Technogym Spazio Forma Service Maintenance Manual
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Technogym Spazio Forma Service Maintenance Manual

Technogym Spazio Forma Service Maintenance Manual

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Summary of Contents for Technogym Spazio Forma

  • Page 1 & ERVICE MAINTENANCE MANUAL . 1.0...
  • Page 3 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.

  • Page 5: Table Of Contents

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 Contents 1. GENERAL NOTICES............................1.1 1.1. I ..............................1.1 NTRODUCTION 1.2. R ............................1.1 ECOMMENDATIONS 1.3. G .......................1.2 ENERAL RULES FOR REPAIR PROCEDURES 2. TECHNICAL CHARACTERISTICS ........................2.1 2.1. M ........................2.1 ECHANICAL CHARACTERISTICS 2.2. E ........................2.1...
  • Page 6 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.3. T ....................6.8 HE POWER ISOLATING BOARD IS NOT WORKING 6.4. T “E 3” ..........................6.10 HE DISPLAY SHOWS 6.4.1. The inverter display shows E01, E02, E03, E04 or E05..............6.11 6.4.2. The inverter display shows E06 or E07...................6.12 6.4.3.
  • Page 7 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 9.2.3. Minutes of up-down motor operation ....................9.2 9.2.4. Distance Covered ..........................9.2 9.3. M ......................9.3 ODIFYING THE WORKING PARAMETERS 9.3.1. Hours of machine operation......................9.3 9.3.2. Hours of tread-belt motor operation ....................9.3 9.3.3.

  • Page 8: Spazio Forma: Service & Maintenance Manual - Rev

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 Page intentionally left blank Page iv...

  • Page 9: General Notices

    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.

  • Page 10: General Rules For Repair Procedures

    1. Always mark any parts or positions which may be confused with each other at the time of reassembly. 2. Use original Technogym spare parts and lubricants of the recommended brands. 3. Use special tools where specified. 4. Consult the technical circulars, which may contain more up-to-date information on adjustments and maintenance than those contained in this manual.

  • Page 11: Technical Characteristics

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 2. TECHNICAL CHARACTERISTICS 2.1. MECHANICAL CHARACTERISTICS Width 816 cm Length 203 cm Height during exercise Height machine closed 1164 cm Weight 162 Kg 2.2. ELECTRICAL CHARACTERISTICS Mains voltage 220 V Frequency...

  • Page 12: Wiring Diagram

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 2.5. WIRING DIAGRAM Page 2.2...

  • Page 13: Connectors

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 2.5.1. ONNECTORS • CPU board name type of connector connection AMP MODU I 4x1 pin f. to driver board (low voltage input) AMP MODU I 2x1 pin f. to LED board (low voltage output) AMP MODU II 9x2 pin f.

  • Page 14: Wiring

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 • Portable connectors name type of connector connection CN28 MOLEX mini-fit 7x2 m. portable to CPU board (actuator drive) CN29 MOLEX mini-fit 7x2 f. portable to driver board (actuator drive) CN30 MOLEX mini-fit 5x2 m.
  • Page 15 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 FR-3/L: Power supply high voltage input cable High voltage distribution terminal block – Power supply Terminal block Signal Color Power supply CN39 Neutral Blue Live Black SF-4A: Inverter high voltage input cable...
  • Page 16 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 SF-6: Low voltage power supply cable Power supply – Power isolating board Power isolating Signal Color Power supply Terminal board block CN39 + 12 Vdc + 5 Vdc Orange Black ground...
  • Page 17 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 FR-10: Braking resistor cable Inverter – Braking resistor Inverter Signal Color Resistor Positive White already connected Negative White already connected SF-12: CPU cable – lower section Portable connector – Driver board...
  • Page 18 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 FR-14: LED board signal cable CPU board – LED board CPU board Signal Color LED board STROLED MUX2 MUX1 MUX0 OELED MOSI This cable incorporates a 65 Ohm, 100 MHz coil-less ferrite.
  • Page 19 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 RL-20: TGS cable CPU board – Serial connector CPU board Signal Color Serial connector +12 Vdc Yellow Green White Brown SF-21A: CPU cable / Emergency signals – upper section CPU board – Portable connector CN28...
  • Page 20 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 SF-22A: Emergency signals – lower section Portable connector CN31 – power isolating board - deck position sensor Portable Signal Color Power Deck CN31 isolating board position sensor +5 Vdc Relay output...

  • Page 21: Principles Of Operation

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 3. PRINCIPLES OF OPERATION 3.1. BLOCK DIAGRAM The block diagram of the machine is shown in the figure below: 3.1.1. ARDIO TRANSMITTER It is worn by the person using the machine, and transmits to the cardio receiver one pulse for every heart beat that is detected.

  • Page 22: Display

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 the receiver becomes saturated and stops receiving any signal. If there are 2 transmitters within its area of reception, it will receive signals from both, and may produce an error or irregular reading.

  • Page 23: Inverter

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 3.1.5. NVERTER This is the device which supplies the three-phase belt motor. It receives a DC reference voltage from the driver board. Variations in this voltage cause corresponding variations in the operating frequency of the sinusoidal wave provided by the inverter to the motor phases, and hence change the speed of the tread-belt.

  • Page 24: Deck Position Sensor

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 is input to the CPU board. If the user is in difficulty and detaches the “Safety switch” from the display by pulling the attached cord, the contact opens and the CPU board detects the transition and the "EMERGENCY ACTIVATED"...

  • Page 25: Tread-Belt Motor Drive

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 3.2. TREAD-BELT MOTOR DRIVE 3.2.1. ECHANICS The tread-belt is actuated by the motor through a linkage consisting of the motor pulley, the driving roller and the belt which connects them. In this way, a given belt motor speed corresponds to a predetermined linear tread-belt speed.

  • Page 26: The Signals Involved

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 3.2.3. HE SIGNALS INVOLVED The machine controls the speed of the belt motor by means of the CPU board and the inverter interface board, as shown in the following figure: CPU board...
  • Page 27 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 • Speed reference signal This is the signal generated by the CPU board (pin 4-12 on connector K4) to control the motor speed. It is a PWM signal, i.e. a fixed-frequency square wave signal with variable duty cycle.

  • Page 28: Up-Down Motor Drive

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 3.3. UP-DOWN MOTOR DRIVE 3.3.1. ECHANICS The machine incline is varied by the up-down motor rod, which moves a frame connected to the front wheels. The motor movement is detected by a hall sensor which provides the motor motion control signal: each motor revolution corresponds to a predetermined number of pulses and to a predetermined displacement of the rod, and hence of the machine incline.

  • Page 29: The Signals Involved

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 3.3.4. HE SIGNALS INVOLVED The machine controls the incline through the CPU board and the driver board, as illustrated in the figure below: CPU board 5-12 3-12 9-11 7-12 Down Pulses...
  • Page 30 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 • Down signal This is the signal generated by the CPU board (pin 3-12 on connector K4) to enable movement of the up-down motor in the “down” direction. In normal conditions the signal is at logic level low (0 Vdc), and it goes high (4.65 Vdc) to actuate the motor.

  • Page 31: Safety Of Moving Parts

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 3.4. SAFETY OF MOVING PARTS 3.4.1. ONTROLS The power isolating board directly controls the power supply to the inverter, which in turn controls the tread belt motor and the up-down motor.
  • Page 32 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 • Trigger signal This is the signal generated by the CPU board and output (pins 4-5 of connector K16) to the power isolating board (pins 4-5 of connector J7) to activate the monostable timer. Under normal operating conditions the signal will appear in the figure below, if viewed with an oscilloscope: The signal level is 4.4 Vdc with pulses at 0 Vdc at a frequency of 63 Hz.

  • Page 33: Accessories

    4. ACCESSORIES 4.1. CONNECTING TO THE TGS The machine can be connected to the Technogym System by installing a special upgrade kit. The CPU board is connected to the serial connector via the cable described below, which is supplied together with the upgrade kit.
  • Page 34 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 Page intentionally left blank Page 4.2...

  • Page 35: Installation Instructions

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 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.
  • Page 36 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 When the machine is turned on it will perform a power-on test which: • sounds the buzzer; • lights all the LEDs; • resets the elevation. After completing this power-on test the machine enters standby mode, awaiting a keyboard command.

  • Page 37: Troubleshooting

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6. TROUBLESHOOTING The troubleshooting procedures are shown in the form of flow charts. In order to facilitate consultation, 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.

  • Page 38: The Display Does Not Illuminate

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.1. THE DISPLAY DOES NOT ILLUMINATE This problem occurs when the supply voltage fails to reach the display. THE DISPLAY DOES NOT ILLUMINATE Are the f uses OK? Replace the blown...
  • Page 39 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 Replace the power Are DC v oltages output by the supply power supply correct? Do all DC v oltages reach the Replace cable SF-6 power isolating board? Replace power isolating Are DC v oltages output by the...
  • Page 40 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 Are all DC v oltages present at the Replace driv er board output of the driv er board? Are all DC v oltages present at the f ree connector CN28? Replace cable SF-12...
  • Page 41 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 Is the mains v oltage present at Replace the mains plug the output of the mains plug? of the machine Replace the cable Is the mains v oltage present at SF-1A...
  • Page 42 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 As for step (2), but on connector J2 of the power isolating board. As for step (3). As for step (2), but on connector J3 of the driver board. As for step (2), but on connector J4 of the driver board.

  • Page 43: The Display Shows "Safety Switch

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.2. THE DISPLAY SHOWS “SAFETY SWITCH” The machine displays this message if: • The “Safety switch” is tripped during a training session. • The emergency system is damaged. THE DISPLAY SHOWS “SAFETY SWITCH”...

  • Page 44: The Power Isolating Board Is Not Working

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.3. THE POWER ISOLATING BOARD IS NOT WORKING THE POWER ISOLATING BOARD DOESN'T WORK Does the CPU correctly output the Replace the CPU board trigger and emergency signals ? Do the trigger and emergency...
  • Page 45 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 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: WARNING: Carry out these checks with the machine powered up.

  • Page 46: T He Display Shows "E 3"

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.4. THE DISPLAY SHOWS “E 3” The machine displays this message if: • it has detected a failure to actuate movement of the belt motor at the start of the training session;...

  • Page 47: The Display Shows

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.4.1. E01, E02, E03, E04 HE INVERTER DISPLAY SHOWS These inverter error messages are related to output short-circuit problems. Is the inv erter output short- Replace the inv erter circuited? Is there a short-circuit on the...

  • Page 48: The Inverter Display Shows E06 Or E07

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.4.2. HE INVERTER DISPLAY SHOWS These inverter error messages are related to problems with the inverter braking group or the braking resistor. Is the braking resistor correctly connected to the Reinstate the connection...

  • Page 49: The Inverter Display Shows E08, E10, E11 Or E22

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.4.3. E08, E10, E11 HE INVERTER DISPLAY SHOWS These inverter error messages are related to HW and SW problems with the inverter. Does the error occur Replace the inverter frequently? Does the machine resume Probable interference.

  • Page 50: The Inverter Display Shows E09

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.4.4. HE INVERTER DISPLAY SHOWS This inverter error message is related to low line voltage problems on the inverter power supply. Does the machine resume Probable low line v oltage. correct operation af ter being...
  • Page 51 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 Check and reinstate the Is the supply v oltage at the Replace the f ilter wiring between the f ilter f ilter output correct? and inv erter 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: Place the tester probe between terminals L1 and N on the inverter.

  • Page 52: The Inverter Display Shows E12

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.4.5. HE INVERTER DISPLAY SHOWS This inverter error message is related to the opening of the motor thermal cutouts. Does the machine resume correct operation Probable ov erheating of the af ter being turned of f f or motor.

  • Page 53: The Inverter Display Shows E14

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.4.6. HE INVERTER DISPLAY SHOWS This inverter error message is related to poor isolation between the motor phases and ground. Are the motor phases isolated f rom ground at the Replace the inv erter...

  • Page 54: The Inverter Display Shows E15

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.4.7. HE INVERTER DISPLAY SHOWS This inverter error message is caused by high voltage problems on the inverter power supply line. Does the machine resume Probable high line v oltage. correct operation af ter being The machine is OK.
  • Page 55 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 Disconnect the supply cables from the filter and place the tester probes across them. The measured voltage should be 220 VAC. Disconnect the filter output cables and place the tester probes across the filter terminals. The measured voltage should be 220 VAC.

  • Page 56: The Inverter Display Shows E21

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.4.8. HE INVERTER DISPLAY SHOWS This inverter error message is associated with problems of high inverter temperature. Probable overheating of Does the machine resume Replace the inverter the inverter. The machine correct operation after being is OK.

  • Page 57: The Inverter Display Does Not Show Any Error

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.4.9. HE INVERTER DISPLAY DOES NOT SHOW ANY ERROR This is an anomalous error condition in which the machine display reports an error but the inverter has not generated an error.
  • Page 58 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 Place the tester probes between terminals AL1 and AL0 of the inverter. The measured voltage should be 5 Vdc in the alarm condition, and 0 Vdc in normal conditions. As for step (1), but between pins 3 (signal) and 4 (ground) of connector J5 on the driver board.

  • Page 59: The Inverter Is Off

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.4.10. T HE INVERTER IS OFF INVERTER OFF Is the power supply at the Replace the inv erter inv erter input OK? Is the power supply v oltage Replace the SF-4A cable...

  • Page 60: The Belt Motor Is Jerking

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.5. THE BELT MOTOR IS JERKING The probable cause of this error is a disconnected phase on the motor or inverter output. THE BELT MOTOR IS JERKING Are the belt motor windings...

  • Page 61: The Belt Motor Starts With Delay

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.6. THE BELT MOTOR STARTS WITH DELAY The problem is caused by the inverter failing to receive the enable signal (Start) or the speed signal. THE BELT MOTOR DOES NOT START OR...

  • Page 62: The Displayed Speed Is Incorrect

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.7. THE DISPLAYED SPEED IS INCORRECT The machine displays this error if: • the calibration is incorrect; • there are HW problems with the CPU board – driver board – inverter and motor group.
  • Page 63 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 Is the inv erter control PWM Check and/or replace Replace the CPU board signal at the output of the cables SF-21A and/or CPU board correct? SF-12 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: See paragraph 9.5.

  • Page 64: The Display Shows

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.8. THE DISPLAY SHOWS “E 5” The machine displays this error if:. • it receives an up-down motor alarm signal from the driver board; • it fails to receive an encoder feedback signal after having actuated the motor;...
  • Page 65 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 Does the driv er board send the Replace the driv er board driv e v oltage to up-down motor? Does the power isolating board receiv e the driv e v oltage to...
  • Page 66 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 Does the encoder signal reach Check the SF-15A and SF-15B the input of the driv er board? cables Does the encoder signal reach the output of the driv er board? Replace the driv er board...
  • Page 67 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 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: Execute the following operations procedure when the machine does the reset at the start up described at paragraph 3.3.2.
  • Page 68 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 (12) Place the tester probes between pins 9 (signal) and 11 (ground) of connector J6 on the driver board. There should be a square wave signal alternating between 0 and 5 Vdc. Using a tester, the reading should be 2.5 Vdc.

  • Page 69: The Up-Down Moves In Only One Direction

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.9. THE UP-DOWN MOVES IN ONLY ONE DIRECTION The machine displays this error if: • a relay on the driver board is defective; • the CPU board fails to send the enable signal;...
  • Page 70 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 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: If it is not possible to perform the following operations with the “↑ ↑ ↑ ↑ ” “↓ ↓ ↓ ↓ ” keys directly, do so when the machine does the reset at the start up described at paragraph 3.3.2.

  • Page 71: The Displayed Elevation Is Incorrect

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.10. THE DISPLAYED ELEVATION IS INCORRECT The machine displays this error if: • the reset procedure detects an incorrect reference; • the encoder signal is incorrect due to a bad reading or noise.
  • Page 72 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 Is there something obstructing Remove the obstruction the movement of the machine? Adjust the current limiter Replace the up-down on the driver board and/or Does the motor draw the correct motor...

  • Page 73: There Is No Heart Rate Signal

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.11. THERE IS NO HEART RATE SIGNAL The machine displays this error if the receiver is not working or if it is not supplied by the CPU board. THERE IS NO...

  • Page 74: The Heart Rate Signal Is Incorrect

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6.12. THE HEART RATE SIGNAL IS INCORRECT The machine displays this error if the receiver is disturbed by electromagnetic noise. THE HEART RATE SIGNAL IS INCORRECT Is the minimum distance Mov e the machines to...
  • Page 75 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 Is the transmitter in good Use a known good working order? transmitter Is the transmitter alway s within Keep the transmitter Change the receiv er a distance of 80 cm f rom the...
  • Page 76 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 Page intentionally left blank Page 6.40...

  • Page 77: Disassembly Of Components

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7. DISASSEMBLY OF COMPONENTS 7.1. DISASSEMBLING THE DISPLAY 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Back off the 4 screws a using a phillips screwdriver.

  • Page 78: Disassembling The Eprom

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.2. DISASSEMBLING THE EPROM Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display placed on a work bench: 1. Remove EPROM a from its socket, using an IC extractor tool.

  • Page 79: Disassembling The Display Boards

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.3. DISASSEMBLING THE DISPLAY BOARDS Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display placed on a work bench: 1. Unplug connectors a. 2. Remove the 4 fasteners b.

  • Page 80: Disassembling The Keyboard

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.4. DISASSEMBLING THE KEYBOARD Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display placed on a work bench: 1. Unplug the KEYBOARD connector a. Figure 7.4-1 2.

  • Page 81: Disassembling The Cardio Receiver

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.5. DISASSEMBLING THE CARDIO RECEIVER Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display placed on a work bench: 1. Unplug connector a of cable SF-2 from the CPU board.

  • Page 82: Disassembling The Safety Switch

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.6. DISASSEMBLING THE SAFETY SWITCH Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display placed on a work bench: 1. Lift up the sticker a situated underneath the “Safety switch”;...

  • Page 83: Disassembling The Gas Damper

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.7. DISASSEMBLING THE GAS DAMPER 1. Close the machine so that the gas dampers are entirely discharged. 2. Using a 4-mm hex wrench, back off the two screws securing the right gas damper to the machine frame.

  • Page 84: Disassembling The Motor Guard

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.8. DISASSEMBLING THE MOTOR GUARD 1. Close the machine so that the gas dampers are fully discharged. 2. Back off the screws a on either side, using a 4-mm hex wrench.
  • Page 85 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 9. Back off the two screws d using a 4-mm hex wrench. Figure 7.8-4 10. Use a 10-mm hex wrench to back off the two nuts e securing the power inlet block and push it toward the inside of the machine.

  • Page 86: Disassembling The Tread-Belt Motor

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.9. DISASSEMBLING THE TREAD-BELT MOTOR Carry out the procedure described in paragraph 7.7. “Disassembling the motor guard”. 1. Raise the machine to an incline of approximately 5%. 2. Turn off the machine and unplug the mains lead from the wall outlet.
  • Page 87 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 If it is necessary to disassemble the outer flywheel, use a pen to mark the top part of both flywheels as shown in the figure. 11. Back off the two screws e using a 4-mm hex wrench.

  • Page 88: Disassembling The Footrest Guide

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.10. DISASSEMBLING THE FOOTREST GUIDE Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard”. 1. Back off the screws a using a 6-mm hex T wrench and remove the rear covering.
  • Page 89 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 4. Back off the 8 screws f which can be accessed with a 10-mm socket wrench. 5. Reposition the tread belt on the ground. Figure 7.10-4 6. Remove the FOOTRESTS GUIDE from the rear side.

  • Page 90: Disassembling The Rear Roller

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.11. DISASSEMBLING THE REAR ROLLER Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard” e .7.10. “Disassembling the footrest guide”. To facilitate the subsequent tightening of the tread-belt, move the seam to the...

  • Page 91: Disassembling The Motor Roller And Drive- Belt

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.12. DISASSEMBLING THE MOTOR ROLLER AND DRIVE- BELT Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard” 7.9. “Disassembling the tread-belt motor”, up until the removal of the belt.
  • Page 92 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 To reassemble the MOTOR ROLLER and the DRIVE-BELT, carry out the above steps in reverse order, remembering to first insert the belt on the roller pulley, followed by guard e and finally the two bushings d.

  • Page 93: Disassembling The Tread-Belt And Running Track

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.13. DISASSEMBLING THE TREAD-BELT AND RUNNING TRACK Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” 7.11. “Disassembling rear roller” 7.12. “Disassembling the motor roller and drive-belt”. 1. Back off the 2 rear screws a using a 13-mm wrench.

  • Page 94: Disassembling The Shock Absorbers

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.14. DISASSEMBLING THE SHOCK ABSORBERS Carry out the procedures described in paragraph 7.13. “Disassembling the tread-belt and running track”. 1. On each side of the machine, remove the SHOCK ABSORBERS a from the top, detaching them from the adhesive film.

  • Page 95: Disassembling The Electronic Circuit Boards

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.15. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS Carry out the procedures described in paragraph 7.8. “Disassembling the motor guard”. 1. Back off the 2 screws a using a 5-mm hex T wrench.
  • Page 96 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 1. Back off the 4 cover fixing screws using a medium phillips screwdriver. 2. Remove the cover, taking care not to damage the connected wires. To disassemble the POWER SUPPLY d: 1.

  • Page 97: Disassembling The Inverter

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.16. DISASSEMBLING THE INVERTER 1. Carry out the procedures described in paragraph 7.8. “Disassembling the motor guard”. 2. Open the INVERTER covers, backing off screw a with a small phillips screwdriver.

  • Page 98: Disassembling The Column And Rubber Guard

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.17. DISASSEMBLING THE COLUMN AND RUBBER GUARD 1. Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard”. 2. Raise the machine to its maximum incline position. 3. Unplug the connectors indicated in the figure.

  • Page 99: Disassembling The Up-Down Motor

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.18. DISASSEMBLING THE UP-DOWN MOTOR 1. Carry out the procedure described in paragraph 7.17. “Disassembling the column and rubber guard”. 2. Disconnect the motor supply cable a from the electrical box.

  • Page 100: Disassembling The Up-Down Frame

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.19. DISASSEMBLING THE UP-DOWN FRAME 1. Raise the machine to its maximum incline position. 2. Overturn the machine on its right side. 3. Remove the snap ring a using the special pliers.

  • Page 101: Disassembling The Handlebars

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 7.20. DISASSEMBLING THE HANDLEBARS 1. Turn off the machine and unplug the mains lead from the wall outlet. For each handlebar: 2. Shift the rubber bushings a. 3. Back off the 2 dowels b using a 5-mm hex T wrench.
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  • Page 103: Adjustments

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 8. ADJUSTMENTS 8.1. TENSIONING A NEW TREAD-BELT 1. After assembling the new tread-belt, turn it until the seam is underneath, and tighten the tread-belt until it is just slightly taut. 2. Place a tape measure along the right edge of...

  • Page 104: Tensioning A Used Tread-Belt

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 8.2. TENSIONING A USED TREAD-BELT 1. Before disassembling the used tread-belt, place a tape measure along the right-hand edge of the tread-belt and, using a pen, make two reference marks spaced exactly 1 meter apart.

  • Page 105: Centering The Tread Belt

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 8.3. CENTERING THE TREAD-BELT 1. Start the machine at a speed of 10 Km/h. 2. Observe the movement of the tread-belt, correcting any tendency to shift to the right or left exclusively by adjusting the screw a.

  • Page 106: Aligning The Tread Belt Motor Drive Belt

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 8.4. ALIGNING THE TREAD-BELT MOTOR DRIVE-BELT 1. Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard”. 2. Using a 3-mm hex wrench, back off the grub screw on the motor shaft pulley.

  • Page 107: Tensioning The Tread-Belt Motor Drive Belt

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 8.5. TENSIONING THE TREAD-BELT MOTOR DRIVE BELT 1. Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard”. 2. Raise the machine to an incline of approximately 5%. 3. Turn off the machine and unplug the mains lead from the wall outlet.

  • Page 108: Calibrating The Tread-Belt Speed

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 8.6. CALIBRATING THE TREAD-BELT SPEED 1. Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard”. The operations described below must be carried out with the machine powered they...

  • Page 109: Adjusting The Up-Down Motor Current Limiter

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 8.7. ADJUSTING THE UP-DOWN MOTOR CURRENT LIMITER 1. Carry out the procedures described in paragraph 7.15. “Disassembling electronic circuit boards”. The operations described below must be carried out with the machine powered...

  • Page 110: Leveling

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 8.8. LEVELING 1. Remove the plastic cap a from one of the two rear wheels. Figure 8.8-1 2. Back off the screw b, using an 8-mm hex wrench. 3. Rotate cam c using the special tool provided, until all four wheels touch the ground.
  • Page 111 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 6. Back off lock-nut e and rotate the foot to adjust it. 7. After completing the operation, reassemble the components by carrying out the above steps in reverse order. Figure 8.8-4...
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  • Page 113: Machine Configuration

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 9. MACHINE CONFIGURATION 9.1. LANGUAGE CONFIGURATION To call up the language configuration procedure, simultaneously press the “1”, “3” and “4” keys with the machine in stand by mode. The machine display shows: P A S S W O R D To access the procedure, type in the password which protects against unauthorized access.

  • Page 114: Viewing The Working Parameters

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 9.2. VIEWING THE WORKING PARAMETERS In order to check the state of wear of the machine and correctly carry out routine machine maintenance, a special procedure is provided for viewing the values of the working parameters. It is called up by simultaneously pressing the “1”, “3”...

  • Page 115: Modifying The Working Parameters

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 9.3. MODIFYING THE WORKING PARAMETERS The procedure for setting the values of the machine’s working parameters (for example, after having replaced the CPU board) is called up by simultaneously pressing the “1”, “3” and “4” keys with the machine in standby mode.

  • Page 116: Up-Down Test

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 9.4. UP-DOWN TEST The procedure for testing the machine’s up-down motor is invoked by simultaneously pressing the “1”, “3” and “4” keys when the machine is in standby mode. The machine display shows:...

  • Page 117: Programming The Hitachi Sj100 Inverter

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 9.5. PROGRAMMING THE HITACHI SJ100 INVERTER The inverter can be programmed using the special keypad installed on board the machine. It is necessary to correctly configure the values of the main functions labeled with an F, and those of the extended functions labeled with A, b, C and H.

  • Page 118: Monitor Function Parameters

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 9.5.1. ONITOR FUNCTION PARAMETERS Parameter Description Motor output frequency Motor current draw Direction of movement Status monitor of intelligent terminal input signals Status monitor of intelligent terminal output signals “Converted” motor output frequency...

  • Page 119: Scheduled Maintenance

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 10. SCHEDULED MAINTENANCE To keep the machine in perfect working order, it is necessary to carry out certain scheduled maintenance actions in order to forestall possible problems. There are essentially 3 types of maintenance operations: •...

  • Page 120: Fortnightly Maintenance Operations

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 10.2. FORTNIGHTLY MAINTENANCE OPERATIONS These operations can be performed by the machine owner and do not require any special skills. The fortnightly maintenance operations involve simple cleaning and lubrication actions and checks on the safety devices, in order to ensure correct and safe operation of the machine.

  • Page 121: Bimonthly Maintenance Operations

    HECKING THE STATE OF WEAR 1. With the machine stopped, check the state of wear of the entire surface of the tread-belt, turning it by hand. If it shows signs of damage or wear, replace it or call in the authorized Technogym Technical Service.

  • Page 122: Yearly Maintenance Operations

    10.4. YEARLY MAINTENANCE OPERATIONS These operations can only be carried out by a qualified technician specifically trained by Technogym and authorized to carry out machine installation and adjustments, as well as special maintenance operations or repairs which require special knowledge of the machine, its operation, safety systems and working procedures.

  • Page 123: Checking The Wear Of The Motor Roller

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 10.4.5. C HECKING THE WEAR OF THE MOTOR ROLLER 1. With the rear and motor rollers, running track and tread-belt disassembled, check the state of wear of the motor roller and clean it to remove any deposits. Replace if there are evident signs of wear.
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  • Page 125: Appendix

    11. APPENDIX 11.1. TECHNICAL NOTES ON CARDIO RECEIVERS Technogym utilizes Polar technology for measuring the heart rate frequency of the person training on the machine. The Polar system consists of: • a transmitter, worn by the person training on the machine, which uses 2 electrodes to detect the electrical activity of the heart and transmits the measured heart rate by sending an electromagnetic signal at a frequency of 5 kHz.

  • Page 126: Type Of Asic

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 There are 3 types of problems which can typically occur on the heart rate signal: • interference caused by disturbances from sources of electromagnetic noise. These problems cause the heart rate signal to deviate from the rear value, typically making it higher;...

  • Page 127: Reducing Receiver Sensitivity

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 of the receiver (detected by the coil) whereas they have no effect on digital components such as the CPU receiver connecting cable. Electromagnetic interference can take different forms: on the one hand, the receiver may detect and hence generate spurious transients or periodic noise pulse, or on the other hand the receiver may become saturated.

  • Page 128: Mechanical Vibrations

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 Sensitivity is reduced by soldering a resistor in parallel with the coil. Normally, the receiver already has a 15 KOhm resistor mounted in parallel with the coil, however it is advisable to check for its presence.

  • Page 129: Routing Of Cables

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 • the receiver must be directed in such a way that its axis of reception is parallel to that of the transmitter, as shown in the figure below: Figure 11.1-2 Please note that even small departures from the above specifications may considerably impair the accuracy of reception.

  • Page 130: Hitachi Sj100 Inverter Error Codes

    In this condition, the dissipator reading is 80 °C. PTC error Problem with the PTC sensor (not used on Spazio Forma). To display the inverter error codes, follow the instructions below or refer to pages 8-2 of the inverter manual:...
  • Page 131 SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 1. Remove the motor guard. 2. Turn on the machine. 3. Repeatedly press the “1” or “2” key on the inverter keypad until the display shows “d08”. 4. Press the “FUNC” key to display the last error which occurred. The following will sequentially appear: •...

  • Page 132: Procedure For Clearing The Error Memory On Hitachi Sj100 Inverter

    SPAZIO FORMA: Service & Maintenance manual - rev. 1.0 11.3. PROCEDURE FOR CLEARING THE ERROR MEMORY ON HITACHI SJ100 INVERTER For all Hitachi SJ100 inverters, it is available an easy procedure for clearing the error memory. To do this: 1. Turn on the machine;...

  • Page 133: Tools To Use

    • 5-gauge hexagonal T-wrench; • 6-gauge hexagonal T-wrench; • 8-gauge hexagonal T-wrench; • 10-gauge hexagonal T-wrench 14; • Special tool provided by Technogym for the eccentrics of the wheels; • Torque wrench. • Hammer CAUTION: Tool measurements are expressed in mm.
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  • Page 136 TECHNOGYM S.p.A. Via G. Perticari, 20 47035 Gambettola (FC) ITALIA Tel.: +39-0547-650438 Fax: +39-0547-650150 e-mail: service@technogym.com 0SM00174-ING...

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