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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.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 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.
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.3. D ........................7.4 ISASSEMBLING THE BOARD 7.4. D ........................7.5 ISASSEMBLING THE KEYBOARD 7.5. D ......................7.6 ISASSEMBLING THE CARDIO RECEIVER 7.6. D ......................7.7 ISASSEMBLING THE UPRIGHT GUARD 7.7.
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 10.3.6. Checking the state of wear of the alternator belt................10.4 10.3.7. Lubricating the lever group......................10.4 10.3.8. Checking the operation of the cardio receiver ................10.4 10.3.9. Checking the operation of the hand sensor receiver ............... 10.4 10.3.10.
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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.
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.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 2.5.1. ONNECTORS • Patch cables Name type of connector connection CN10 AMP MATE-N-LOCK 6-pin M free to connection on frame CN11 AMP MATE-N-LOCK 6-pin F panel to alternator board • CPU board...
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 2.5.2. IRING RT-1A: Internal connecting cable CPU board – Connector on frame CPU board Signal Color Patch cable CN10 +12 Vdc + 5 Vdc Orange Ground Black -12 Vdc Blue...
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 RT-5/L: Alternator cable Alternator interface board – Alternator – Resistor Alternator Signal Color Alternator Resistor interface board Alternator RPM X 6 Violet eyelet 4 Resistor - Blue Yellow eyelet 6...
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 CR-XT: Non coded heart rate meter cable CPU board – Cardio receiver CPU board Signal Color Receiver +5 Vdc Pulse per beat Blue Ground Black RT-3FRX: Hand sensor cable CPU board –HS interface board...
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 2.6. WIRING DIAGRAM WITH CODED RECEIVER The only difference compared to the model with non-coded receiver is the NSC-XT cable between the CPU board and the coded receiver, which is described below:...
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 NSC-XT: Non coded heart rate meter cable CPU board – Cardio receiver CPU board Signal Color Receiver +5 Vdc Pulse per beat Blue Ground Black Page 2.8...
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 3. PRINCIPLES OF OPERATION 3.1. BLOCK DIAGRAM The block diagram of the machine is shown in the figure below: 3.1.1. ISPLAY It consists of various components that will be individually described below:...
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 CARDIO RECEIVER It is connected to the machine’s CPU board and receives the pulses sent by the transmitter. There are 2 types of receiver: • Non-coded: this is the standard product.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 • 1 serial port for connecting to the TGS reader; • 1 serial port, currently not used, for future connections; • 1 RJ45 port for the power supply to the portable Cardio Theater unit.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 3.2. ALTERNATOR CONTROL 3.2.1. ECHANICS The movement of the pedals turns the alternator by means of a belt. The pedal resistance perceived by the user results from a combination of 2 factors: •...
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 3.2.3. HE CONTROL SIGNALS The machine controls the difficulty level of the workout by means of the CPU board, the alternator interface board and the alternator, as illustrated in the figure below:...
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 • RPM Signal This is the speed signal output by the alternator. It enters the alternator interface board (pin 1-5 of connector CN2) and is a square wave which varies from –1 Vdc to a maximum value...
4. ACCESSORIES 4.1. CONNECTING TO THE TGS The machine is connected to the Technogym System by means of the 9 pin male D-connector, situated on the back of the control panel, which provides the RS 232 serial port for connecting the TGS reader.
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 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.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 5.3. FIRST POWER-ON After completing the installation procedure, the machine is ready to be powered up. To turn on the machine, simply toggle the on/off switch from the 0 position to the 1 position.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 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.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 6.1. THE DISPLAY DOES NOT ILLUMINATE This error is generated when the supply voltage does not reach the control panel. THE DISPLAY DOES NOT ILLUMINATE Connect machine to a Does the wall output supply...
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 Replace cable Is the mains voltage present connecting the input at the filter input? socket / on-off switch block to the filter Is the mains voltage present Replace the filter...
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 Are all DC voltages present at Replace the alternator the output of the alternator interface board interface board? Replace cable connecting the Are all the DC voltages alternator interface present on panel connector?
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 As for step (5) but on connector CN1 of the alternator interface board. As for step (5) but on panel connector. As for step (5) but on connector CN1 of the display CPU board.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 6.2. THERE IS NO RESISTANCE This error can be caused by absence of the speed signal, problems with the excitation circuit, overheating of the alternator or defective alternator brushes. THERE IS NO...
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 6.3. THE RESISTANCE IS INCORRECT The resistance is incorrect if the alternator does not receive the correct excitation signal or if the power resistor is defective. RESISTANCE IS INCORRECT Is the alternator excitation...
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 Does the CPU board send Replace the alternator the correct control signal to interface board the alternator interface board? Replace the cable Replace the cable between the panel Is the control signal at the...
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 BE AWARE: Because all tester probes have a non zero internal resistance, which varies depending on the model and may be in the same order of magnitude as the quantity being measured, the following procedure is recommended: 1.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 6.4. THE SPM VALUE IS INCORRECT The occurrence of this error indicates problems with the RPM signal output by the alternator. THE SPM VALUE IS INCORRECT Is the SPM purple wire of...
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 Replace cable which connects the alternator Is the SPM signal on panel interface board to panel connector CN11 correct? connector CN11 Replace cable which Replace the display CPU connects the CPU board...
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 6.5. THERE IS NO HEART RATE SIGNAL 6.5.1. ELEMETRIC RECEIVER The machine displays this error if the receiver is not functioning, or if it fails to receive the power supply from the CPU board.
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 THERE IS NO HEART RATE SIGNAL Are the sensors correctly connected to the HS interface Reinstate the connection board? Does the correct supply voltage reach connector HD4 of the HS...
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 6.6. THE TELEMETRIC HEART RATE SIGNAL IS INCORRECT The machine generates this error if the receiver is disturbed by electromagnetic noise in the surrounding environment. THE HEART RATE SIGNAL IS...
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 Is the transmitter always Keep the transmitter within a distance of 80 cm within the minimum Change the receiver from the receiver? reception distance Follow the procedure step by step to correctly diagnose the problem. Take particular care with the...
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7. DISASSEMBLY OF COMPONENTS 7.1. DISASSEMBLING THE DISPLAY 1. Turn off the machine and unplug the mains lead from the wall output. 2. Unscrew the 2 screws a using a large Phillips screwdriver.
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 5. Open the DISPLAY taking care to the RJ45- RS232 board c. To remove the DISPLAY: 1. Disconnect connectors d. 2. Remove the DISPLAY. To reassemble the DISPLAY, carry out the above steps in reverse order.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.2. DISASSEMBLING THE EPROM Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display on a work bench: 1. Remove EPROM a from its socket using an integrated-circuit extractor tool.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.3. DISASSEMBLING THE CPU BOARD Carry out the procedures described in paragraph 7.1. “Disassembling the display”. With the display placed on a work bench: 1. Disconnect the connectors a. 2. Remove the 5 screws b, using a small Phillips screwdriver.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.4. DISASSEMBLING THE KEYBOARD Carry out the procedure described in paragraph 7.1. “Disassembling the display”. 1. Disconnect KEYBOARD connector a. Figure 7.4-1 With the display placed on a work bench: 1.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.5. DISASSEMBLING THE CARDIO RECEIVER Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display on a work bench: 1. Unscrew the 2 screws a using a small Phillips screwdriver.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.6. DISASSEMBLING THE UPRIGHT GUARD 1. Turn off the machine and unplug the mains lead from the wall output. 2. Unscrew the 6 screws a which secure the UPRIGHT GUARD, using a large Phillips screwdriver.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.7. DISASSEMBLING THE FRAME GUARDS 1. Turn off the machine and unplug the mains lead from the wall output 2. Back off the screw a using a large Phillips screwdriver.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.8. DISASSEMBLING THE CENTER HANDLEBAR Carry out the procedure described in paragraph 7.6. “Disassembling the upright guard”. 1. Disconnect the 2 connectors a. 2. Cut the locking strips of the sensor cables.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.9. DISASSEMBLING THE SIDE HANDLEBARS Carry out the procedure described in paragraphs 7.6. “Disassembling the upright guard” and 7.8. “Disassembling the center handlebar”. 1. Unscrew the 2 screws a using a 6-mm hex T wrench.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.10. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS Carry out the procedure described in paragraph 7.7. “Disassembling the frame guards”. 1. On each side, back off the 2 nuts a using a 10-mm wrench.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.11. DISASSEMBLING THE HS INTERFACE BOARD Carry out the procedure described in paragraph 7.6. “Disassembling the upright guard”. 1. Disconnect connectors a and b. 2. Back off the 2 screws c using a medium Phillips screwdriver.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.12. DISASSEMBLING THE HAND SENSORS 1. Turn off the machine and unplug the mains lead from the wall output. For each SENSOR: 2. Use a pointed tool (such as a screwdriver) to leverage inside the SENSOR slot a.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.13. DISASSEMBLING THE ALTERNATOR Carry out the procedure described in paragraph 7.7. “Disassembling the frame guards”. 1. Disconnect the ALTERNATOR cables. 2. Unscrew the nut a using a 17-mm wrench.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.14. DISASSEMBLING THE BELT Carry out the procedure described in paragraph 7.7. “Disassembling the frame guards”. 1. Back off the nut a with a 17-mm wrench. 2. Back off the dowel b with a 4-mm hex T wrench.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.15. DISASSEMBLING THE REAR COVER 1. Turn off the machine and unplug the mains lead from the wall output. 2. Turn the machine over on one side. 3. Back off the 4 nuts a using a 19 mm wrench.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.16. DISASSEMBLING THE PEDAL LEVER GROUP Version A: TNS - locked pedals. Carry out the procedures described in paragraphs 7.7. “Disassembling the frame guards” and 7.15. “Disassembling the rear cover”.
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 Version B: TNSS - floating pedals. Carry out the procedures described in paragraphs 7.7. “Disassembling the frame guards” and 7.15. “Disassembling the rear cover”. On each side: 1. Unscrew the screw a fixing the PEDAL LEVER GROUP to the flywheel, using a 6- mm T wrench.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.17. DISASSEMBLING THE PEDALS GROUP For each PEDAL: 1. Unscrew the 4 screws a fixing the PEDAL to the pedal lever using a 5-mm T wrench. 2. Remove the PEDAL.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.18. DISASSEMBLING THE PEDAL WHEEL TRACK Carry out the procedure described in paragraph 7.15. “Disassembling the rear cover”. On each side: 1. Unscrew the 3 screws a fixing the PEDAL WHEEL TRACK to the frame using a 5-mm hex wrench.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.19. DISASSEMBLING THE PEDAL WHEELS Carry out the procedure described in paragraph 7.15. “Disassembling the rear cover”. For each PEDAL WHEEL: 1. Unscrew the screw a using a 24-mm pin wrench.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.20. DISASSEMBLING THE FLYWHEELS Carry out the procedures described in paragraphs 7.7. “Disassembling the frame guards” and 7.16. “Disassembling the pedal lever group”. To disassemble the RIGHT FLYWHEEL: 1. Unscrew the fixing screw a of the RIGHT FLYWHEEL using a 17-mm wrench.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 7.21. DISASSEMBLING THE ALTERNATOR BRUSHES Carry out the procedure described in paragraph 7.7. “Disassembling the frame guards”. 1. Disassemble the alternator cable a. 2. Unscrew the BRUSH group clamping screw b using a large Phillips screwdriver.
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 8. ADJUSTMENTS 8.1. BELT ALIGNMENT Carry out the procedure described in paragraph 7.7. “Disassembling the frame guards”. 1. Back off the lock nut a on the alternator pivot b using a 19-mm wrench.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 8.2. BELT TENSION Carry out the procedure described in paragraph 7.7. “Disassembling the frame guards”. 1. Back off the nut a using a 17-mm wrench. 2. Back off the dowel b of alternator pivot c.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 8.3. WEAR OF ALTERNATOR BRUSHES Carry out the procedure described in paragraph 7.21. “Disassembling the alternator brushes”. 1. Inspect the 2 brushes for wear, referring to the figures at left and the descriptions below: •...
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 9. CONFIGURING THE MACHINE 9.1. USER SETTING PARAMETERS To change the settings of the machine, when the equipment is in the standby mode, press numeric keys 314 at the same time. The following will appear on the LED matrix: PASSWORD = 0 Now, use the numeric keys to enter 2406 (the password) and press ENTER to confirm.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 EASUREMENT SYSTEM EUR = EUROPEAN USA = AMERICAN and press ENTER to confirm your choice. 9.1.3. AXIMUM TIME You can set the maximum time that can be programmed for each exercise. To change the current...
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 9.1.6. “ENTER” NABLING THE The “ENTER” key can be enabled to increase the amount of exercising time during manual and CPR training sessions. To change the current setting, when the setting is actually in use will scroll...
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 EVER SYSTEM TNS = FIXED TYPE TNSS = MOVABLE TYPE and press ENTER to confirm your choice. 9.2.2. NABLING USE OF THE HAND SENSOR It is possible to enable the use of the sensors acquisition of the heart rate. To change this setting,...
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 HOURS ON = xxx Press ENTER to go ahead. 9.3.2. OURS OF USE The number of hours the machine has been operating: HOURS OF USE = xxx Press ENTER to go ahead.
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 10. SCHEDULED MAINTENANCE To keep the machine in perfect working order and prevent the risk of malfunction, it is necessary to perform the scheduled maintenance operations set out in the table below. There are 3 basic types of maintenance operations: •...
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 10.2. ROUTINE MAINTENANCE OPERATIONS These operations can be carried out by the owner of the machine and do not require any special skills. The internal cleaning procedures are simple cleaning operations aimed at keeping the interior of the machine clean.
10.3. SPECIAL 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.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 10.3.6. C HECKING THE STATE OF WEAR OF THE ALTERNATOR BELT 1. Check the state of wear of the belt, turning it by hand using the alternator flywheel. In particular, check the edges and the inner part of the belt.
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.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 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;...
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 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.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 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.
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 Figure 11.1-2 Please note that even small departures from the above specifications may considerably impair the accuracy of reception. The optimal configuration is therefore that shown in the figure below: Figure 11.1-3...
ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 11.2. PERSONAL CODED DEVICE The machine can be equipped with a new heart rate receiver based on the PERSONAL CODED DEVICE technology developed exclusively by Technogym in conjunction with POLAR.
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ROTEX 600 XTPRO: Service & Maintenance Manual - rev. 1.1 Code T (msec) At the start of the training session, the coded receiver first of all seeks to detect a coded signal for a maximum of 10 seconds. This is done in reduced sensitivity mode to avoid receiving a signal from users on adjacent machines.
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TECHNOGYM INDUSTRIE S.r.l. Via G. Perticari, 20 47035 Gambettola (FC) ITALIA Tel.: +39-0547-56047 Fax: +39-0547-650150 e-mail: service@technogym.com 0SM00079-ING...
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