Technogym Step 500i SP, Step 500i, Step 700i, Step 700i S, Step 700i E Service Maintenance Manual

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SERVICE & MAINTENANCE MANUAL

REV. 1.4

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The information contained in this manual is intended for QUALIFIED TECHNICIANS who have completed a specific TECHNOGYM training course and are authorized to perform machine start-

up and adjustment procedures as well as extraordinary maintenance or repairs which require a

thorough knowledge of the machine, its operation, its safety devices and working procedures.

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

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Summary

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. AVAILABLE VERSIONS ........................................................................................................................................2.2

2.3. MECHANICAL CHARACTERISTICS ....................................................................................................................... 2.3

2.4. ELECTRICAL CHARACTERISTICS ......................................................................................................................... 2.3

2.5. CONFORMITY TO REGULATIONS.......................................................................................................................... 2.4

2.6. AMBIENT SPECIFICATIONS ..................................................................................................................................2.4

2.7. WIRING DIAGRAMS............................................................................................................................................. 2.5

2.7.1. 500i model........................................................................................................................................2.5

2.7.1.1. Powered version................................................................................................................................................................ 2.5

2.7.1.2. Cordless version................................................................................................................................................................ 2.6

2.7.2. 500i model – ARM board..................................................................................................................2.7

2.7.2.1. Powered version................................................................................................................................................................ 2.7

2.7.2.2. Cordless version................................................................................................................................................................ 2.8

2.7.3. 700i model........................................................................................................................................2.9

2.7.3.1. Powered version................................................................................................................................................................ 2.9

2.7.3.2. Cordless version.............................................................................................................................................................. 2.10

2.7.4. 700i model – ARM board................................................................................................................2.11

2.7.4.1. Powered version.............................................................................................................................................................. 2.11

2.7.4.2. Cordless version.............................................................................................................................................................. 2.12

2.7.5. 700iE WTV model...........................................................................................................................2.13

2.7.5.1. Wellness TV Touch screen NCB version....................................................................................................................... 2.13

2.7.5.2. Wellness TV Touch screen UB version ......................................................................................................................... 2.14

2.8. WIRING ............................................................................................................................................................ 2.15

3. PRINCIPLES OF OPERATION............................................................................................................................ 3.1

3.1. BLOCK DIAGRAM................................................................................................................................................ 3.1

3.1.1. Display boards..................................................................................................................................3.2

3.1.1.1. 500i and 500i SP versions................................................................................................................................................. 3.2

3.1.1.2. 500i ARM and 500i SP ARM models .............................................................................................................................. 3.3

3.1.1.3. 700i and 700i SP versions................................................................................................................................................. 3.3

3.1.1.4. 700i ARM and 700i SP ARM models .............................................................................................................................. 3.4

3.1.1.5. 700i E Wellness TV Touch screen ................................................................................................................................... 3.5

3.1.1.6. 700iE Wellness TV Touch screen UB model................................................................................................................... 3.6

3.1.2. CSafe Board......................................................................................................................................3.7

3.1.3. TGS reader .......................................................................................................................................3.8

3.1.4. Hand Sensor Board ..........................................................................................................................3.8

3.1.5. Cardio receiver.................................................................................................................................3.8

3.1.6. Connectors panel..............................................................................................................................3.8

3.1.7. Brake board...................................................................................................................................... 3.8

3.1.8. Brake.................................................................................................................................................3.9

3.1.9. Speed sensor.....................................................................................................................................3.9

3.1.10. NTC...................................................................................................................................................3.9

3.1.11. Power entry module.......................................................................................................................... 3.9

3.1.12. Alternator .......................................................................................................................................3.10

3.1.13. Battery ............................................................................................................................................3.10

3.1.14. External power supply input...........................................................................................................3.10

3.2. BRAKE CONTROL .............................................................................................................................................. 3.11

3.2.1. Mechanics.......................................................................................................................................3.11

3.2.2. Controls..........................................................................................................................................3.11

3.2.3. The signals involved .......................................................................................................................3.12

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4. ACCESSORIES ....................................................................................................................................................... 4.1

4.1. CARDIO THEATER CONNECTION.......................................................................................................................... 4.1

4.2. PC LINK FOR PROGRAMMING .............................................................................................................................. 4.1

4.3. CABLE FOR EXCHANGING TV CHANNEL TUNING DATA BETWEEN TWO MACHINES.............................................. 4.2

4.4. MONITOR PLUG FOR CSAFE PORT ....................................................................................................................... 4.3

4.5. WELLNESS TV UPGRADE KIT.............................................................................................................................. 4.4

4.5.1. Installation procedure ...................................................................................................................... 4.5

5. INSTALLATION INSTRUCTIONS...................................................................................................................... 5.1

5.1. SPECIFICATIONS AND REQUIREMENTS ................................................................................................................ 5.1

5.2. INSTALLATION REQUIREMENTS AND SPECIFICATIONS FOR WELLNESS TV MACHINES......................................... 5.1

5.3. INSTALLATION.................................................................................................................................................... 5.2

5.4. FIRST POWER-ON ................................................................................................................................................5.2

6. TROUBLESHOOTING .......................................................................................................................................... 6.1

6.1. SERVICE TROUBLESHOOTING MENU.................................................................................................................... 6.2

6.1.1. Automatic Test..................................................................................................................................6.3

6.1.1.1. I2C Devices Test............................................................................................................................................................... 6.3

6.1.1.2. LED Test (not on 700iE models)...................................................................................................................................... 6.3

6.1.1.3. Serial Ports Test ................................................................................................................................................................ 6.4

6.1.2. Manual Test...................................................................................................................................... 6.4

6.1.2.1. Man. Keyboard Test.......................................................................................................................................................... 6.4

6.2. THE DISPLAY FAILS TO ILLUMINATE ................................................................................................................... 6.5

6.2.1. 500i and 700i Models.......................................................................................................................6.5

6.2.2. 500i SP and 700i SP Models ............................................................................................................ 6.7

6.2.3. 700i E Model with Wellness TV........................................................................................................6.9

6.3. NO AUDIO SOUND .............................................................................................................................................6.13

6.4. NO TV PICTURE................................................................................................................................................ 6.14

6.5. THE RADIO DOES NOT PLAY ..............................................................................................................................6.16

6.6. “THE EQUIPMENT IS BLOCKED” MESSAGE ON DISPLAY ........................................................................... 6.18

6.7. ERROR DETECTED BY BRAKE BOARD................................................................................................................ 6.19

6.7.1. Brake board error 1........................................................................................................................6.19

6.7.2. Brake board error 8........................................................................................................................6.19

6.8. THERE IS NO RESISTANCE ................................................................................................................................. 6.20

6.9. THE RESISTANCE IS INCORRECT ........................................................................................................................6.21

6.10. THE SPEED SIGNAL IS INCORRECT .....................................................................................................................6.22

6.11. THE MACHINE DOES NOT READ THE TGS.......................................................................................................... 6.24

6.12. THERE IS NO HEART SIGNAL.............................................................................................................................. 6.26

6.12.1. HFU telemetric receiver................................................................................................................. 6.26

6.12.2. Hand sensor.................................................................................................................................... 6.27

6.13. THE TELEMETRIC HEART RATE SIGNAL IS INCORRECT....................................................................................... 6.29

7. DISASSEMBLY OF COMPONENTS ................................................................................................................... 7.1

7.1. DISASSEMBLING THE DISPLAY ............................................................................................................................ 7.1

7.1.1. 700i and 700i SP LED version.........................................................................................................7.1

7.1.2. 700i E Wellness TV Touch screen Version....................................................................................... 7.2

7.1.3. 500i and 500i SP version..................................................................................................................7.3

7.2. DISASSEMBLING THE CIRCUIT BOARDS FROM THE DISPLAY ................................................................................ 7.4

7.2.1. 700i and 700i SP LED version.........................................................................................................7.4

7.2.2. 700i E Wellness TV Touch screen version........................................................................................7.6

7.2.2.1. NCB models...................................................................................................................................................................... 7.6

7.2.2.2. UB models......................................................................................................................................................................... 7.9

7.2.3. 500i and 500i SP version................................................................................................................7.13

7.3. DISASSEMBLING THE KEYBOARD...................................................................................................................... 7.14

7.3.1. 700i and 700i SP LED version.......................................................................................................7.14

7.3.2. 700iE Touch screen Wellness TV version.......................................................................................7.15

7.3.3. 500i and 500i SP version................................................................................................................7.17

7.4. DISASSEMBLING THE CARDIO RECEIVER ........................................................................................................... 7.18

7.5. DISASSEMBLING THE HANDLEBAR.................................................................................................................... 7.21

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7.6. DISASSEMBLING THE SENSOR ........................................................................................................................... 7.23

7.7. DISASSEMBLING THE GUARDS .......................................................................................................................... 7.24

7.8. DISASSEMBLING THE ELECTRICAL BOX............................................................................................................. 7.26

7.9. DISASSEMBLING THE PEDALS ........................................................................................................................... 7.27

7.10. DISASSEMBLING THE PEDAL LEVERS ................................................................................................................ 7.28

7.11. DISASSEMBLING THE BRAKE WINDING.............................................................................................................. 7.30

7.12. DISASSEMBLING THE FLYWHEEL ASSEMBLY..................................................................................................... 7.31

7.13. DISASSEMBLING THE BELT ............................................................................................................................... 7.35

7.14. DISASSEMBLING THE PRIMARY SHAFT ASSEMBLY ............................................................................................ 7.36

7.15. DISASSEMBLING THE SECONDARY SHAFT ASSEMBLY ....................................................................................... 7.38

7.16. DISASSEMBLING THE SPEED SENSOR................................................................................................................. 7.40

7.17. DISASSEMBLING THE POWER ENTRY MODULE AND THE WHEELS ...................................................................... 7.41

7.18. DISASSEMBLING THE PLATFORMS..................................................................................................................... 7.42

7.19. DISASSEMBLING THE BATTERY......................................................................................................................... 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 CHAIN CONNECTING THE PRIMARY AND SECONDARY SHAFTS ........................................................... 8.4

8.5. TENSION THE CHAIN CONNECTING THE PRIMARY AND SECONDARY SHAFTS ....................................................... 8.5

8.6. ALIGN THE PULLEY AND BELT ............................................................................................................................ 8.6

8.7. LEVELLING ......................................................................................................................................................... 8.7

9. MACHINE CONFIGURATION ............................................................................................................................ 9.1

9.1. USER MENU CONFIGURATION FOR 700 MODELS .................................................................................................. 9.1

9.1.1. Language..........................................................................................................................................9.1

9.1.2. Distance............................................................................................................................................9.2

9.1.3. Priority setting..................................................................................................................................9.2

9.1.4. Maximum excercise time...................................................................................................................9.2

9.1.5. Pause time ........................................................................................................................................9.3

9.1.6. Enable TGS.......................................................................................................................................9.3

9.1.7. Enable keyboard...............................................................................................................................9.3

9.1.8. Modifiable target heart rate ............................................................................................................. 9.3

9.1.9. Enable custom messages ..................................................................................................................9.4

9.1.10. Edit custom messages.......................................................................................................................9.4

9.1.11. Change messagges languages..........................................................................................................9.4

9.1.12. Enable multi-language mode............................................................................................................ 9.5

9.1.13. Resetting parameters to default values.............................................................................................9.5

9.1.14. Format P&P.....................................................................................................................................9.5

9.1.15. SN .....................................................................................................................................................9.5

9.1.16. Lubricated.........................................................................................................................................9.6

9.1.17. Standby.............................................................................................................................................9.6

9.2. USER MENU CONFIGURATION FOR 500 MODELS .................................................................................................. 9.7

9.2.1. Language..........................................................................................................................................9.7

9.2.2. Change message language ............................................................................................................... 9.8

9.2.3. Units of measurement.......................................................................................................................9.8

9.2.4. Maximum exercise time .................................................................................................................... 9.8

9.2.5. Pause time ........................................................................................................................................9.8

9.2.6. Default age .......................................................................................................................................9.9

9.2.7. Default weight...................................................................................................................................9.9

9.2.8. Default duration ...............................................................................................................................9.9

9.2.9. Default calories ..............................................................................................................................9.10

9.2.10. Default distance..............................................................................................................................9.10

9.2.11. Modifiable target frequencies......................................................................................................... 9.10

9.2.12. Enable TGS.....................................................................................................................................9.11

9.2.13. Enable keyboard.............................................................................................................................9.11

9.2.14. Enable custom messages ................................................................................................................9.11

9.2.15. Resetting parameters to default values...........................................................................................9.12

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9.2.16. Format P&P key.............................................................................................................................9.12

9.2.17. Lubricated.......................................................................................................................................9.12

9.2.18. SN ...................................................................................................................................................9.12

9.3. SERVICE MENU CONFIGURATION ...................................................................................................................... 9.13

9.3.1. Time and date .................................................................................................................................9.14

9.3.1.1. Hour ................................................................................................................................................................................ 9.15

9.3.1.2. Minutes............................................................................................................................................................................ 9.15

9.3.1.3. Day .................................................................................................................................................................................. 9.15

9.3.1.4. Month .............................................................................................................................................................................. 9.15

9.3.1.5. Year................................................................................................................................................................................. 9.15

9.3.1.6. Set Clock ......................................................................................................................................................................... 9.15

9.3.2. Low kit parameter...........................................................................................................................9.15

9.3.2.1. Read from low kit ........................................................................................................................................................... 9.16

9.3.2.2. Write to low kit ...............................................................................................................................................................9.16

9.3.2.3. Default ravell .................................................................................................................................................................. 9.16

9.3.2.4. Table of configuration parameters.................................................................................................................................. 9.17

9.3.3. Operating data................................................................................................................................9.17

9.3.3.1. Read from low kit ........................................................................................................................................................... 9.18

9.3.3.2. Write to low kit ...............................................................................................................................................................9.18

9.3.3.3. Machine usage data......................................................................................................................................................... 9.18

9.3.4. Errors log .......................................................................................................................................9.18

9.3.4.1. Read from low kit ........................................................................................................................................................... 9.19

9.3.4.2. Reset Errors..................................................................................................................................................................... 9.19

9.3.4.3. COM.Fault ...................................................................................................................................................................... 9.19

9.3.4.4. View Errors ..................................................................................................................................................................... 9.20

9.3.5. Standard settings ............................................................................................................................9.20

9.3.6. Low kit menu...................................................................................................................................9.20

9.3.6.1. Low kit version ............................................................................................................................................................... 9.21

9.3.6.2. Low Kit fault code ..........................................................................................................................................................9.21

9.3.7. High kit version ..............................................................................................................................9.21

9.3.8. BOOT version.................................................................................................................................9.21

9.3.9. Floors climbed between successive lubrications............................................................................ 9.22

9.3.10. Last lubrication...............................................................................................................................9.22

9.3.11. Lubrication number........................................................................................................................9.22

9.3.12. TV Standard (700i E version only)................................................................................................. 9.22

9.3.13. Screen saver....................................................................................................................................9.23

9.3.14. Waiting time....................................................................................................................................9.24

9.4. TV MENU CONFIGURATION FOR 700I E MODELS ............................................................................................... 9.25

9.4.1. Tuning TV channels........................................................................................................................9.25

9.4.2. Wellness TV adjustments ................................................................................................................ 9.27

9.5. RADIO MENU CONFIGURATION FOR 700I E MODELS.......................................................................................... 9.28

9.5.1. Tuning radio channels....................................................................................................................9.28

9.5.1.1. Procedure for manually entering radio channel frequencies .......................................................................................... 9.29

9.5.1.2. Automatic radio channel tuning procedure .................................................................................................................... 9.30

9.6. TRANSFERRING THE TUNING DATA ...................................................................................................................9.31

9.6.1. Using the TGS.................................................................................................................................9.31

9.6.2. Using the connecting cable.............................................................................................................9.31

9.7. TOUCH SCREEN CALIBRATION .......................................................................................................................... 9.32

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. MONTHLY MAINTENANCE OPERATIONS ............................................................................................................ 10.2

10.2.1. Cleaning operations .......................................................................................................................10.2

10.2.2. Lubrication ..................................................................................................................................... 10.2

10.2.3. Checking the state of wear of the pedal chains ..............................................................................10.2

10.2.4. Checking the amount of play on the ball joints ..............................................................................10.2

10.2.5. Checking the operation of the cardiotester receiver.......................................................................10.2

10.2.6. Checking the operation of the hand sensor receiver ...................................................................... 10.2

10.3. TWICE-YEARLY MAINTENANCE OPERATIONS.................................................................................................... 10.3

10.3.1. Carrying out the monthly maintenance procedure.........................................................................10.3

10.3.2. Setting up the operation..................................................................................................................10.3

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10.3.3. Checking the working conditions....................................................................................................10.3

10.3.4. Checking the wear of rubber parts.................................................................................................10.3

10.3.5. Checking the belt............................................................................................................................10.3

10.3.6. Checking the chains........................................................................................................................ 10.3

10.3.7. Checking the wear of the pulleys.................................................................................................... 10.3

10.3.8. Checking the play of the lever and pedal group............................................................................. 10.4

10.3.9. Checking the display.......................................................................................................................10.4

10.3.10. Checking the wiring and connections............................................................................................. 10.4

10.4. LUBRICATION OF THE PEDALS CHAINS .............................................................................................................. 10.5

11. APPENDIX ............................................................................................................................................................. 11.1

11.1. UPDATING THE SW .......................................................................................................................................... 11.1

11.2. REQUIRED TOOLS ............................................................................................................................................. 11.2

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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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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 Newsletters, 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.

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2. TECHNICAL SPECIFICATIONS

2.1. PRODUCT CODES

The machine codes take into account all the possible variants and options available for the products. The machine code, which does not include the Serial Number, consists of 16 alphanumeric characters arranged as follows:

Characters description key to values

1,2,3 Machine type: Step Excite

4 Product version

5 Type of power supply

6 Type of display

8, 9 Color of the frame 10, 11 Color of the paddings 12 Color of the guards

13 Type of TV model

14,15 Language

16 Type of packaging

Device for downloading data used by the Wellness System

For example, the code below:

D43 5 = Step 500i 7 = Step 700i 3 = multi-voltage (110-220) 4 = self-powered L = LED display E = Wellness TV N = not available T = TGS AL = aluminium 00 = none G = grey 0 = none 1 = Pal B/G 2 = Pal I 3 = Pal N 4 = NTSC M 5 = Secam E/L 6 = Secam D/K 7 = NTSC M44 8 = Pal D/K 9 = Secam B/G A = Secam K1 B = Pal M IT = Italian DE = German FR = French US = American English NL = Dutch BR = Portuguese JP = Japanese UK = British English ES = Spanish I = Italy E = standard international S = overseas international 0 = none

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would be interpreted as follows:

D43 7 3 L T AL 00 G 0 UK E

700i model

Step Excite

interfaced to TGS key reader

LED display

mains powered supply with multi-voltage inlet

STEP EXCITE: Service & maintenance manual - rev. 1.4

D4373LTAL00G0UKE

British English language

no TV model

grey guard

no paddings

aluminium frame color

international packing

2.2. AVAILABLE VERSIONS

There machine is available in 5 versions:

• Step 500i: mains operated machine

• Step 500i SP: self-powered machine

• Step 700i: mains operated machine

• Step 700i SP: self-powered machine

• Step 700i E: mains operated machine with Wellness TV display

all of which have the same structure but are differentiated by certain characteristics.

VERSION

Hand sensor Touch sensor CSafe Cardio receiver

Training programs

CARATTERISTICA

Test functions

500I 500I SP 700I - 700I E 700I SP

NO YES

NO YES YES YES HFU HFU

Quick Start

Goal

Quick Start

Goal CPR

6 profiles

CPR

Training zone

Weight Loss

Custom program

Fitness test Fitness test

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2.3. MECHANICAL CHARACTERISTICS

500i – 700i - 700i E 500i SP – 700i SP Width Length Height Weight

VERSION

79 cm – 31.1 in 112 cm – 44.1 in 184 cm – 72.4 in

100 kg - 220 lbs

2.4. ELECTRICAL CHARACTERISTICS

500I 700I – 700I E

Mains voltage

Frequency

Consumption

Fuses

Europe / Asia USA / Canada Europe / Asia USA / Canada Europe / Asia USA / Canada Europe / Asia USA / Canada

VERSION

90 - 260 VAC 90 - 130 VAC

50 - 60 Hz

100 VA

2 x F 3.15 A

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2.5. CONFORMITY TO REGULATIONS

The machine conforms to the following standards:

EMI

Safety

Directives

In addition:

• Electrical isolation class: Class I (mains operated machine), Class II (self powered machine);

• Protection rating: IP20.

Europe USA

EN 55014-1

EN 55014-2 EN 61000-3-2 EN 61000-3-3

EN 60335-1

EN 957-1

EN 957-8 class SA

73/23/CE

89/366/CE

98/37/CE

UL 1647

2.6. AMBIENT SPECIFICATIONS

Temperature

Humidity

Operating from 5° to 35° C Storage from -10° to 70° C Operating from 30% to 80% non-

Storage from 5% to 85% non-condensing

condensing

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2.7. WIRING DIAGRAMS

2.7.1. 500I MODEL

2.7.1.1. Powered version

CSAFE

BOARD

CBQ-13

KEYBOARD

VAC

CBQ-32

TGS

READER

POWER

ENTRY

MODULE

386 BO ARD

DISPL AY BOARD

ELT-16

HFU

RECEIVER

DISPLAY

STP-00

STP-04

STP-03

BRAKE BOARD

Patch Conn.

STP-05

NTC

BRAKE

Patch Conn.

SPEED

SENSOR

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2.7.1.2. Cordless version

STEP EXCITE: Service & maintenance manual - rev. 1.4

CBQ-32

TGS

BOARD

CSAFE

KEYBOARD

BOARD

CBQ-13

386

BOARD

ELT-16

DI SPLAY BOA RD

HFU

RECEIVER

DISPLAY

BATTERY

ALTERNATOR

BATT ERY CHARGER

INPUT

Patch Conn.

STP-01

STP-04 STP-03

BRAKE

BOARD

STP-05

BRAKE

Patch Conn.

NTC

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2.7.2. 500I MODEL – ARM BOARD

2.7.2.1. Powered version

CSAFE

BOARD

CBQ-13

ARM DIS PL AY BOARD

KEYBOARD

ELT-16

HFU

RECEIVER

VAC

CBQ-32

TGS

READER

POWER

ENTRY

MODULE

STP-00

STP-04

STP-03

BRAKE BOARD

DISPLAY

Patch Conn.

STP-05

Patch Conn.

NTC

BRAKE

SPEED

SENSOR

Page 2.7

Page 20

2.7.2.2. Cordless version

STEP EXCITE: Service & maintenance manual - rev. 1.4

CBQ-32

TGS

READER

CSAFE

KEYBOARD

BOARD

CBQ-13

ARM DISP LAY BOARD

ELT-16

HFU

RECEIVER

DISPLAY

BATTERY

ALTERNATOR

BATTERY CHARGER

INPUT

Patch

Conn.

STP-01

STP-04 STP-03

BRAKE

BOARD

STP-05

BRAKE

Patch Conn.

NTC

Page 2.8

Page 21

STEP EXCITE: Service & maintenance manual - rev. 1.4

2.7.3. 700I MODEL

2.7.3.1. Powered version

HFU

RECEIVER

TGS

READER

CSAFE

BOARD

CBQ-13

ELT-16

CBQ-32

386 BOARD

DISP LAY BOARD

KEYBOARD

STP-06 STP-06

DISPLAY

RIGHT

TOUCH

SENSOR

STP-04 STP-03

CBQ-25-1

TOUCH

SENSOR

LEFT

HAND

SENSOR

BOARD

L LOWER

SENSOR

STP-06

L UPPER SENSOR

R LOWER

SENSOR

R UPPER SENSOR

VAC

POWER

ENTRY

MODULE

STP-00

Patch

Conn.

BRAKE

BOARD

STP-05

Patch Conn.

NTC

BRAKE

SPEED

SENSOR

Page 2.9

Page 22

2.7.3.2. Cordless version

STEP EXCITE: Service & maintenance manual - rev. 1.4

HFU

RECEIVER

TGS

READER

CSAFE

BOARD

CBQ-13

ELT-1 6

CBQ-32

386 BOARD

DISPLAY BOARD

KEYBOARD

STP-06 STP-06

DISPLAY

RIGHT

TOUCH

SENSOR

STP-04 STP-03

SENSOR

CBQ-25-1

LEFT

TOUCH

HAND

SENSOR

BOARD

L LOWER

SENSOR

STP-06

L UPPER SENSOR

R LOWER

SENSOR

R UPPER SENSOR

BATTERY

ALTE RNA TOR

BATT ERY CHARGER

INPUT

Patch

conn.

STP-01

BRAKE

BOARD

STP-05

Patch

conn.

NTC

BRAKE

Page 2.10

Page 23

STEP EXCITE: Service & maintenance manual - rev. 1.4

2.7.4. 700I MODEL – ARM BOARD

2.7.4.1. Powered version

HFU

RECEIVER

TGS

READER

CSAFE

BOARD

CBQ-13

ELT-16

CBQ-32

ARM DIS PLA Y BOARD

KEYBOARD

STP-06 STP-06

DISPLAY

RIGHT

TOUCH

SENSOR

STP-04 STP-03

CBQ-25-1

TOUCH

SENSOR

LEFT

HAND

SENSOR

BOARD

L LOWER

SENSOR

STP-06

L UPPER SENSOR

R LOWER

SENSOR

R UPPER SENSOR

VAC

POWER

ENTRY

MODULE

STP-00

Patch

Conn.

BRAKE

BOARD

STP-05

Patch Conn.

NTC

BRAKE

SPEED

SENSOR

Page 2.11

Page 24

2.7.4.2. Cordless version

STEP EXCITE: Service & maintenance manual - rev. 1.4

HFU

RECEIVER

TGS

READER

CSAFE

BOARD

CBQ-13

ELT-1 6

CBQ-32

ARM DIS PLAY BO ARD

KEYBOARD

STP-06 STP-06

DISPLAY

RIGHT

TOUCH

SENSOR

STP-04 STP-03

SENSOR

CBQ-25-1

LEFT

TOUCH

HAND

SENSOR

BOARD

L LOWER

SENSOR

STP-06

L UPPER SENSOR

R LOWER

SENSOR

R UPPER SENSOR

BATTERY

ALTE RNA TOR

BATT ERY CHARGER

INPUT

Patch

conn.

STP-01

BRAKE

BOARD

STP-05

Patch

conn.

NTC

BRAKE

Page 2.12

Page 25

STEP EXCITE: Service & maintenance manual - rev. 1.4

2.7.5. 700IE WTV MODEL

2.7.5.1. Wellness TV Touch screen NCB version

CN1

CN2

CN3

CN4

S-Video

IN PUT

AUX BOARD

Right

Left

CVBS

CONNECTORS

PAN EL

Antenna

inle t

DISPLAY

IN VERTER

C C

STP-07

CB-9

CN1

CONNECTORS

CSAFE BOARD

CBQ-13

BOARD

CU82

Patch Conn.

LEFT

HEADPHONE

JACK

HFU

RECEIVER

CN11

ELT-16

CBQ-25-1

HAND

SEN SOR

BOARD

LEFT

TOUCH

SENSO R

L LOWER

SEN SOR

STP-06

L UPPER SENSO R

R LOWER

SENSO R

R UPPER

SEN SOR

RIGHT

TOUCH

SENSO R

TGS

READER

BOARD

TTL

CBQ-32

LCD

SPLITTER

A MPLIFIER

CU40

CN15

TUNE R

CPU

BOARD

CU125

CU81

Patch Conn.

RIGHT

HEADPHONE

JACK

TOUCH SCREEN

INTERFACE

BOARD

TOUCH

SCRE EN

VAC

POWE R

ENTRY

MODULE

STP-00

STP-04 STP-03

BRAKE

BOARD

Patch Conn.

STP-05

Patch Conn.

NTC

SPEED

SEN SOR

BRAKE

Page 2.13

Page 26

2.7.5.2. Wellness TV Touch screen UB version

STEP EXCITE: Service & maintenance manual - rev. 1.4

DISPLAY

TGS

READER

INVERTER

C C

CBQ-32

CU98

LCD

CU82

Pach

Conn.

CN7 USB

TTL

BOARD

CN8

CSAFE

AUX INPUT

CN4

S-Vide o

BOARD

CN3 CVBS

CU99

CN1

CN2

Right

Left

CU124

CB-9

CONNECTORS

PANEL

STP-07

Antenna

HFU

RECEIVER

intel

ELT-16

CPU

BOARD

CBQ-25-1

HAND

SENSOR

BOARD

L LOWER SENSOR

STP-06

L UPPER SENSOR

R LOWER

SENSOR

R UPPER

SENSOR

LEFT

TOUCH

SENSOR

RIGHT

TOUCH

SENSOR

CU82

Pach

Conn.

RIGHT

HEADPHONE

JACK

VAC

POWER

ENTRY

MODULE

TOUCH

SCREEN

STP-00

STP-04 STP-03

BRAKE BOARD

LEFT

HEADPHONE

JACK

Patch Conn.

STP-05

Patch Conn.

NTC

SPEED

SENSOR

BRAKE

Page 2.14

Page 27

STEP EXCITE: Service & maintenance manual - rev. 1.4

2.8. WIRING

CB-9: DVD video input cable

Connector board - AUX input board

Connector board

CN1

1 Color Red 1 2 left audio IN White 2 3 Gnd Braid 3 4 right audio IN Red 4 5 Gnd Braid 5 6 video IN Yellow 6 7 Gnd Braid 7 8 Switching White 8

Display Board

CN8

1 Digital #1 Flat cable 1 … … … … 14 Digital #14 Flat cable 14

Display Board

CN4

1 +5 Vdc power supply Red 2

5 Pulse out Blue 3

6 Reference Black 1

Display Board

CN7

1 +12 Vdc power supply Yellow 1

3 Rx White 8

5 Tx Green 7

9 Gnd Brown 3

Signal Color Input board

CBQ-13: CSafe board cable;

Display Board – CSafe Board

Signal Color CSafe Board;

CBQ-25-1: Hand sensor board cable Display Board – Hand Sensor Board

Signal Color Hand sensor

CBQ-32: TGS Cable

Display Board – TGS reader

Signal Color TGS reader;

CN1

board

CN1

Page 2.15

Page 28

STEP EXCITE: Service & maintenance manual - rev. 1.4

CV-302: LCD inverter power supply cable

CPU Board - LCD Inverter

CPU Board

CN5

2 Gnd Black 2

3 +3.3 Vdc power supply Black 3

4 Gnd Black 4

5 +12 Vdc power supply Orange 5

Signal Color LCD Inverter

ELT-16: HFU Receiver cable

Display Board – HFU Receiver

Display Board

CN3

1 +5 Vdc power supply White 2

7 Pulse (beat to beat) Black 4

8 Gnd Green 1

Signal Color HFU Receiver

STP-00: High voltage cable

Power entry module – Brake board

Power entry module Signal Color Brake board

F Line White 1

N Neutral Brown 3

T Earth Green 5

STP-01: Alternator cable

Brake board – Alternator – Battery – Inlet for battery charging

Brake board

CN3

1 V+ voltage from

2 V- voltage from

3 RPM signal White Faston 4 V+ voltage from

5 V- voltage from

6 Battery V+ Red - Faston 7 Battery V- Black - Faston -

Signal Color Alternator Battery Battery charging

Red Faston -

alternator

Black Faston -

alternator

Red - soldered to

battery charger

Black - soldered to

battery charger

internal contact

external contact

CN1

CN3

inlet

Page 2.16

Page 29

STEP EXCITE: Service & maintenance manual - rev. 1.4

STP-03: Power supply cable between upper and lower assemblies

Brake board - Display Board

Brake board

CN1

2 Gnd White 2 3 Gnd Yellow 3 4 - sensing +5 Vdc digital Pink 4 6 +12 Vdc Brown 6 7 +5 Vdc Green 7 8 +sensing +5 Vdc digital Grey 8

Signal Color Display Board

STP-04: Serial communication cable between upper and lower assemblies

Brake board - Display Board

Brake board

CN4

1 Digital Gnd Orange-White 1 2 Digital Gnd Orange 2 3 NC Green-White 3 4 Download Blue 4 5 Reset Blue-White 5 6 NC Green 6 7 485 Tx/Rx + Brown-White 7 8 485 Tx/Rx - Brown 8

Signal Color Display Board

STP-05: Brake supply cable

Brake board – Brake – Speed sensor - NTC

Brake board

CN2

1 Brake supply + Brown Faston - 2 Brake supply - Blue Faston - -

3 SPM Grey -

4 SPM Reference Black - eyelet 5 NTC + White - - 2 6 NTC - Brown - - 1

Signal Color Brake Speed sensor NTC

Faston connected

to brown cable

CN1

CN9

Page 2.17

Page 30

STEP EXCITE: Service & maintenance manual - rev. 1.4

STP-06: Hand sensor – Touch sensor cable

Hand Sensor Board - Sensors

Hand sensor

board

J2 - J4

1 Right sensor signal White up 2 Sensor signal reference Brown down 3 Gnd Black - 4 Left sensor signal White - up 5 Sensor signal reference Brown - down 6 Gnd Yellow/green - -

Signal Color

Sensors

Right Left

Display board – Touch sensor

Display board

CN5 / CN6

1 + 5Vdc White 1 2 Button Brown 3 4 Reference Green 4

Signal Color Touch sensor

Page 2.18

Page 31

STEP EXCITE: Service & maintenance manual - rev. 1.4

3. PRINCIPLES OF OPERATION

3.1. BLOCK DIAGRAM

The machine block diagram is illustrated in the figure below:

Antenna

inlet

(W TV onl y)

DISPLAY

NET

CONNECTORS PANEL

CSAFE BOARD

LEFT

SENSOR

RIGHT

SENSOR

CARDIO

RECEIVER

POWERED VERSIO N

VAC

POWER

ENTRY

MODULE

TGS READER

BRAKE BOARD

DISPL AY BO ARDS

- KEYBOARD

- TOUCH SCREEN (W TV only)

BRAKE

BOARD

HAND

SENSOR

BOARD

LEFT

TOUCH

SENSORS

CORDLESS VE RSION

BATTERY

CHARGER

INPUT

RIGHT

TOUCH

SENSORS

External

power supply

SPEED

SENSOR

NTC

BRAKE

NTC

Page 3.1

Page 32

STEP EXCITE: Service & maintenance manual - rev. 1.4

3.1.1. DISPLAY BOARDS

3.1.1.1. 500i and 500i SP versions

The display comprises the following circuit boards:

• 386 BOARD

This is the circuit board which comprises the CPU, a 386 microprocessor, its logic circuits and a FLASH EPROM containing the operating program for the machine.

• DISPLAY BOARD

This is the heart of the display: this board acts as the interconnection hub for all the components of the display, and serves as the point of connection with the electrical box. In fact it:

> receives commands of the machine program from the 386 Board; > sends to the 386 Board the signals received from:

- Keyboard;

- Cardio receiver;

- TGS reader;

- CSafe Board;

distributes the voltages received from the Brake board to the display;

> exchanges, via the RS-485 serial link to the Brake board, the commands for controlling the

brake;

> controls the LEDs and the 7-segment displays which provide feedback about the exercise

session.

The board includes the following indicator LEDs:

LED name Color Description

DL1 green

DL2 yellow

DL3 green

and 2 jumpers:

Jumper Name Setting Description

JP1 open if closed resets the board.

JP2 closed

if ON the +12 Vdc power supply from the Brake board correctly reaches the board. if ON the +5 Vdc power supply from the Brake board correctly reaches the board. if ON the +5 Vdc stabilized digital power supply is correctly generated.

if closed allows the backup battery to keep the system clock active.

Page 3.2

Page 33

STEP EXCITE: Service & maintenance manual - rev. 1.4

3.1.1.2. 500i ARM and 500i SP ARM models

The display comprises the following circuit boards:

• ARM DISPLAY BOARD

This is the heart of the display: this is the circuit board which comprises the CPU, an ARM microprocessor, its logic circuits and a FLASH EPROM containing the operating program for the machine moreover, acts as the interconnection hub for all the components of the display and serves as the point of connection with the electrical box. In fact it receives and process signals from:

- Keyboard;

- Cardio receiver;

- TGS reader;

- CSafe Board;

distributes the voltages received from the Brake board to the display;

> exchanges, via the RS-485 serial link to the Brake board, the commands for controlling the

brake;

> controls the LEDs and the 7-segment displays which provide feedback about the exercise

session.

The board includes the following indicator LEDs:

LED name Color Description

LED1 yellow

LED2 green

if ON the +5 Vdc power supply from the Brake board correctly reaches the board. if ON the +12 Vdc power supply from the Brake board correctly reaches the board.

3.1.1.3. 700i and 700i SP versions

The display comprises the following circuit boards:

• 386 BOARD

This is the circuit board which comprises the CPU, a 386 microprocessor, its logic circuits and a FLASH EPROM containing the operating program for the machine.

• CPU

BOARD

This is the heart of the display: this board acts as the interconnection hub for all the components of the display, and serves as the point of connection with the electrical box. In fact it:

> receives commands of the machine program from the 386 Board; > sends to the 386 Board the signals received from:

- Keyboard;

- Cardio receiver;

- Hand Sensor Board;

- TGS reader;

- CSafe Board;

Page 3.3

Page 34

- Touch sensor.

> distributes to the display the voltages received from the Power Supply Board; > exchanges, via the RS-485 serial link to the Brake board, the commands for controlling

the brake;

> controls the LEDs and the 7-segment displays which provide feedback about the

exercise session.

The board includes the following indicator LEDs:

LED name Color Description

DL1 green

DL2 yellow

DL3 green

and 2 jumpers:

Jumper Name Setting Description

JP1 open if closed resets the board.

JP2 closed

if closed allows the backup battery to keep the system clock active.

STEP EXCITE: Service & maintenance manual - rev. 1.4

3.1.1.4. 700i ARM and 700i SP ARM models

The display comprises the following circuit boards:

• ARM DISPLAY BOARD

- Keyboard;

- Cardio receiver;

- TGS reader;

- CSafe Board;

> distributes the voltages received from the Brake board to the display; > exchanges, via the RS-485 serial link to the Brake board, the commands for controlling the

brake;

> controls the LEDs and the 7-segment displays which provide feedback about the exercise

session.

Page 3.4

Page 35

STEP EXCITE: Service & maintenance manual - rev. 1.4

The board includes the following indicator LEDs:

LED name Color Description

LED1 yellow

LED2 green

if ON the +5 Vdc power supply from the Brake board correctly reaches the board. if ON the +12 Vdc power supply from the Brake board correctly reaches the board.

3.1.1.5. 700i E Wellness TV Touch screen

The display comprises the following circuit boards:

• NEW CONNECTOR BOARD NCB

This board acts as the interconnection hub for all the components of the display, and serves as the point of connection with the electrical box. It includes connectors for the following:

Cardio receiver;

> Hand Sensor Board; > CSafe Board; > AUX video input board; > Antenna signal; > Power supplies from the Brake board; > RS-485 serial link with the brake; > Touch sensor.

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

D10 red

if ON the +12 Vdc power supply from the Brake board correctly reaches the board.

and one Faston:

Name Description

J2 SHLD: denotes a ground node on the circuit board.

• CPU BOARD

This is the heart of the display: it is the circuit board which incorporates the CPU, a microprocessor, its control logic, the FLASH EPROM containing the operating program of the machine, and the tuner for the audio and video channels. Through the connector board, it receives signals from the various machine components.

This circuit board is directly connected to:

TGS reader;

> TTL Board; > Touch screen;

Page 3.5

Page 36

STEP EXCITE: Service & maintenance manual - rev. 1.4

> Headphone jack; > Splitter / amplifier; > LCD power supply inverter.

The principal functions of the board are:

Distributes the voltages received from the Brake board to the display;

> Exchanges, via the RS-485 serial link to the Brake board, the commands for controlling the

brake;

> Tunes the audio and video channels; > Manages the display of images on the LCD.

The board includes the following 2 jumpers:

Jumper Name Setting Description

JP1 open if closed, resets the microprocessor

CN2 open if closed, enables writing to the flash eprom

and a 3-pin connector (CN18) that can be used for testing the power supplies output by the board: 0 Vdc (ground), 5Vdc and 3.3 Vdc.

3.1.1.6. 700iE Wellness TV Touch screen UB model

The display includes only one board which carry out all the functions previously done by the connectors board and CPU board.

It is the circuit board which incorporates the CPU, its control logic, the FLASH EPROM containing the operating program of the machine, and the tuner for the audio and video channels. Through the connector board, it receives signals from the various machine components.

The main functions of the board are:

Distributes the voltages received from the brake board to the display;

> Exchanges, via the RS-485 serial link to the brake board, the commands for controlling the

brake;

> Tunes the audio and video channels; > Manages the display of images on the LCD.

> Acts as the interconnection hub for all the components of the display, and serves as the point

of connection with the brake board. It includes connectors for the following:

- Cardio receiver;

- Hand sensor board;

- TGS reader;

- Touch sensor;

- Touch screen;

- Headphone jack;

- AUX input board;

- LCD;

- Power supply inverter for LCD;

- Antenna signal;

Page 3.6

Page 37

STEP EXCITE: Service & maintenance manual - rev. 1.4

- Voltage received from the brake board;

- RS-485 serial link to the brake board.

The board includes the following indicator LED:

LED name Color Description

D41 green

if ON the +12 Vdc supply from the AT driver box, correctly reaches the board.

and a faston:

Name Description

J2 SHLD: denotes a ground node on the circuit board.

• SPLITTER / AMPLIFIER;

This device amplifies the signal received from the antenna, separating the FM radio channel from the TV channel, which it sends to the tuner.

• TTL BOARD;

This is an RGB buffer board with six bits per color, which interfaces the video signals sent from the CPU board to the LCD.

• 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 CPU board, and generates the AC voltage (380 Vac) needed to power the LCD.

• 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.

• AUX INPUT BOARD

This board provides 3 RC connectors and one mini DIN connector for interfacing external audio visual devices to the machine. An input on this board allows the external source to be displayed on the LCD base band.

• HEADPHONE JACK

The machine display has two jacks for connecting headphones. The two jacks are connected in parallel to a stereo output of the CPU board. In addition to the audio signals, the connector also includes a sense signal for routing the output to either the headphones or external speakers, if the latter are installed. The sense contact is NC and opens when the headphone jack is plugged in.

3.1.2. CSAFE BOARD

This board makes available a communication port, on 1 externally accessible connector, which can be used for interfacing compatible CSafe devices such as the CardioTheater readers. This connector is situated on the back of the display.

These connectors can also be interfaced, using a special cable, to an external PC for programming the FLASH EEPROM.

Page 3.7

Page 38

STEP EXCITE: Service & maintenance manual - rev. 1.4

3.1.3. TGS READER

This board enables the machine to read the user's TGS key for performing workouts programmed with the Wellness System.

3.1.4. HAND SENSOR BOARD

This is the board which manages the hand sensors, interfacing them with the Display board. It processes the analog signal received from the sensors and outputs one pulse for each heart beat that is detected. The signal level is normally 5 Vdc; it goes to 0 Vdc when the user's hands are placed on the contacts, and a 5 Vdc pulse (having a width of approximately 30 msec) is output at each detected heart beat.

3.1.5. CARDIO RECEIVER

This board manages the signal received from the telemetric transmitter used by the person exercising. It receives the power supply signal from the display board and outputs a negative logic pulse for every heart beat that is detected: the signal level is normally 5 Vdc, with a pulse at 0 Vdc (having a width of approximately 30 msec) at each heart beat. The receiver reception area is approximately a circle with a 1 m radius. If there is electromagnetic noise (produced by high voltage lines, radio transmitters, monitors, motors etc.) within this area, the receiver becomes saturated and no longer receives any signal.

3.1.6. CONNECTORS PANEL

This is located on the side of the front platform, and provides a connector for the antenna cable (on 700i E model only).

3.1.7. BRAKE BOARD

There are 2 versions of the Brake board, one which is used on the mains powered version and the other on the self-powered version. In either case, the Brake board consists of:

• Power supply section which generates the low voltages used by the machine: +5 Vdc and +12

Vdc. Depending on the machine version, these voltages will be generated either from the 110 VAC or 220 VAC mains supply, or from the alternator-battery.

• Section for RS-485 serial communications with the Display Board for:

- commands determining the resistance that is required of the brake;

- brake error messages;

- commands for modifying the circuit board configuration parameters;

- commands for viewing the errors logged by the circuit board.

• Section which generates the current for the brake winding: varying the current produces a

proportional variation in the resistance of the brake. The excitation current supplied to the brake is a function of the effort level selected on the display and the RPM value measured by the speed sensor (angular velocity of the brake disk) and is determined by the values stored in the braking table.

Page 3.8

Page 39

STEP EXCITE: Service & maintenance manual - rev. 1.4

The board includes the following indicator LEDs:

LED name Color Description

if ON the board is supplying the brake

LED1 green

LED2 yellow

winding. if BLINKING the Brake board is in an error condition. if ON there is the +5 Vdc supply from the circuit board.

3.1.8. BRAKE

This is an eddy current brake, consisting of a flywheel mass and a flat copper disk that rotates in the air gap of a winding. Variations in the winding current produce a change in the resulting field, which consequently varies the eddy currents induced within the copper disk and hence its resistance to movement.

The winding has a resistance of approximately 3.3 Ohm.

A klixon thermal cut-out, installed directly on the winding, interrupts the circuit whenever it detects a temperature exceeding 140°C.

3.1.9. SPEED SENSOR

Only for 500i, 700i and 700i E versions.

This consists of a magnetic induction sensor which detects the heads of the brake disk fixing screws.

3.1.10. NTC

On the machine there are two NTC thermistors used for monitoring the temperature of the Brake board and the brake winding. The monitoring of these two components makes it possible to reduce the power when a given temperature threshold is reached, or open the circuit and cut off the power altogether if this reduction fails to stop the rise in temperature.

3.1.11. POWER ENTRY MODULE

Only for 500i, 700i and 700i E versions.

This is a module consisting of:

• power inlet socket;

• power outlet socket;

• fuse-holder for protecting line voltage and neutral with two 3.15A fast-blow fuses.

It is situated on the side of the rear platform. The power entry module has a maximum current rating of 10 A. This places an upper limit on the number of machines that can be connected together.

Page 3.9

Page 40

STEP EXCITE: Service & maintenance manual - rev. 1.4

Therefore, do not connect more than 14 Step Excite machines with a 220 VAC mains supply, or 7 machines with a 110 VAC mains supply.

WARNING: If other types of machines are connected together, the maximum number is

determined by their current draw.

3.1.12. ALTERNATOR

Only for 500i SP and 700i SP versions.

The alternator consists of a stator winding whose rotor is put into rotation by the movement of the pedals, generating the voltage necessary for the machine’s operation.

Depending on the rate of pedaling and the resulting speed of rotation, it generates an alternating voltage which ranges from approximately 15-17 VAC at about 30-35 RPM to over 40 VAC for higher pedaling speeds.

The alternator has a built-in speed sensor which provides to the brake board the speed signal.

3.1.13. BATTERY

Only for 500i SP and 700i SP versions.

This is a 12 V – 4.5 AH battery which, in the self-powered version, supplies the machine whenever the alternator is unable to produce a sufficient voltage for powering the machine, and for at least 30 seconds after the user has stopped pedaling to allow data to be saved in memory.

The battery can be recharged in 2 ways:

• during the exercise, through the brake board;

• in the standby condition, from an external power supply included with the machine, which is

able to fully recharge the battery in 8 hours.

Do not use the machine during recharging with the external power supply.

3.1.14. EXTERNAL POWER SUPPLY INPUT

Only for 500i SP and 700i SP versions.

This is a socket for plugging in the external power supply that comes with the machine, which can be used to recharge the battery. It is situated on the side of the front platform.

Page 3.10

Page 41

STEP EXCITE: Service & maintenance manual - rev. 1.4

3.2. BRAKE CONTROL

3.2.1. MECHANICS

The motion of the pedals imparts a rotation to the primary shaft via the chain connected to the 2 pedals. This chain actually consists of sections of chain coupled with springs. The primary shaft is connected to the secondary shaft by means of a chain, which is in turn connected to the brake by means of a belt. The speed sensor (only on mains operated models) attached to the frame detects the heads of the screws which secure the disk to the flywheel, and generates a signal proportional to the speed. On self powered machine, the speed value is detected measuring a phase of the alternator.

3.2.2. CONTROLS

The control block diagram is as follows:

Display Board

Pulses

Brake board

3-4/CN2

Speed sensor

To obtain a given exercise effort level, the display board sends the required value of exercise speed in step per minute to the Brake board via the RS-485 serial link. Based on the commands received the brake board will then apply the appropriate excitation current to the brake winding, which generates an electromagnetic field.

CN9

RS-485

CN4

1-2/CN2

Excitation Current

Brake

Green LED

When the brake interface board receives the signal to generate resistance, the green

LED illuminates.

The electromagnetic field produced by the winding and the rotation of the disk will induce eddy currents in the disk itself, giving rise to a force that tends to brake its motion. This generates the exercise resistance.

A higher brake excitation signal will produce a correspondingly higher exercise resistance.

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Due to the eddy currents, energy is dissipated on the brake disk in the form of heat.

During the movement, the speed sensor detects the heads of the brake disk fixing screws, and produces a speed feedback signal that is sent to the Brake board. The brake board will adjust s the excitation current of the brake winding so that the speed detected by the speed sensor is equal to the set value.

NOTE: Closed-loop control.

If the brake board does not receive a speed signal, which indicates that an exercise

session is in progress, the machine will not produce any resistance.

During the movement, the brake board monitors for possible malfunctions. The errors which can occur are:

Error

Description

Code

OVERHEATING: this condition occurs when the temperature detected by

the sensor on the circuit board exceeds 90°C. OVERVOLTAGE: this condition occurs when the +12 Vdc voltage goes above 13.7 Vdc (only on the 500i, 700i, and 700i E models).

In all the cases, the brake board interrupts the supply of current to the brake, the green LED changes from being steadily on to blinking and sends an error message to the display board which displays the “THE EQUIPMENT IS BLOCKED” message.

3.2.3. THE SIGNALS INVOLVED

The machine uses the following control signals:

• RS-485 Signal

This is a digital signal exchanged between the brake board and the display board. There is no provision for monitoring its state.

• Excitation current

This is the current generated by the brake board (pins 1-2 of connector CN2) which supplies the brake winding. The current supplied is a function of the adjustment algorithm.

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• Pulses

This is the signal produced by the speed sensor, and has the waveform shown in the figure below:

Figure 3.2-1

The signal enters the brake board (pins 3-4 on connector CN2), where it is used to determine the speed value that is sent to the display board via the RS-485 serial link.

This signal can also be measured qualitatively using a multimeter. The voltage

measured across the sensor terminals should be 0 Vdc when the machine is stopped, and should increase to a few hundred mV during pedal movement: the higher the speed, the higher the measured voltage.

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4. ACCESSORIES

4.1. CARDIO THEATER CONNECTION

The machine can be connected to the CardioTheater by means of the RJ45 connector on the CSafe board. The CardioTheater unit must be provided with a power cable having the following pin-out:

RJ45 Connector Signal

5 +5 Vdc 7 Ground

ATTENTION: for the numbering of the pins, on RJ45 connector, please refer to the

diagram below:

4.2. PC LINK FOR PROGRAMMING

The machine can be connected to a PC for programming by means of the RJ45 connector on the CSafe board.

The cable to use (code 0WC00434AB) must be wired as follows:

ATTENTION: for the numbering of the pins, on RJ45 connector, please refer to the

diagram below:

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When programming the machine sometimes it is necessary to fit plug into the free RJ-45

port on the back of the display, to avoid any type of interference during the operation.

The wiring diagram of the RJ-45 plug is as follows:

Programming cable and plug can be ordered using the code H0002534AA.

4.3. CABLE FOR EXCHANGING TV CHANNEL TUNING DATA

BETWEEN TWO MACHINES

The link for transferring the TV channel tuning data from one machine to the other is effected via a special cable, which plugs into the RJ45 connectors of the CSafe boards.

The cable to use (code 0WC00644AA) must be wired as follows:

Cable

CSafe Board;

RJ45

3 Tx White 4 4 Rx Brown 3 7 Digital Ground Green 7 8 Ground Shield Yellow 8

Signal Color CSafe Board;

RJ45

ATTENTION: for the numbering of the pins, on RJ45 connector, please refer to the

diagram below:

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4.4. MONITOR PLUG FOR CSAFE PORT

When the plug code 0WC00639AA is fitted into any one of the CSafe ports on the machine, the corresponding LED should illuminate to indicate the presence of the 5 Vdc supply on the port. During the CSafe port test function, the plug connects the transmit channel directly to the receive channel, thereby producing a positive test outcome if the port is functioning correctly.

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4.5. WELLNESS TV UPGRADE KIT

There are upgrade kits available for converting Excite machines from the version with traditional LED display to the version with Wellness TV display. The kit also includes all the cables and connectors required for the input of the antenna signal. The table below gives the codes of the kits for each machine.

WELLNESS TV

UPGRADE KIT

STEP 700 A0000169AA-#

Where the character ‘#’ must be replaced with the multistandard code matching the TV standard of the country where the machine has to be installed:

Multistandard

code

TV Standard Countries

code

1 PAL B/G

2 PAL I

5 SECAM E/L

6 SECAM D/K

8 PAL D/K

9 SECAM B/G

A SECAM K1

3 PAL N

4 NTSC

7 NTSC M44

B PAL M

Albania Australia Austria Bahrain Belgium Cameroon Croatia Cyprus Czech Rep Denmark Finland Germany Ghana Greece Hungary India Israel Italy Jordan Kenya Luxembourg Malaysia Malta Netherlands New Zealand Nigeria Norway Pakistan Poland Portugal Romania Singapore Slovakia Slovenia Spain Sri Lanka Sweden Switzerland Thailand Turkey United Arab E Zambia Zimbabwe

Botswana Hong Kong Ireland South Africa Seychelles UK

France

Bulgaria Estonia Ex URSS Latvia Lithuania Poland Russia Ukraine

Czech Rep China Poland

Saudi Arabia Iran Iraq Morocco Tunisia Syria

French Guyana Guadeloupe Madagascar Martinique New Caledonia Senegal Togo Zaire

Argentina Paraguay Uruguay

Bahamas Bermuda Canada Chile Costa Rica Guatemala Japan Korea Peru Philippines Taiwan Trinidad USA Venezuela

Mexico

Brazil

CODE

Page 4.4

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4.5.1. INSTALLATION PROCEDURE

NOTE: It is always advisable, in any case, to upgrade the brake interface board to the

latest SW version.

The upgrade kit consists of:

Figure 4.5-1

(1) External connector board cover plate

(cod. 0C000550AB);

(2) External connector board

(cod. 0WQ00115AC);

(3) Self-tapping screws 5x14 (cod. 0Z775); (4) Self-tapping screws 3.5x6 (cod. 0Z7018); (5) Washers (cod. 0Z343); (6) Connector plate (cod. 0G000353AB); (7) Union connector (cod. 0K000303AA); (8) STP_07 cable (cod. 0WCU0008AA); (9) CB-9 cable (cod. 0WC00447AB); (10) Code sticker (cod. 0E109);

(11) 12-inch LCD display assembly.

Figure 4.5-2

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1. Turn off the machine and unplug the mains

lead from the wall outlet.

2. Back off the 4 screws a using a medium

Phillips screwdriver.

Figure 4.5-3

Figure 4.5-4

3. Unplug the connectors indicated in the

figure.

4. Remove the display.

5. Turn the machine over on one side.

6. Back off the 4 screws b using a Phillips

screwdriver.

7. Remove the cover c.

Page 4.6

Figure 4.5-5

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STEP EXCITE: Service & maintenance manual - rev. 1.4

Figure 4.5-6

8. Remove connector plate d from the front

platform.

Figure 4.5-7

Figure 4.5-8

9. Assemble union connector 7 on connector

plate 6, securing it with its own lock-nut after inserting the washer, as shown in the figure.

10. Insert cable 8 (STP_07) into hole e, and

bring it out from the top of the machine.

If the cable doesn’t pass trough the

machine frame, use a cable puller.

11. Plug the lower end of cable 8 (STP_07) into

union connector 7, previously assembled on connector plate 6.

12. Snap connector plate 6 into its seat on the

platform.

13. Turn the machine back upright.

Continued on following page →

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14. Remove cover plate f, backing off the 4

screws h using a Phillips screwdriver.

Figure 4.5-9

Figure 4.5-10

15. Insert external connector board 2 along the

special guides on cover plate 1, in such a way that the connectors on the board match up with the holes on the cover plate.

16. Secure external connector board 2 with

screws and washers 4 and 5, using a Phillips screwdriver.

17. Connect cable 9 (CB-9) to connector board

18. Assemble cover plate 1 inside the rear

display housing, using the 4 screws 3 and a Phillips screwdriver.

Page 4.8

Figure 4.5-11

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STEP EXCITE: Service & maintenance manual - rev. 1.4

Figure 4.5-12

Figure 4.5-13

19. Remove the covering from the LED display,

backing off the 3 screws h using a medium Phillips screwdriver.

20. Unplug the TGS cable, if present.

21. Assemble the covering removed previously

in step 19 onto the WTV display, and secure using the 3 screws h.

22. Connect the following cables to the WTV

display:

• Cable 8 (STP_07) on connector j1 of the

connector board.

• All the connectors previously

disconnected from the display in step 3.

• The TGS cable, if present, on connector

CN8 of the CPU board.

23. Fix the new display on the machine using the

4 screws removed previously in step 2.

Figure 4.5-14

24. Affix the sticker 10 in the position indicated

in the figure.

25. Turn on the machine and check that it is

working properly.

26. Carry out the Wellness TV configuration and

tuning procedure.

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5. INSTALLATION INSTRUCTIONS

5.1. SPECIFICATIONS AND REQUIREMENTS

For correct machine installation, make sure that:

1. The machine is installed on a level surface that is free of vibrations and has sufficient carrying

capacity for the combined weight of the machine and user.

2. The place of installation is free of dust and sand.

3. The place of installation meets the operating temperature and humidity conditions specified in

paragraph 2.6. “Ambient specifications”.

4. The m

(television sets, electrical motors, antennas, high voltage lines, household appliances, etc...) or medical equipment.

5. To eliminate possible interference with the cardio receiver, no transmitters should be placed less

than 1 meter from the display.

Only for 500i, 700i and 700i E models.

6. The mains voltage must match the value specified on the machine rating plate.

7. The electrical system must be correctly earthed.

8. The wall outlet used should be reserved for the machine and have a rating of at least 100 VA.

9. The maximum number of machines connected in cascade should be that indicated in paragraph

3.1.11. “Power entry module”.

10. Position the m

achine is not positioned close to sources of heat, sources of electromagnetic noise

ains lead of the machine where it will not be underfoot.

5.2. INSTALLATION REQUIREMENTS AND SPECIFICATIONS

FOR WELLNESS TV MACHINES

1. Ensure that the specifications and requirements for installation have been met (see paragraph

5.1. “Specifications and requirements”).

2. To obtain a good video signal, the S/N ratio at the antenna signal input of a W

machine should be between 70 and 80 dB.

WARNING: If the machine is not connected to a terrestrial antenna--or if it is but the antenna line is split by devices such as TV distribution units, modulators, etc.--the machine will not be able to receive a usable antenna signal for radio channel tuning.

ellness TV

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5.3. INSTALLATION

To correctly install the machine, proceed as follows:

1. Ensure that the specifications and requirements for installation have been met (see paragraph

5.1. “Specifications and requirements”).

2. Position the machine as specified above, on a level surface that is free of vibrations and has

sufficient carrying capacity for the combined weight of the machine and user.

3. The machine is shipped fully assembled and packed in a carton fixed to a wooden pallet.

Only for 500i, 700i and 700i E models.

4. Connect the mains lead to the power inlet socket on the machine.

5. Place the on/off switch in the 0 position.

6. Plug the mains lead into the wall outlet.

Only for 700i E model.

7. Connect the antenna cable to the socket.

5.4. FIRST POWER-ON

After completing the installation procedure, the machine is ready for use.

On the 500i, 700i and 700i E models, simply turn the on/off switch from position 0 to position 1, while on the 500i SP and 700i SP models it is necessary to get on the machine and start pedaling.

On power-up the machine performs a self-test of the upper and lower assemblies. After completing the self-test, the machine enters the stand by state, awaiting a command from the keyboard.

To check the correct operation of the machine:

• get on the machine;

• start exercising;

• check that the displayed speed varies accordingly;

• check that exercise resistance varies when the “+” and “-“ effort level keys are pressed, or the

touch sensors on the 700i, 700i SP and 700i E models are pressed, and the effort level change from 1 to 25;

• put on the heart rate meter and check that the machine correctly reads the heart rate value;

• only for 700i, 700i SP and 700i E: grasp the sensors and check that the machine correctly reads

the heart rate value.

• only for 700i E: Carry out the procedure described in paragraph 9.7. “Touch screen calibration”.

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6. TROUBLESHOOTING

The troubleshooting procedures are illustrated by means of flow diagrams. To facilitate interpretation of these diagrams, the following standard box shapes are used:

This type of box is the START point of the troubleshooting procedure. It typically contains a description of the problem or malfunction.

This type of box represents a decision point in the troubleshooting procedure. It typically contains a description of the CHECK to be made, with an outcome that is either a positive (YES) or negative (NO) response.

This type of box is a step in the troubleshooting procedure where an ACTION must be carried out. It typically contains a description of the ACTION necessary to resolve the problem Therefore, after executing the specified ACTION:

1. Check whether the problem has been resolved;

2. If the problem persists, it is recommended to resume the troubleshooting

procedure from the point before the action was carried out.

A circled number (such as that shown on the left) next to a box of the troubleshooting procedure indicates that more detailed instructions for performing that particular check or action are provided below the flowchart.

A circled letter (such as that shown on the left) is used to mark a point in the procedure. Typically, this indicator is used in page changes.

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6.1. SERVICE TROUBLESHOOTING MENU

The configuration procedure is invoked when the machine is in standby mode, using a different procedure for the 500 and 700 models.

• Accessing configuration of 500 models

Simultaneously press the ENTER, ↑, CLEAR keys. The following prompt appears on the LED display:

ENTER PASSWORD:

To access the procedure, type in the password 2501 which protects against unauthorized access and press “Enter” to confirm. To enter the password, increase or decrease the displayed value using the ↑ and ↓ keys, or use the +/- GOAL keys to scroll through and modify the individual digits. At this point there are two options available:

↑ = Tech Config ↓ = Troubleshooting

Press numeric key ↑ to access the menu for configuring technical parameters; the machine display will begin showing the current configuration, structured as in the diagram below:

• Accessing configuration of 700 models

Simultaneously press the keys 369 for 700 LED models, whereas on 700 Wellness TV models the keys 0369 must be pressed one after the other. The following prompt appears on the display:

ENTER PASSWORD:

To access the procedure, type in the password 2501 which protects against unauthorized access and press the “Enter” key to confirm. At this point there are two options available:

1 = Tech Config 2 = Troubleshooting

Press numeric key 1 to access the menu for configuring technical parameters; the machine display will begin showing the current configuration, structured as in the diagram below:

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TROUBLESHOOTING

AUTOMATIC TEST M ANUAL T ES T

I2C Devices Test

LED Test

SERIAL PORT S

TEST

TGS COM Test

Low Kit COM Test

CSafe COM Test

MAN.KEYBOARD

TEST

To scroll through the list of available functions, press the + or – effort level keys to display the next or the preceding item; confirm the choice by pressing ENTER. To cancel the operation, press the CLEAR key for a few seconds.

The tests are divided into two groups: Automatic and Manual, and the prompt for a choice appears immediately on accessing the troubleshooting menu.

6.1.1. AUTOMATIC TEST

The tests grouped under this section conduct checks on the machine’s operation in a fully automatic manner. After selecting the desired test using the + and – effort level keys, press ENTER to initiate the test and then await the result. Press ENTER again to continue, and use the CLEAR key to return to the higher menu level, holding it down for a few seconds. The various tests are described below.

6.1.1.1. I2C Devices Test

The I2C Devices test checks the com outcomes:

• “Test Successful, press Enter to continue”: Signifies that the transmission and reception of

data packets between the I2C devices and the display board was completed successfully.

• “EEPROM Error, press Enter to continue”: Signifies that the display board is having

problems communicating with its memories.

6.1.1.2. LED Test (not on 700iE models)

The LED test checks the functioning of the display by lighting all the LEDs in the matrix. It also tests the buzzer by changing the frequency to produce a variation in the tone of the sound.

munication following the 32K and 256K. The test can have

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There is no message displayed concerning the outcome of this test, which must therefore be checked visually.

6.1.1.3. Serial Ports Test

The serial ports test checks the communications on the following interface ports:

• CSafe COM test;

• Low Kit COM test;

• TGS COM test.

Using the + and – effort level keys, select the desired test item and confirm by pressing ENTER. The test can have two outcomes:

• “Test Successful, press Enter to continue”: This means that the test was completed

successfully, i.e. that the communications on the selected serial port are functioning correctly.

• “COMx error, press Enter to continue”: This means that the outcome of the test was

negative: the message will specify COM1 in the case of the CSafe COM test, COM2 in the case of communications with the low kit, or COM3 in the case of the TGS COM test.

The “TGS COM test” done on machine not provided with the key reader gives a fail

outcome. The same if the “CSafe COM test” is done on a machine which CSafe port is not plugged with the monitor plug described at paragraph 4.4. “Monitor plug for CSafe port”.

6.1.2. MANUAL TEST

The tests grouped under this section conduct checks on the machine’s operation in a fully automatic manner. After selecting the desired test using the + and – effort level keys, press ENTER to initiate the test and then await the result. To exit test mode, press and hold down the CLEAR key for a few seconds.

6.1.2.1. Man. Keyboard Test

The m the test by pressing ENTER, the message “Press all buttons (beep=OK)” appears on the display. Pressing each key will produce an audible signal; if a key does not produce the beep it means it is not working properly.

On Wellness TV machines, pressing the keys does not produce an audible signal, but if the key is working correctly it lights up green.

anual keyboard test checks the functioning of all the keys on the keyboard. After accessing

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6.2. THE DISPLAY FAILS TO ILLUMINATE

This error occurs when the power supply voltage is not reaching the upper assembly.

6.2.1. 500I AND 700I MODELS

THE DISPLAY

DOES NO T

ILLUMINATE

Does t h e wall out let s upply t he

correct v olt ag e?

Plug the mac hi ne int o a working elec trical out l et

YES

Is t he m ains lead OK?

YES

Are the f uses OK?

YES

Is the v olt age at t he

output of t he mac hine's

power entry modul e

correct?

Replace t he m ain s lead

Replace the fuses

Replace t he power

entry m odul e on the

machine

YES

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Replace t he display

board and/or the 386

board

YES

Does t h e m ains v oltage

reach t he input to t he

brake boar d?

YES

Are the DC voltages at t he

output of t he brake board

correct?

YES

Are the D C volt ages at t he

input t o t he dis play board

correct?

Replace c able STP-00

Replace the brake

board

Replace c able STP-03

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

To speed up the troubleshooting procedure, check the state of the power indicator LEDs

on the various circuit boards.

(1) Slightly lift up the fastons on the machine power entry module. Place the tester probes across

the live and neutral pins on the same connector. The measured value should be approximately 220 VAC or 110 VAC depending on the mains voltage.

(2) As for step (1) but across pins 3 and 1 of connector CN3 on the Brake board. (3) Using a tester, check that all the output voltages on connector CN1 of the brake board are

correct, referring to paragraph 2.8. “Wiring”.

(4) As for step (3) but on connector CN1 of the display board.

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6.2.2. 500I SP AND 700I SP MODELS

THE DISPLAY

DOES NO T

ILLUMINATE

Is the us er i s ex ercis i ng?

YES

Is there a v olt ag e at t he output of the alt ernat or?

YES

Is there a v olt ag e at t he

input t o t he br ak e boar d?

Correct operation: af t er

30 seconds without do

the ex er c ise, t he

machine switches off

Replace the alt ernat or

Replace cable STP-01

or the fuse in the same

cable

Replace t he display

board

YES

Are the D C volt ages at t he

output of t he brake board

correct?

YES

Are the D C volt ages at t he

input t o t he dis play board

correct?

Replace the brake

board

Replace c able STP-03

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Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

To speed up the troubleshooting procedure, check the state of the power indicator LEDs

on the various circuit boards.

(1) Check if the machine stays on for 30 seconds after having stopped pedalling. If the machine

switches off in few seconds, check if the fuse on the STP-01 cable is blown.

(2) Place the tester probes across the ends of the cable from the alternator. The measured voltage

should be approximately 15-17 VDC at a speed of about 30 SPM.

(3) As for step (1) but across pins 1 and 2 of connector CN3 on the brake board. (4) Using a tester, check that all the output voltages on connector CN1 of the brake board are

correct, referring to paragraph 2.8. “Wiring”.

(5) As for step (4) but on connector CN1 of the display board.

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6.2.3. 700I E MODEL WITH WELLNESS TV

THE DISPLAY

DOES NO T

ILLUMINATE

Does t h e wall out let s upply t he

correct v olt ag e?

YES

Is t he m ains lead OK?

YES

Are the t he f uses OK ?

YES

Plug th e m ac hine i nt o a working elec trical out l et

Replace the mains lead

Replace t he f us es

Is the v olt age at t he

output of t he machine's

power entry modul e

Does the mains voltage

reach t he input to t he

brake board?

Continued on the following page.

correct?

YES

Replace t he power

entry module on the

machine

Replace c able STP-00

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Are the DC voltages at the

output of t he brak e board

correct?

YES

Replace the brake

board

Are the DC

voltages c orre c t at t he:

-input of t he c onn. board?

-input of the C PU bo ard (UB models )?

YES

Are the D C volt ages at the output of the C PU board to

the LC D i nv ert er c or rec t?

YES

Are the D C volt ages at the

input t o t he LCD inv ert er

correct?

Replace cable STP-03

Replace t he C PU

and/or connec t or

board

Replace cable:

-CV-302 ( N C B m odels)

-CU98 (U B m odels )

Are the AC v olt ages at t he

output t o the LCD i nv erter

Continued on the following page.

Page 6.10

YES

Replace LC D inv ert er

correct?

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STEP EXCITE: Service & maintenance manual - rev. 1.4

Replace the LCD

Is the LC D neon la m p on?

YES

Chec k the c onnect ion or

try t o rep lac e the c able

between CPU board and

TTL board.

It works?

Try t o replace t he C PU

board.

It works?

Replace LC D

YES

Cable dam ag e

YES

CPU board dam ag e

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

To speed up the troubleshooting procedure, check the state of the power indicator LEDs

on the various circuit boards.

(1) Place the tester probes across the ends of the cable coming from the generator. The measured

value should be approximately 110 or 220 VAC, depending on the mains voltage.

(2) As for step (1) but across pins 1 and 2 of connector CN3 on the Brake board. (3) Using a tester, check that all the output voltages on connector CN1 of the brake board are

correct, referring to paragraph 2.8. “Wiring”.

(4) As for step (3) but on connector CN16 of the connector board. (5) As for step (3) but on connector CN5 of the CPU board.

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(6) As for step (3) but on connector CN1 of the LCD inverter. (7) Place the tester probes across the two pins of connectors CN2 and CN3 on the LCD inverter

board. The measured value should be approximately 380 VAC.

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6.3. NO AUDIO SOUND

This error can be due to an incorrect machine configuration, or to problems with the audio circuit.

NO AUDI O SOUND

Replace the CPU board

Is the TV st anda rd c or rec tly

conf igured?

YES

Replace t he headph one jack .

Does it work?

Try re plac i ng t he C PU. D oes i t

work?

YES

Correct ly c onf igur e t he

"TV Standard"

parameter

Def ec t i v e headphone

jack

Defect iv e C PU board

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) Carry out the configuration procedure described in paragraph 9.3.12. “TV Standard (700i E

version only)”.

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6.4. NO TV PICTURE

Check that the machine is connected to an antenna signal

This error can be due to an incorrect machine configuration, or to problems with the antenna signal.

NO TV P ICT URE

Is the ant enn a c able properl y

connected t o t he connec tor

board?

Connec t t he c abl e

The signal derived f rom

the v ideo signal is

insuf fi c ient . C ont ac t t he

sy stem adm i nis trator

YES

Is the TV standard c orrec tly

conf igured?

YES

Dis c onnec t the s plitt er and

connect t he t uner direct ly t o an

antenna cable. D oes it work?

Try re plac i ng t he C PU.

Does it work?

Correct ly c onf igur e t he

"TV Standard"

parameter

YES

Replace t he s pl itt er

YES

Defective CPU board

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) Check that the antenna cable is correctly connected to connector J1 on the connector board.

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STEP EXCITE: Service & maintenance manual - rev. 1.4

(2) Carry out the configuration procedure described in paragraph 9.3.12. “TV Standard (700i E

version only)”.

(3) For models with European electronics, unplug the antenna cable from the connector board

and plug it into the tuner; while for models with US electronics, plug the external antenna cable into the tuner.

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6.5. THE RADIO DOES NOT PLAY

The radio signal can only be acquired from an analog antenna signal. If the machine is

connected to a digital source it will be impossible to use the radio function.

This error can be due to an incorrect machine configuration, or to problems with the antenna signal.

THE RADIO DO ES NOT

PLAY

Is the antenna input connected

to a t e rres trial ant e nna c able

without any ty pe of interruption

(multiplexer, TV dist r ibution

module)?

YES

Is the TV channel sound OK?

YES

Dis c onnect t he s plit t er and

connect t he t uner direct ly t o an

antenna cable. D oes it work?

Connect a s ignal t hat

meet s thes e requirements

Perform the "Audio do es

not work" procedure

YES

Replace t he s pl itt er

The signal derived f rom

the v ideo signal is

insuf f ic ie nt . C o nt ac t t he

sy stem adm i nis trator

Try repl ac i ng the C PU .

Does it work?

YES

Defective CPU board

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

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STEP EXCITE: Service & maintenance manual - rev. 1.4

(1) After disconnecting the splitter from the tuner, procure a female RC connector and a copper

wire about 1.5 m long. Connect the copper wire to the tuner through the RC connector, so that it serves as an antenna.

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6.6. “THE EQUIPMENT IS BLOCKED” MESSAGE ON DISPLAY

This error message can be caused by:

• loss of communication between the lower and upper assemblies;

• the brake board has detected an error condition, causing it to generate an alarm and store the

error code in memory.

"THE EQUIPMENT IS BL O C KED"

MESSAGE ON THE D ISPL A Y

Carry out the "Error

detected by brake

board" t roubl es ho ot i ng

procedure

YES

Is the serial

comm unic at ion bet ween

display and lower

elect ronic correct?

Reins tat e the

communication link

between the upper and

lower assem blies

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) Use the serial communications test described in paragraph 6.1.1.3 “Serial Ports Test”. (2) To reinstate communications between the lower and upper assemblies:

• check that cable STP-04 is correct using the Test Box Excite;

• try replacing the brake board and the display board in turn, and check whether the

communication works.

(3) Check whether the brake interface board is in an error condition, by accessing the “Low kit

fault code” function in the “Low kit menu” described in paragraph 9.3.6.2 “Low Kit fault code”. If the displayed parameter value is “0”, there is no error condition.

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6.7. ERROR DETECTED BY BRAKE BOARD

When the brake board detects an error, it stops and interrupts the power supply to the brake winding, writes a code identifying the fault condition to the error history log and sends an error status signal to the display board. When this error signal is received by the display board, it interrupts the exercise and shows the “THE EQUIPMENT IS BLOCKED” message on the display.

The errors logged by the brake board can also be viewed from the machine keyboard as described in paragraph 9.3.4. “Errors log” or in paragraph 9.3.6.2 “Low Kit fault code”.

ERROR DETECTED BY

BRAKE BOA RD

Error 1

Check the error code

stored in memory

Error 8

The following paragraphs describe the troubleshooting procedures for these cases.

6.7.1. BRAKE BOARD ERROR 1

This code indicates an overheating error: this condition occurs when the temperature detected by the sensor on the circuit board exceeds 90°C.

Try switching the machine off for 1 hour. If it resumes working correctly, the machine probably overheated as a result of intensive use. If, on the other hand, the error persists, it is necessary to replace the Brake board.

6.7.2. BRAKE BOARD ERROR 8

This code indicates an overvoltage error: this condition occurs when the +12 Vdc voltage exceeds

13.7 Vdc.

This error is caused by surges in the voltage output by the power supply section of the Brake board, as a result of defective components. If the error persists or recurs frequently, replace the Brake board.

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6.8. THERE IS NO RESISTANCE

The machine will not produce resistance if:

• the display board is not receiving a speed signal;

• the brake board is not generating current;

• the brake is defective.

TH ER E IS N O RESISTANCE

STEP EXCITE: Service & maintenance manual - rev. 1.4

Replace c able ELT-02

Are the Watt and SPM values

shown on t he di s pl ay dif f erent

from zero?

YES

Does the brake board supply curre nt t o the brake winding?

YES

Does t h e brak e winding receiv e

current f rom the brake board?

YES

Carry out the "SPM value

is incorrect "

troubles hoot ing proc edure

Replace the brake board

Replace the brake winding

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) Disconnect the brake winding and measure the current output by the brake board with a load

of at least 5 Ohm and 80 Watts. The value should be different from 0 A.

(2) As for step (1) but with everything reconnected, and across the brake winding.

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STEP EXCITE: Service & maintenance manual - rev. 1.4

6.9. THE RESISTANCE IS INCORRECT

The machine will produce an incorrect resistance if:

• the mechanical components are not in perfect condition;

• the speed measurement is incorrect;

• the brake board is defective;

• the brake is defective.

THE

RESIST ANCE IS

INCORRECT

Repair t he f ault y mechanical part s

Replace the brake board

Replace the brake winding

YES

Are the m echanics of t he

machine in good condition?

YES

Carry out the "Speed is

Inc orrec t " t roubles hoot ing

procedure

Does t h e brak e boar d out p ut

the current to t he br ak e

winding?

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) Check that the mechanical system, consisting of the pedals, belt and brake, moves smoothly

and without higher than normal friction or resistance.

(2) Measure the voltage supplied by the brake interface board to the winding. In QUICK START

mode, select the effort level and check that the value is different from 0.

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6.10. THE SPEED SIGNAL IS INCORRECT

The speed signal is incorrect if:

• The brake disk is incorrectly fixed to the flywheel;

• The speed sensor is defective;

• The brake board is defective.

TH E SPEED IS

INCORRECT

Is the brake dis k c orrec tly fixed

to t h e f ly wheel?

YES

Does t h e s peed s ensor s e nd

the c or rec t s igna l t o the brak e

board?

YES

Check if t he parameters

conf iguration i s r igh t . I s the

speed signal c or rect ?

Fix it correctly

Replace the

speed sens or / generat or

YES

Configuration param et er

not c orrec t

YES

SW not c orr ec t l y loaded

YES

Upload t he brak e board SW. I s

the s pee d s ignal c orr ec t ?

Replace the brake board

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

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STEP EXCITE: Service & maintenance manual - rev. 1.4

(1) Check that the 6 screws fixing the disk brake to the flywheel are all locked down.

The speed sensor detects the heads of these screws.

(2) Powered models: Place the tester probes across the terminals of the speed sensor. The

measured signal should be that indicated in Figure 3.2-1. In addition, when pedaling at 80 SPM the frequency of the signal should be 136 Hz.

Self-Powered models: Check the signal on the STP-01 cable referring to paragraph 2.8.

“Wiring”. The measured signal should be that indicated in Figure

3.2-1. In addition, when pedaling at 80 SPM the frequency of the signal should be 136 Hz.

The speed signal can also be observed qualitatively, using a multimeter. The value

should be 0 Vdc when the machine is stopped, and gradually increase as the speed increases.

(3) Launch the default setting for the low kit parameters. (4) Update the low kit SW uploading both firmware and brake table. At the end launch the

default setting for the low kit parameters.

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6.11. THE MACHINE DOES NOT READ THE TGS

The machine displays this error if the TGS reader is not working properly, or if it is not supplied by the display board.

TH E MA CH INE DOES

NOT READ THE TGS

Replace the dis play board

Does t he s upply voltage

correct ly reach t he inp ut to t he

TGS reader?

Is the s upply v olt age correct at

the output to t he display board

correct?

Is the serial c om m unic ation link

between the display board and

the TGS reader OK?

YES

Replace c able C B Q-32

YES

Replace the TGS reader

YES

TGS reader defec tiv e

Replace the dis play board

Replace t he TGS reader. I s t he

comm unic at ion li nk bet ween the

displ ay board and t he TGS

reader OK?

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

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STEP EXCITE: Service & maintenance manual - rev. 1.4

(1) Place the tester probes across pins 1 and 3 of connector CN1 of the TGS reader. The

measured value should be +12 Vdc.

(2) As for step (1) but across pins 1 and 9 of connector CN7 on the display board. (3) Use the serial communications test described in paragraph 6.1.1.3 “Serial Ports Test”.

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6.12. THERE IS NO HEART SIGNAL

6.12.1. HFU TELEMETRIC RECEIVER

The machine displays this error if:

1. electromagnetic noise saturate the HR receiver which does not display any value due to a

specific SW filter which cut every signal, greater than 220 bpm;

2. the receiver is not working properly;

3. the receiver is not supplied by the display board.

TH ER E IS N O HR

SIGNAL

Carry out the

troubl es hoo t ing pr oc edur e

"THE TELEMETRIC

SIGN AL I S IN C OR R EC T"

YES

Replace the rec eiv er

YES

Replace C BQ-28 c abl e

Replace display board

Is the supply voltage c orrect at

the inp ut t o the receiv er?

Is the supply voltage c orrect at

the output of t he di s pl ay board?

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) Carry out the troubleshooting procedure 6.13. “The telemetric heart rate signal is incorrect”. (2) Place the tester probes across pins 1 and 3 of connector CN1 of the receiver. The measured

value should be +5 Vdc.

(3) As for step (1) but across pins 1 and 8 of connector CN3 on the display board.

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STEP EXCITE: Service & maintenance manual - rev. 1.4

6.12.2. HAND SENSOR

The machine displays this error if the HS interface board is not working, or if it is not supplied by the display board.

For an easier and quicker diagnosis of the problem, we recommend to use the

functions of Test Box Excite.

TH ER E IS N O HR

SIGNAL

Chec k the earth c onnect ion

of t h e m ac hin e

Replace the dis play board

Are the sens ors c orrect ly

connected to the HS interface

board?

YES

Is the s upply v olt age correct at

the input to the HS interface

board?

Is the s upply v olt age correct at

the out put of the dis play board?

Reinstat e the connec tion

YES

Replace the HS interf ace

board

YES

Replace cable CBQ-25-1

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) Check the earthing of the machine using a tester to measure the resistance between the ground

pin on the power supply cable and the ground node to which the receiver is connected inside the display. The value must be less than 1 Ohm.

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STEP EXCITE: Service & maintenance manual - rev. 1.4

(2) Check the connections, referring to paragraph 2.8. “Wiring”. (3) Place the tester probes across pins 2 and 1 of connector J3 on the HS interface board. The

measured value should be +5 Vdc.

(4) As for step (2) but across pins 1 and 6 of connector CN4 on the display board.

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STEP EXCITE: Service & maintenance manual - rev. 1.4

6.13. THE TELEMETRIC HEART RATE SIGNAL IS INCORRECT

The machine displays this error if the receiver is disturbed by sources of electromagnetic noise.

THE TELEMETRIC

HR SIG N AL IS

INCORRECT

Check t he eart h c onnec tion

of the mac hine

Are the m achines c orrect l y

spac ed by t he r equir ed m inim u m

distance?

YES

Is the receiver correctly

positioned an d are t he

connect ing c ab les proper ly

routed?

YES

Are there s ourc es of

electrom agn et ic nois e near t he

receiv er?

Reposition t he mac hines

so t hey are adequately

spaced

Correct t he po s ition of t he receiv er and the rout ing of

the c abl es

YES

Move the mac hi ne away

fr om t he noi s e s our c e or

att enuat e the power of t he

noise

Continued on the following page.

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STEP EXCITE: Service & maintenance manual - rev. 1.4

Is the t ransm it ter in good

working order?

YES

Us e a c orr ec t l y

func tioni ng t ransm itt er

Replac e the rec ei v er

YES

Is the transmitter always within

the 80 cm range from t he rec eiv er

Reposition the transmitter

within range

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) Check the earthing of the machine using a tester to measure the resistance between the ground

pin on the power supply cable and the ground node to which the receiver is connected inside the display. The value must be less than 1 Ohm.

(2) For machine positioning layouts, use the following diagram as a reference.

89 60

99 78

99 77

102

Receiver

115 86

103

95 76

103

where:

1. The distances are in centimeters.

2. The smaller number indicates the maximum locking distance for signal reception at the

start of the exercise.

3. The higher number indicates the maximum reception distance during the exercise.

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STEP EXCITE: Service & maintenance manual - rev. 1.4

(3) Check that the cardio receiver has been assembled properly as described in the procedure 7.4.

“Disassembling the cardio receiver”.

(4) To check for electromagnetic noise near the machine, use Test Box Excite as detailed here

below. You can use one of the following cables ELT-16 (0WC00518AB), CBQ-28 (0WC00390AC) or TRM-28 (0WC00336AC) as connection cable.

HFU

Receiver

Connection

cable

HR receive

TEST BOX

EXCITE

The circuit lights the LED for each heart beat and/or disturbance received: in this way it is possible to determine whether there is any interference, and identify its sources.

(5) Check the battery power level, using a tester if possible. Otherwise use a receiver or another

reference machine to check the operation up to a distance of about 80 cm from the receiver.

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Page intentionally left blank

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7. DISASSEMBLY OF COMPONENTS

7.1. DISASSEMBLING THE DISPLAY

7.1.1. 700I AND 700I SP LED VERSION

1. Turn off the machine and unplug the mains

lead from the wall outlet.

2. Back off the 4 screws a using a medium

Phillips screwdriver.

Figure 7.1-1

Figure 7.1-2

3. Unplug the connectors indicated in the figure

at left.

4. Remove the display.

5. Back off the 2 screws b, using an 8-mm hex

wrench, to remove the rear display support.

To reassemble the display, carry out the above steps in reverse order.

Figure 7.1-3

Page 7.1

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STEP EXCITE: Service & maintenance manual - rev. 1.4

7.1.2. 700I E WELLNESS TV TOUCH SCREEN VERSION

1. Turn off the machine and unplug the mains

lead from the wall outlet.

2. Back off the 4 screws a using a medium

Phillips screwdriver.

Figure 7.1-4

Figure 7.1-5

3. Unplug the cables indicated in the figure

from the connector board and the CSafe board.

4. Remove the display.

5. Back off the 2 screws b, using an 8-mm hex

wrench, to remove the rear display support.

To reassemble the display, carry out the above steps in reverse order.

Page 7.2

Figure 7.1-6

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STEP EXCITE: Service & maintenance manual - rev. 1.4

7.1.3. 500I AND 500I SP VERSION

Figure 7.1-7

1. Turn off the machine and unplug the mains

lead from the wall outlet.

2. Back off the 4 screws a using a medium

Phillips screwdriver.

Figure 7.1-8

Figure 7.1-9

3. Unplug the connectors indicated in the figure

at left.

4. Remove the display.

5. Back off the 2 screws b, using an 8-mm hex

wrench, to remove the rear display support.

To reassemble the display, carry out the above steps in reverse order.

Page 7.3

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STEP EXCITE: Service & maintenance manual - rev. 1.4

7.2. DISASSEMBLING THE CIRCUIT BOARDS FROM THE

DISPLAY

7.2.1. 700I AND 700I SP LED VERSION

Carry out the procedure described in paragraph

7.1. “Disassembling the display”.

Then place the display on a work bench. It is now possible to disassemble its three circuit boards:

• The 386 board a;

• The display board b;

• The CSafe board c.

Figure 7.2-1

Figure 7.2-2

386 board a:

1. Remove the hot glue and release the fixing

tabs. The board will lift up slightly.

2. Extract it from the connector on the display

board.

display board b:

1. Unplug the keyboard connector indicated in

the figure.

2. Back off the 5 screws d using a medium

Phillips screwdriver.

3. Remove the circuit board.

CSafe board c:

1. Unplug the connector indicated in the figure.

2. Remove the circuit board from the top.

Page 7.4

Figure 7.2-3

Continued on following page →

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STEP EXCITE: Service & maintenance manual - rev. 1.4

Figure 7.2-4

To remove the hand sensor board:

1. Unplug the 2 connectors indicated in the

figure.

2. Release the 3 clips e and remove the hand

sensor board.

To reassemble the electronics boards, carry out the above steps in reverse order.

Page 7.5

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STEP EXCITE: Service & maintenance manual - rev. 1.4

7.2.2. 700I E WELLNESS TV TOUCH SCREEN VERSION

7.2.2.1. NCB models

Carry out the procedure described in paragraph

7.1. “Disassembling the display”.

Then place the display on a work bench. It is now possible to disassemble its circuit boards:

• The CSafe board a.

• The LCD inverter b;

• The connector board c;

• The CPU board d;

• The Touch Screen interface board e.

Figure 7.2-5

Figure 7.2-6

CSafe Board a:

1. Unplug connector f from the CSafe board.

2. Remove the circuit board from the top.

LCD inverter b:

1. Back off the two screws g using a Phillips

screwdriver.

2. Raise the inverter cover plate.

Page 7.6

Figure 7.2-7

Continued on following page →

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STEP EXCITE: Service & maintenance manual - rev. 1.4

Figure 7.2-8

1. Unplug the connectors indicated in the

figure.

2. Back off the two screws h securing the board

to the plate of the display.

3. Remove the LCD inverter.

Figure 7.2-9

Figure 7.2-10

Connector board c:

1. Unplug connectors i and l.

2. Back off the screws m using a medium

Phillips screwdriver.

3. Remove the circuit board from the display,

taking care not to damage the connector that attaches it to the CPU board.

CPU Board d:

1. Disassemble the connector board.

2. Unplug the cables indicated in the figure,

coming from the TTL board, LCD inverter, touch screen and headphone jack.

3. To unplug the cable from the TTL board,

open the connector on the CPU as shown in the close-up at the top left, and remove the cable.

4. Back off the 5 screws n using a small

Phillips screwdriver.

5. Remove the CPU board.

Continued on following page →

Page 7.7

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STEP EXCITE: Service & maintenance manual - rev. 1.4

Touch screen interface board e:

1. Unplug the cables on connectors CN1 and

CN5, indicated in the figure, coming from the touch screen and CPU respectively.

2. Back off the screws o using a small Phillips

screwdriver.

3. Remove the circuit board from the display.

Figure 7.2-11

Figure 7.2-12

To disassemble the LCD:

1. Unplug the connectors of the cables leading

from the touch screen to the touch screen interface board, to the TTL board and to the LCD (on the inverter) indicated in the figure.

2. Back off the 6 screws p securing the plate

and all the display boards to the front cover.

3. To unplug the cable from the TTL board,

open the connector on the CPU as illustrated in the close-up at left, and remove the cable.

4. Back off the 2 screws q securing the

headphone jack to the display, using a small Phillips screwdriver.

5. Unplug the connectors indicated in the

figure.

6. Remove the two headphone jacks from the

display housing.

7. Lift up the plate to which all the circuit

boards and the LCD are fixed.

Page 7.8

Figure 7.2-13

Continued on page 7.11 →

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STEP EXCITE: Service & maintenance manual - rev. 1.4

7.2.2.2. UB models

Figure 7.2-14

Carry out the procedure described in paragraph

7.1. “Disassembling the display”.

Then place the display on a work bench. It is now possible to disassem

ble its circuit boards:

• The LCD inverter a;

• The CPU board b.

Figure 7.2-15

LCD inverter b:

1. Back off the two screws c using a Phillips

screwdriver.

2. Raise the inverter cover plate.

3. Unplug the connectors indicated in the

figure.

4. Back off the two screws d securing the board

to the plate of the display.

5. Remove the LCD inverter.

Figure 7.2-16

Continued on following page →

Page 7.9

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STEP EXCITE: Service & maintenance manual - rev. 1.4

CPU Board b:

1. Disassemble the connector board.

2. Unplug the cables indicated in the figure,

coming from the TTL board, LCD inverter and headphone jack.

To unplug the cable from the TTL

board, open the connector on the CPU as shown in the close-up at the top left, and remove the cable.

3. Back off the 5 screws n using a small

Figure 7.2-17

Phillips screwdriver.

4. Remove the CPU board.

To disassemble the LCD:

1. Unplug the connectors of the cables leading

from the touch screen, to the TTL board and to the LCD (on the inverter) indicated in the figure.

Figure 7.2-18

Figure 7.2-19

To unplug the cable from the TTL

board, open the connector on the CPU as shown in the close-up at left and remove the cable.

2. Back off the 5 screws f securing the plate and

all the display boards to the front cover.

3. Back off the screws g securing the

headphone jack to the display, using a small Phillips screwdriver.

4. Unplug the connectors indicated in the

figure.

5. Remove the two headphone jacks from the

display housing.

6. Lift up the plate to which all the circuit

boards and the LCD are fixed.

Continued on following page →

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STEP EXCITE: Service & maintenance manual - rev. 1.4

Figure 7.2-20

7. Back off the 10 screws r using a small

Phillips screwdriver.

8. Remove the touch screen protection plate.

9. Shift on one side, the touch screen s paying

attention to its cable.

10. Back off the 4 screws t using a small Phillips

screwdriver.

11. Lift up and remove the LCD.

Figure 7.2-21

To disassemble the AUX input board:

1. Work on the rear display support.

2. Back off the 2 screws s using a small Phillips

screwdriver.

3. Remove the board from its housing.

Figure 7.2-22

Continued on following page →

Page 7.11

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STEP EXCITE: Service & maintenance manual - rev. 1.4

To remove the hand sensor board:

1. Unplug the 2 connectors indicated in the

figure.

2. Release the 3 clips t and remove the hand

sensor board.

To reassemble the circuit boards and the LCD, carry out the above steps in reverse order.

Figure 7.2-23

Page 7.12

Technogym Step 500i SP, Step 500i, Step 700i, Step 700i S, Step 700i E Service Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Summary

1. GENERAL NOTICES

1.1. INTRODUCTION

1.2. RECOMMENDATIONS

1.3. GENERAL RULES FOR REPAIR PROCEDURES

2. TECHNICAL SPECIFICATIONS

2.1. PRODUCT CODES

2.2. AVAILABLE VERSIONS

2.3. MECHANICAL CHARACTERISTICS

2.4. ELECTRICAL CHARACTERISTICS

2.5. CONFORMITY TO REGULATIONS

2.6. AMBIENT SPECIFICATIONS

2.7. WIRING DIAGRAMS

2.7.1. 500I MODEL

2.7.1.1. Powered version

2.7.1.2. Cordless version

2.7.2. 500I MODEL – ARM BOARD

2.7.2.1. Powered version

2.7.2.2. Cordless version

2.7.3. 700I MODEL

2.7.3.1. Powered version

2.7.3.2. Cordless version

2.7.4. 700I MODEL – ARM BOARD

2.7.4.1. Powered version

2.7.4.2. Cordless version

2.7.5. 700IE WTV MODEL

2.7.5.1. Wellness TV Touch screen NCB version

2.7.5.2. Wellness TV Touch screen UB version

2.8. WIRING

3. PRINCIPLES OF OPERATION

3.1. BLOCK DIAGRAM

3.1.1. DISPLAY BOARDS

3.1.1.1. 500i and 500i SP versions

3.1.1.2. 500i ARM and 500i SP ARM models

3.1.1.3. 700i and 700i SP versions

3.1.1.4. 700i ARM and 700i SP ARM models

3.1.1.5. 700i E Wellness TV Touch screen

3.1.1.6. 700iE Wellness TV Touch screen UB model

3.1.2. CSAFE BOARD

3.1.3. TGS READER

3.1.4. HAND SENSOR BOARD

3.1.5. CARDIO RECEIVER

3.1.6. CONNECTORS PANEL

3.1.7. BRAKE BOARD

3.1.8. BRAKE

3.1.9. SPEED SENSOR

3.1.10. NTC

3.1.11. POWER ENTRY MODULE

3.1.12. ALTERNATOR

3.1.13. BATTERY

3.1.14. EXTERNAL POWER SUPPLY INPUT

3.2. BRAKE CONTROL

3.2.1. MECHANICS

3.2.2. CONTROLS

3.2.3. THE SIGNALS INVOLVED

4. ACCESSORIES

4.1. CARDIO THEATER CONNECTION

4.2. PC LINK FOR PROGRAMMING

4.4. MONITOR PLUG FOR CSAFE PORT

4.5. WELLNESS TV UPGRADE KIT

4.5.1. INSTALLATION PROCEDURE

5. INSTALLATION INSTRUCTIONS

5.1. SPECIFICATIONS AND REQUIREMENTS

5.3. INSTALLATION

5.4. FIRST POWER-ON

6. TROUBLESHOOTING

6.1. SERVICE TROUBLESHOOTING MENU

6.1.1. AUTOMATIC TEST

6.1.1.1. I2C Devices Test

6.1.1.2. LED Test (not on 700iE models)

6.1.1.3. Serial Ports Test

6.1.2. MANUAL TEST

6.1.2.1. Man. Keyboard Test

6.2. THE DISPLAY FAILS TO ILLUMINATE

6.2.1. 500I AND 700I MODELS

6.2.2. 500I SP AND 700I SP MODELS