................6.14
6.3.5. The inverter display shows E12 ......................................................................................................6.16
6.3.6. The inverter display shows E14 ......................................................................................................6.17
6.3.7. The inverter display does not show any error..................................................................................6.18
6.4. THE BELT MOTOR IS JERKING.......................................................................................................................6.20
6.5. THE BELT MOTOR STARTS WITH DELAY........................................................................................................6.21
6.6. THE DISPLAYED SPEED IS INCORRECT...........................................................................................................6.23
6.7. THE DISPLAY SHOWS “E5”..........................................................................................................................6.26
6.8. THE UP-DOWN MOVES IN ONLY ONE DIRECTION............................................................................................6.31
6.9. THE DISPLAYED ELEVATION IS INCORRECT...................................................................................................6.34
6.10.THERE IS NO HEART RATE SIGNAL................................................................................................................6.35
6.11.THE HEART RATE SIGNAL IS INCORRECT .......................................................................................................6.36
7. DISASSEMBLY OF COMPONENTS..............................................................................................................7.1
7.1. DISASSEMBLING THE DISPLAY .......................................................................................................................7.1

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7.2. DISASSEMBLING THE EPROM .........................................................................................................................7.2
7.3. DISASSEMBLING THE CPU BOARD...................................................................................................................7.3
7.4. DISASSEMBLING THE KEYBOARD ...................................................................................................................7.4
7.5. DISASSEMBLING THE CARDIO RECEIVER.........................................................................................................7.5
7.6. DISASSEMBLING THE EMERGENCY BUTTON....................................................................................................7.8
7.7. DISASSEMBLING THE MOTOR GUARD............................................................................................................7.10
7.8. DISASSEMBLING THE FRONT PLATE..............................................................................................................7.11
7.9. DISASSEMBLING THE RUNNING TRACK.........................................................................................................7.12
7.10.DISASSEMBLING THE DRIVEN ROLLER, THE DRIVING ROLLER, THE TREAD BELT AND THE MOTOR BELT............7.14
7.11.DISASSEMBLING THE BELT MOTOR...............................................................................................................7.17
7.12.DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS .....................................................................................7.19
7.13.DISASSEMBLING THE INVERTER...................................................................................................................7.20
7.14.DISASSEMBLING THE UP-DOWN MOTOR BELT ...............................................................................................7.21
7.15.DISASSEMBLING THE UP-DOWN MOTOR........................................................................................................7.22
7.16.DISASSEMBLING THE UP-DOWN MOTOR BRUSHES..........................................................................................7.25
7.17.DISASSEMBLING THE ELEVATION BARS ........................................................................................................7.26
7.18.DISASSEMBLING THE LEAD SCREW NUTS ......................................................................................................7.27
7.19.DISASSEMBLING THE LIMIT SWITCHES..........................................................................................................7.29
7.20.DISASSEMBLING THE PHOTOCELL ................................................................................................................7.30
8. ADJUSTMENTS...............................................................................................................................................8.1
8.1. TENSIONING A NEW TREAD BELT ..................................................................................................................8.1
8.2. TENSIONING A USED TREAD BELT ..................................................................................................................8.2
8.3. CENTERING THE TREAD BELT ........................................................................................................................8.3
8.4. ADJUSTING THE TENSION AND ALIGNMENT OF THE TREAD-BELT MOTOR BELT .................................................8.4
8.5. TENSIONING THE UP-DOWN MOTOR BELT.......................................................................................................8.6
8.6. ALIGNING THE ELEVATION BARS ...................................................................................................................8.7
8.7. CALIBRATING THE TREAD BELT SPEED ...........................................................................................................8.8
8.8. CENTERING THE PHOTOCELL.........................................................................................................................8.9
9. MACHINE CONFIGURATION.......................................................................................................................9.1
9.1. CHANGING THE SETTINGS ON THE DISPLAY PANEL..........................................................................................9.1
9.1.1. Language used .................................................................................................................................9.1
9.1.2. Measurement system.........................................................................................................................9.1
9.1.3. Maximum time..................................................................................................................................9.2
9.1.4. Activating the “+” and “−” keys......................................................................................................9.2
9.1.5. Disabling the function keys...............................................................................................................9.2
9.1.6. Enabling the “ENTER” key..............................................................................................................9.2
9.2. MAINTENANCE INFORMATION.......................................................................................................................9.3
9.2.1. Hours on ..........................................................................................................................................9.3
9.2.2. Hours of use .....................................................................................................................................9.3
9.2.3. Hours of motor use...........................................................................................................................9.3
9.2.4. Minutes of up-down motor use..........................................................................................................9.3
9.2.5. Distance travelled ............................................................................................................................9.3
9.3. CHANGING THE MAINTENANCE INFORMATION................................................................................................9.3
9.3.1. Hours on ..........................................................................................................................................9.3
9.3.2. Hours of use .....................................................................................................................................9.4
9.3.3. Hours of motor use...........................................................................................................................9.4
9.3.4. Minutes of up-down motor use..........................................................................................................9.4
9.3.5. Distance travelled ............................................................................................................................9.4
9.4. PROGRAMMING THE HITACHI J100 INVERTER .............................................................................................9.5
9.4.1. Version E2........................................................................................................................................9.5
9.4.2. Versions E3, E4 and E5....................................................................................................................9.5
10.SCHEDULED MAINTENANCE....................................................................................................................10.1
11.APPENDIX......................................................................................................................................................11.1

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11.1.TECHNICAL NOTES ON CARDIO RECEIVERS ...................................................................................................11.1
11.1.1. type of ASIC.................................................................................................................................11.1
11.1.2. Presence of electromagnetic fields...............................................................................................11.2
11.1.3. Reducing receiver sensitivity .......................................................................................................11.2
11.1.4. Mechanical vibrations .................................................................................................................11.3
11.1.5. Position of the receiver................................................................................................................11.3
11.1.6. Routing of cables.........................................................................................................................11.5
11.2.HITACHI J100 INVERTER ERROR CODES.....................................................................................................11.6
11.3.MULTIMETER MEASUREMENTS....................................................................................................................11.8
11.3.1. AC voltage...................................................................................................................................11.8
11.3.2. DC voltage ..................................................................................................................................11.8
11.3.3. AC and DC current......................................................................................................................11.9

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RUN XT: Service & Maintenance Manual - rev. 2.0
Page 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 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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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.
WARNING: The tool sizes quoted in this manual are expressed in mm.

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2. TECHNICAL CHARACTERISTICS
2.1. MECHANICAL CHARACTERISTICS
Width 80 cm
Length 190 cm
Height 142 cm
Weight 183 kg
2.2. ELECTRICAL CHARACTERISTICS
There are two separate models of the machine for 220 and 110 V mains electricity supplies, which
differ in certain components detailed in paragraph 2.7. :
110 Model 220 and 220 USA Models
Mains voltage 115 VAC 230 VAC
Frequency 50 - 60 Hz 50 - 60 Hz
Consumption ~ 1800 Watt - 8 A ~ 1800 Watt - 8 A
Fuses 5x20 4 A slow-blow 5x20 4 A slow-blow
2.3. AMBIENT SPECIFICATIONS
Temperature Operating from 5° to 35° C
Storage from -20 to 55° C
Humidity Operating from 30% to 80% non-
condensing
Storage from 5% to 85% non-condensing
2.4. CONFORMITY TO REGULATIONS
The machine conforms to the following directives:
•EMC Directive 89/336/EEC.
•LVD Directives 73/23/EEC and 93/68/EEC.
And is therefore certified with the EC Mark.
The US version of the machine, both for 110 and 220 V mains supply, conforms to the UL 1950
standard.

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2.5. WIRING DIAGRAM FOR THE 220 MODEL
2.5.1. CONNECTORS
•CPU board
name type of connector connection
CN1 AMP MATE-N-LOCK 12-pin F. to up-down and inverter interface boards
CN2 AMP MODU II 2-pin M. to emergency button
CN4 AMP MODU II 4-pin M. to cardio receiver
•Power supply
name type of connector connection
CN1 PANDUIT 6-pin to mains electricity supply
CN2 PANDUIT 8-pin to inverter interface board

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•Inverter interface board
name type of connector connection
CN1 AMP MATE-N-LOCK 6-pin F. to inverter
CN2 AMP MATE-N-LOCK 12-pin F. to CPU board
CN4 AMP MOD I 4-pin M to power supply
•Up-down board
name type of connector connection
CN1 AMP MOD II 4-pin M. to photocell
CN2 AMP MATE-N-LOCK 4-pin F. to CPU board
CN3 AMP MATE-N-LOCK 6-pin F. to up-down motor
CN4 AMP MATE-N-LOCK 2-pin F. to mains electricity supply
CN5 Sauro 2-pin to transformer
CN6 Sauro 2-pin to rectifier bridge
2.5.2. WIRING
RX-1: Internal connection cable
CPU – Inverter interface board – Up-down board
CPU/CN1 Signal Color Inverter interf.
board /CN2 Up-down board/CN2
1+12 V Blue 1 1-
2+ 5 V Brown 1 2-
3ground Gray 1 3-
4-12 V White 5-
5not used Violet 12 -
6Tread belt speed
reference (PWM) Red 10 -
7Start Black 8-
8Inverter alarm Orange 9-
9
Status (pulse every ½
degree) Brown 2 -1
10 Up Pink -2
11 Down Blue 2 -3
12 ground Gray 2 -4
BK-7: Heart rate monitor cable
CPU – Cardio receiver
CPU/CN4 Signal Color Receiver
1+5 V Red 1
2Pulse per beat Blue 2
3ground Black 3

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RX-13: Emergency button cable
CPU – Emergency button
CPU/CN2 Signal Color Emergency
button
1NC contact Brown 1
2Reference Blue 2
RX-5: Inverter cable
Inverter interface board – Inverter – Motor thermal cutout
Inverter interf.
board / CN1 Signal Color Inverter Motor thermal cutout
1Reference White PV24 -
-Thermal cutout reference Red PV24 1
-NC thermal cutout Red 1 2
2Start Gray FW -
3NC Alarm Violet AL1 -
4Alarm reference Red AL0 -
5Inverter control
(0-10 Vdc) Brown 0-
6Inverter control
reference Black L-
RX-14: Belt motor cable
Inverter – Belt motor
Inverter Signal Color Belt motor
UPhase U Blue U
VPhase V Black V
WPhase W Brown W
PE ground Yellow-Green Casing
RX-6: Up-down motor cable
Up-down board – Up-down motor – Limit Switches
Up-down
board / CN3 Signal Color Up-down motor Upper LS Lower LS
1Motor power supply Brown 1- -
2Motor ground Blue 2- -
3NO upper limit White -3-
4NC lower limit switch Violet - - 2
6Limit switch ground Black -1 1

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RX-11: Up-down motor power supply cable
Up-down board – Rectifier bridge
Up-down board Signal Color Rectifier bridge
CN6
148 Vac Red +
2Ground Black −
RX-12: Photocell cable
Up-down board – Photocell
Up-down
board / CN1 Signal Color Photocell
1+ 5 Vdc Red 1
2Clock Orange 2
3Direction Blue 3
4ground Black 4
RX-8: Low voltage power supply cable
Power supply – Inverter interface board
Power supply/
CN2 Signal Color Inverter interf. board / CN4
1+ 5 V Yellow 4
2-4-5 Ground Black 3
3+ 12 V Red 2
6- 12 V Blue 1
The high voltage power supply cables and the ground connections are not described here, in that
they can be easily determined from the wiring diagram above.

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2.6. WIRING DIAGRAM FOR THE 220 USA MODEL
The differences between the 220 USA Model and the 220 Model are:
•power supply cable;
•high voltage wiring;
•use of separate filters for the inverter and the power supply - up-down board;
•presence of an additional emergency device called a "Safety Switch" in series with the standard
emergency button. This device consists of a reed relay and a magnet, connected to a cable which
clips onto the user running on the machine. If the user moves away from the display, the cable is
pulled taut and eventually detaches the magnet when the distance becomes excessive. The
absence of the magnet causes the reed relay to commutate from closed to open, generating the
emergency signal. The safety switch requires cable RX-13 to be modified as follows:

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RX-13 USA: Emergency cable
CPU – Emergency button – Safety switch reed relay
CPU/CN2 Signal Color Emergency
button Safety
reed relay
1NC contact Brown 1-
-NC contact Blue 2 1
2Reference Orange -2
OBSERVE: An upgrade kit is available (code 0WK247) for installing the safety switch
on European machines.
The other cables are unchanged. Therefore, for their description, refer to the details provided for the
220 Model.

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2.7. WIRING DIAGRAM FOR THE 110 MODEL
The differences between the 110 Model and the 220 Model are:
•the automatic circuit breaker is 20 A - class D instead of 10 A - class C;
•autotransformer 110 - 220;
•mains lead with different cable section and plug;
•presence, as on the 220 USA Model, of the safety switch.
As regards the wiring, the safety switch uses cable RX-13 USA, while the other cables remain
unvaried. Therefore, for their description, refer to the details provided for the 220 and 220 USA
Models.

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3. PRINCIPLES OF OPERATION
3.1. BLOCK DIAGRAM
The machine block diagram is shown in the figure below:
(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.
(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

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(produced by high voltage lines, radio transmitters, monitors, motors, etc.) within its reception
area, the receiver becomes saturated and stops receiving any signal. If there are 2 transmitters
within its area of reception, it will receive signals from both, and may produce an error or
irregular reading.
(3) CPU BOARD
This is the heart of the machine, which controls all the machine functions by executing the
program stored in EPROM. It receives information from the user (age, weight, etc.) during
set-up of the training session, from the cardio receiver (user’s heart rate), from the inverter
interface board and from the up-down interface board. It controls the speed selected with the
“+” “−” keys and the elevation selected with the “↑” “↓” keys or according to the chosen
training program. It receives the error signal from the inverter interface board and the status
signal from the up-down interface board
(4) INVERTER INTERFACE BOARD
Receives from the display a PWM signal proportional to the selected speed, and converts it
into a continuous voltage for controlling the inverter. Receives the error signal generated by
the inverter in the event of problems and transmits it to the display. Receives the low voltages
output by the power supply and passes them to the display. There are 2 LEDs on the board:
DL1 illuminates when the tread belt is moving, while DL2 illuminates when the inverter does
not detect any error conditions and therefore the alarm signal is inactive.
(5) UP-DOWN BOARD
Receives from the display the enable signal for elevation motion and converts it into a control
for the up-down motor. Generates its power supply and the DC power supply for the motor by
means of 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. Checks the lower and upper travel limits
by means of 2 limit switches. The board includes 2 LEDs associated to the limit switches,
which are normally illuminated: DL1 comes off when the upper limit switch is tripped, while
DL3 comes off if the lower limit switch is tripped.
(6) INVERTER
This is the device which supplies the three-phase belt motor. It receives a DC control voltage
from the inverter interface board. Variations in this voltage cause corresponding variations in
the operating frequency of the inverter/motor, and hence change the speed of the tread belt. It
handles motor drive errors and, in the event of an error, shuts down the power supply to the
motor and sends an alarm signal through the interface board to the display. The event which
caused the error is memorized as an error code.
(7) PHOTOCELL
This is the device which provides feedback on the motion of the up-down motor. It transmits
one pulse for each slot detected on the encoder which is fixed to the gearmotor, and a signal
indicating the direction of movement. The up-down board, receiving the pulses, sends the
status signal to the display which stops the motor when the number of pulses received
coincides with the desired elevation.