WAVE EXCITE CLASS & TREND User manual

SERVICE &MAINTENANCE MANUAL
REV.2.0

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 Wave Excite™ trademark is property of Technogym S.p.A.

CARDIO WAVE EXCITE Class & Trend: Service & maintenance manual- rev.2.0
Pagina 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
2. TECHNICAL SPECIFICATIONS ........................................................................................................................2.1
2.1. PRODUCT CODES................................................................................................................................................. 2.1
2.2. COLOUR OPTIONS ............................................................................................................................................... 2.2
2.3. PRODUCT CHARACTERISTICS .............................................................................................................................. 2.3
2.4. MECHANICAL CHARACTERISTICS ....................................................................................................................... 2.4
2.5. AMBIENT SPECIFICATIONS .................................................................................................................................. 2.5
2.6. CONFORMITY TO REGULATIONS.......................................................................................................................... 2.5
2.7. WIRING DIAGRAMS............................................................................................................................................. 2.6
2.7.1. 500 model (ARM Board)...................................................................................................................2.6
2.7.1.1. Powered version (500)...................................................................................................................................................... 2.6
2.7.1.2. Self-Powered version (500SP).......................................................................................................................................... 2.7
2.7.2. 700 model (ARM board)...................................................................................................................2.8
2.7.2.1. Powered version (700)...................................................................................................................................................... 2.8
2.7.2.2. Self-Powered version (700SP).......................................................................................................................................... 2.9
2.7.3. 700 Wellness TV model – Digital TV..............................................................................................2.10
2.7.3.1. Powered version (700WTV).......................................................................................................................................... 2.10
2.7.3.2. 700 and 900 models ATSC Digital Tuner ...................................................................................................................... 2.11
2.7.3.3. 700 and 900 models ISDB-T Digital Tuner ................................................................................................................... 2.11
2.8. WIRING 2.12
2.8.1. CBQ cables.....................................................................................................................................2.12
2.8.2. CU cables .......................................................................................................................................2.13
2.8.3. ELT cable........................................................................................................................................2.19
3. PRINCIPLES OF OPERATION............................................................................................................................3.1
3.1. BLOCK DIAGRAM................................................................................................................................................ 3.1
3.1.1. LED ARM Display boards (500 and 500SP)....................................................................................3.2
3.1.2. Led Arm Display Boards (700 and 700SP)......................................................................................3.3
3.1.3. Wellness TV Display boards –Digital TV (700WTV) .......................................................................3.4
3.1.3.1. CPU board......................................................................................................................................................................... 3.4
3.1.3.2. Digital TV board ............................................................................................................................................................... 3.4
3.1.3.3. LCD Inverter..................................................................................................................................................................... 3.5
3.1.3.4. Touch screen interface board............................................................................................................................................ 3.5
3.1.3.5. AUX input board .............................................................................................................................................................. 3.5
3.1.3.6. iPod docking station ......................................................................................................................................................... 3.5
3.1.3.7. Headphone jack................................................................................................................................................................. 3.5
3.1.4. CSafe board......................................................................................................................................3.5
3.1.5. Dual TGS reader ..............................................................................................................................3.6
3.1.6. Cardio receiver.................................................................................................................................3.6
3.1.7. Brake board......................................................................................................................................3.6
3.1.8. Brake.................................................................................................................................................3.7
3.1.9. Speed sensor.....................................................................................................................................3.7
3.1.10. NTC...................................................................................................................................................3.7
3.1.11. Power entry module..........................................................................................................................3.7
3.1.12. Alternator .........................................................................................................................................3.8
3.1.13. Battery ..............................................................................................................................................3.8
3.1.14. External power supply input.............................................................................................................3.8
3.2. BRAKE CONTROL ................................................................................................................................................ 3.9
3.2.1. Mechanics.........................................................................................................................................3.9
3.2.2. Controls............................................................................................................................................3.9
3.2.3. The signals involved .......................................................................................................................3.11

CARDIO WAVE EXCITE Class & Trend: Service & maintenance manual- rev.2.0
Pagina 1.2
4. ACCESSORIES.......................................................................................................................................................4.1
4.1. CARDIO THEATER CONNECTION.......................................................................................................................... 4.1
4.2. PC LINK FOR PROGRAMMING .............................................................................................................................. 4.2
4.3. CABLE FOR EXCHANGING TV CHANNEL TUNING DATA BETWEEN TWO MACHINES.............................................. 4.3
4.4. MONITOR PLUG FOR CSAFE PORT ....................................................................................................................... 4.4
4.5. WELLNESS TV UPGRADE KIT.............................................................................................................................. 4.5
5. INSTALLATION INSTRUCTIONS......................................................................................................................5.1
5.1. SPECIFICATIONS AND REQUIREMENTS ................................................................................................................ 5.1
5.2. MOVING THE MACHINE....................................................................................................................................... 5.2
5.3. RECOMMENDED ANTENNA SIGNAL REQUIREMENT.............................................................................................. 5.3
5.3.1. DIGITAL SIGNAL ............................................................................................................................5.3
5.3.2. ANALOGUE SIGNAL.......................................................................................................................5.4
5.4. INSTALLATION.................................................................................................................................................... 5.5
5.5. FIRST POWER-ON ................................................................................................................................................ 5.5
6. TROUBLESHOOTING..........................................................................................................................................6.1
6.1. TROUBLESHOOTING SERVICE MENU:ACTIVE WELLNESS TV MODELS ............................................................... 6.2
6.1.1. I2C Device Test ................................................................................................................................6.3
6.1.2. CSafe COM test................................................................................................................................6.3
6.1.3. Low Kit COM Test............................................................................................................................6.3
6.1.4. TGS COM Test..................................................................................................................................6.4
6.1.5. DVT Board TEST..............................................................................................................................6.4
6.2. SERVICE TROUBLESHOOTING MENU:MODELLI LED ........................................................................................... 6.5
6.2.1. Automatic Test..................................................................................................................................6.6
6.2.1.1. I2C Devices Test............................................................................................................................................................... 6.6
6.2.1.2. LED Test ........................................................................................................................................................................... 6.7
6.2.1.3. Serial Ports Test ................................................................................................................................................................ 6.7
6.2.2. Manual Test......................................................................................................................................6.7
6.2.2.1. Man. Keyboard Test.......................................................................................................................................................... 6.7
6.3. THE DISPLAY FAILS TO ILLUMINATE ................................................................................................................... 6.8
6.3.1. 500 and 700 Models .........................................................................................................................6.8
6.3.2. 500SP and 700SP Models ..............................................................................................................6.10
6.3.3. 700WTV Wellness TV models.........................................................................................................6.12
6.4. THE TOUCH SCREEN DOES NOT WORK /IT’S NOT CALIBRATED .......................................................................... 6.16
6.5. NO AUDIO SOUND ............................................................................................................................................. 6.17
6.6. NO TV PICTURE................................................................................................................................................ 6.18
6.7. THE RADIO DOES NOT PLAY .............................................................................................................................. 6.21
6.8. THE IPOD DOES NOT WORK ............................................................................................................................... 6.23
6.9. “THE EQUIPMENT IS BLOCKED (COM)” MESSAGE ON DISPLAY .............................................................. 6.26
6.10.THERE IS NO RESISTANCE ................................................................................................................................. 6.27
6.11.THE RESISTANCE IS INCORRECT ........................................................................................................................ 6.29
6.12.THE SPEED SIGNAL IS INCORRECT ..................................................................................................................... 6.31
6.13.THE MACHINE DOES NOT READ THE TGS.......................................................................................................... 6.33
6.14.THERE IS NO HEART RATE SIGNAL..................................................................................................................... 6.35
6.14.1. SALUTRON telemetric receiver......................................................................................................6.35
6.14.2. Hand Sensor ...................................................................................................................................6.37
6.15.THE TELEMETRIC HEART RATE SIGNAL IS INCORRECT....................................................................................... 6.39
7. DISASSEMBLY OF COMPONENTS...................................................................................................................7.1
7.1. DISPLAY DISASSEMBLY ...................................................................................................................................... 7.1
7.1.1. LED Version 500 and 500SP............................................................................................................7.1
7.1.2. LED Version 700 and 700SP............................................................................................................7.2
7.1.3. 700WTV version (Wellness TV)........................................................................................................7.3
7.2. DISPLAY BOARDS DISASSEMBLY ........................................................................................................................ 7.4
7.2.1. 500 and 500SP Version ....................................................................................................................7.4
7.2.2. 700 and 700SP LED Version............................................................................................................7.5
7.2.3. 700WTV version (Wellness TV)........................................................................................................7.6
7.3. 500AND 700 KEYBOARDS AND TOUCH SCREEN DISASSEMBLY.......................................................................... 7.10

CARDIO WAVE EXCITE Class & Trend: Service & maintenance manual- rev.2.0
Pagina 1.3
7.3.1. 500 and 500SP models ...................................................................................................................7.10
7.3.2. 700 and 700SP LED Version..........................................................................................................7.11
7.3.3. 700WTV version (Wellness TV)......................................................................................................7.12
7.4. CARDIO/HAND SENSOR RECEIVER DISASSEMBLY ............................................................................................. 7.13
7.5. FIXED HANDGRIPS DISASSEMBLY...................................................................................................................... 7.15
7.6. DISASSEMBLING THE SENSOR ........................................................................................................................... 7.16
7.7. DISASSEMBLING THE GUARDS .......................................................................................................................... 7.17
7.8. DISASSEMBLING THE UPPER COLUMN ............................................................................................................... 7.19
7.9. BRAKE BOX DISASSEMBLY ............................................................................................................................... 7.20
7.10.DISASSEMBLING THE FOOTBOARDS .................................................................................................................. 7.21
7.11.FOOTBOARD LEVER BELT DISASSEMBLY........................................................................................................... 7.22
7.12.FOOTBOARDS LEVER DISASSEMBLY.................................................................................................................. 7.24
7.13.FOOTBOARDS LEVER DISASSEMBLY (LAST VERSION) .................................................................................... 7.27
7.14.DISASSEMBLING THE LEVERS TENSIONING SPRING ........................................................................................... 7.30
7.15.DISASSEMBLING THE BRAKE WINDING.............................................................................................................. 7.32
7.16.DISASSEMBLING THE SECONDARY SHAFT ASSEMBLY ....................................................................................... 7.33
7.16.1. 700 Powered and 700WTV models.................................................................................................7.34
7.16.2. 700SP Self-Powered models...........................................................................................................7.35
7.17.DISASSEMBLING THE PRIMARY SHAFT ASSEMBLY ............................................................................................ 7.37
7.18.DISASSEMBLING THE CONNECTION BELT BETWEEN PRIMARY AN D SECONDARY SHAFT.................................... 7.39
7.19.SPEED SENSOR DISASSEMBLY ........................................................................................................................... 7.40
7.20.DISASSEMBLING THE POWER ENTRY MODULE................................................................................................... 7.41
7.21.DISASSEMBLING THE PLATFORMS..................................................................................................................... 7.42
7.22.SMONTAGGIO BATTERIA................................................................................................................................... 7.43
8. ADJUSTMENTS......................................................................................................................................................8.1
8.1. BELT TENSION .................................................................................................................................................... 8.1
8.2. SPEED SENSOR POSITION..................................................................................................................................... 8.2
8.3. BRAKE WINDING POSITION ................................................................................................................................. 8.3
8.4. ALIGN THE BELT CONNECTING THE PRIMARY AND SECONDARY SHAFTS ............................................................. 8.4
8.5. THE DISTANCE BETWEEN THE PEDALS ................................................................................................................ 8.5
8.6. TIE ROD LENGTH................................................................................................................................................. 8.6
8.7. THE MACHINE IS NOT FLAT ................................................................................................................................. 8.8
9. MACHINE CONFIGURATION............................................................................................................................9.1
9.1. USER MENU CONFIGURATION FOR 500 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. Resetting parameters to default values.............................................................................................9.6
9.1.15. Format P&P key...............................................................................................................................9.6
9.1.16. SN .....................................................................................................................................................9.6
9.2. USER MENU CONFIGURATION FOR 700 MODELS.................................................................................................. 9.7
9.2.1. Language..........................................................................................................................................9.8
9.2.2. Distance............................................................................................................................................9.8
9.2.3. Maximum excercise time...................................................................................................................9.8
9.2.4. Pause time ........................................................................................................................................9.9
9.2.5. Cooldown time..................................................................................................................................9.9
9.2.6. Enable TGS.......................................................................................................................................9.9

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Pagina 1.4
9.2.7. Enable keyboard.............................................................................................................................9.10
9.2.8. Modifiable target heart rate ...........................................................................................................9.10
9.2.9. Enable custom messages ................................................................................................................9.10
9.2.10. Edit custom messages.....................................................................................................................9.11
9.2.11. Change messagges languages........................................................................................................9.11
9.2.12. Enable multi-language mode..........................................................................................................9.11
9.2.13. Resetting parameters to default values...........................................................................................9.11
9.2.14. Format P&P...................................................................................................................................9.12
9.2.15. SN ...................................................................................................................................................9.12
9.3. USER MENU CONFIGURATION FOR 700 WTV MODELS ...................................................................................... 9.13
9.3.1. SN ...................................................................................................................................................9.14
9.3.2. Language........................................................................................................................................9.14
9.3.3. Measure..........................................................................................................................................9.14
9.3.4. Enable TGS.....................................................................................................................................9.15
9.3.5. Keys ................................................................................................................................................9.15
9.3.6. Maximum excercise time.................................................................................................................9.15
9.3.7. Pause time ......................................................................................................................................9.15
9.3.8. Cooldown time................................................................................................................................9.16
9.3.9. Top exercise programs for you shortcut.........................................................................................9.16
9.3.10. Modifiable target heart rate ...........................................................................................................9.17
9.3.11. Standby...........................................................................................................................................9.17
9.3.12. Language........................................................................................................................................9.17
9.3.13. Default config.................................................................................................................................9.17
9.3.14. Format P&P...................................................................................................................................9.17
9.3.15. Screen saver minutes......................................................................................................................9.18
9.3.16. Display in the workout....................................................................................................................9.18
9.3.17. Radio...............................................................................................................................................9.19
9.3.18. iPod connection option...................................................................................................................9.19
9.3.19. Standby channel..............................................................................................................................9.19
9.3.20. Other language...............................................................................................................................9.19
9.4. SERVICE MENU CONFIGURATION FOR 500 AND 700 LED MODELS .................................................................... 9.20
9.4.1. Low kit parameter...........................................................................................................................9.22
9.4.1.1. Read from low kit ........................................................................................................................................................... 9.22
9.4.1.2. Write to low kit ............................................................................................................................................................... 9.22
9.4.1.3. Default Setting ................................................................................................................................................................ 9.23
9.4.1.4. Table of configuration parameters.................................................................................................................................. 9.23
9.4.2. Operating data................................................................................................................................9.24
9.4.2.1. Read from low kit ........................................................................................................................................................... 9.24
9.4.2.2. Write to low kit ............................................................................................................................................................... 9.25
9.4.2.3. Machine usage data......................................................................................................................................................... 9.25
9.4.3. Errors log .......................................................................................................................................9.26
9.4.3.1. Read from low kit ........................................................................................................................................................... 9.26
9.4.3.2. Reset Errors..................................................................................................................................................................... 9.26
9.4.3.3. COM.Fault ...................................................................................................................................................................... 9.27
9.4.3.4. View Errors ..................................................................................................................................................................... 9.27
9.4.4. Standard settings ............................................................................................................................9.28
9.4.5. Low kit menu...................................................................................................................................9.28
9.4.5.1. Low kit version ............................................................................................................................................................... 9.28
9.4.5.2. Low Kit fault code .......................................................................................................................................................... 9.29
9.4.6. High kit version ..............................................................................................................................9.29
9.4.7. BOOT version.................................................................................................................................9.29
9.4.8. Key Reader Version........................................................................................................................9.29
9.5. SERVICE MENU CONFIGURATION 700 WTV MODELS ........................................................................................ 9.30
9.5.1. Low kit parameter...........................................................................................................................9.31
9.5.1.1. Read from low kit ........................................................................................................................................................... 9.31
9.5.1.2. Write to low kit ............................................................................................................................................................... 9.31
9.5.1.3. Default Setting ................................................................................................................................................................ 9.31
9.5.1.4. Table of configuration parameters.................................................................................................................................. 9.32
9.5.2. Operating data................................................................................................................................9.33
9.5.2.1. Read from low kit ........................................................................................................................................................... 9.33
9.5.2.2. Write to low kit ............................................................................................................................................................... 9.33
9.5.3. Errors log .......................................................................................................................................9.33
9.5.3.1. Read from low kit ........................................................................................................................................................... 9.33

CARDIO WAVE EXCITE Class & Trend: Service & maintenance manual- rev.2.0
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9.5.3.2. Reset Errors..................................................................................................................................................................... 9.33
9.5.3.3. COM.Fault ...................................................................................................................................................................... 9.34
9.5.4. SW version devices .........................................................................................................................9.35
9.5.5. Standard settings ............................................................................................................................9.35
9.5.6. TV Standard....................................................................................................................................9.36
9.6. TV MENU CONFIGURATION FOR 700WTV MODELS .......................................................................................... 9.37
9.6.1. Tuning TV channels........................................................................................................................9.37
9.6.2. Wellness TV adjustments ................................................................................................................9.41
9.7. RADIO MENU CONFIGURATION FOR 700WTV MODELS ..................................................................................... 9.42
9.7.1. Tuning radio channels....................................................................................................................9.42
9.8. TRANSFERRING THE TUNING DATA ................................................................................................................... 9.45
9.8.1. Using the TGS key ..........................................................................................................................9.45
9.8.2. Connecting two machines using a CSafe connection (Method recommended)..............................9.46
9.9. TOUCH SCREEN CALIBRATION .......................................................................................................................... 9.47
10.FUNCTIONAL TEST MD MODELS..................................................................................................................10.1
10.1.ELECTRICAL SAFETY TEST ................................................................................................................................10.1
10.2.MECHANICAL SAFETY TESTS ............................................................................................................................ 10.3
10.2.1. Checking the assembly of the transmission and levers systems......................................................10.3
10.2.2. Checking the assembly of the guards..............................................................................................10.3
10.3.START-UP CHECK.............................................................................................................................................. 10.3
10.4.LIST OF CRITICAL SPARE PARTS ........................................................................................................................ 10.4
11.SCHEDULED MAINTENANCE.........................................................................................................................11.1
11.1.DAILY MAINTENANCE OPERATIONS .................................................................................................................. 11.1
11.1.1. Setting up the operation..................................................................................................................11.1
11.1.2. External cleaning operations..........................................................................................................11.1
11.2.MONTHLY MAINTENANCE OPERATIONS ............................................................................................................ 11.2
11.2.1. Cleaning operations .......................................................................................................................11.2
11.2.2. Checking the state of wear of the pedal lever belt..........................................................................11.2
11.2.3. Checking the amount of play on the ball joints ..............................................................................11.2
11.2.4. Checking the operation of the cardiotester receiver.......................................................................11.2
11.2.5. Checking the operation of the hand sensor receiver ......................................................................11.2
11.3.TWICE-YEARLY MAINTENANCE OPERATIONS .................................................................................................... 11.3
11.3.1. Carrying out the monthly maintenance procedure.........................................................................11.3
11.3.2. Setting up the operation..................................................................................................................11.3
11.3.3. Checking the working conditions....................................................................................................11.3
11.3.4. Checking the wear of rubber parts.................................................................................................11.3
11.3.5. Checking the belts...........................................................................................................................11.3
11.3.6. Checking the play of the lever and pedal group.............................................................................11.3
11.3.7. Checking the display.......................................................................................................................11.3
11.3.8. Checking the wiring and connections.............................................................................................11.4
12.APPENDIX.............................................................................................................................................................12.1
12.1.UPDATING THE SW .......................................................................................................................................... 12.1
12.2.REQUIRED TOOLS ............................................................................................................................................. 12.2

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