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T631 Repair Manual

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T631 Repair Manual (Electronics) Table of Contents 1-1-1. 1-2-1. 1-3-1. 1-3-2. 1-4-1. 1-5-1. 1-5-2. 1-5-3. 1-6-1. 1-6-2. 1-7-1. Product Picture-T631 Display-T631 Component Placement-T631 Display Component Placement-T631 Drive Board Area Block Diagram-T631 Connections-T631 Display Board Connections-T631 Bridge Board Connections-T631 Bridge Board Indicator LEDs-T631 Display Board Indicator LEDs-T631 Drive Board Display Specifications-T631 2-1-1. Electronics Troubleshooting Chart-T631 3-1-1. 3-2-1. 3-3-1. 3-3-2. 3-4-1. 3-5-1. 3-6-1. 3-6-2. 3-6-3. 3-7-1. 3-8-1. 3-9-1. 3-10-1. Troubleshooting-Safety Key Malfunction-T631 Troubleshooting-Unit Will Not Start Operating-T631 Troubleshooting-Key Malfunction-T631 Troubleshooting-Key Malfunction-T631 Troubleshooting-Telemetry Heart Rate Malfunction-T631 Troubleshooting-Contact (HTR) Heart Rate Malfunction-T631 Troubleshooting-The Fuse Breaks at Start-T631 Troubleshooting-The Fuse Breaks at Motor Start-T631 Troubleshooting-The Fuse Breaks during Use-T631 Troubleshooting-ERROR_1_1_T631 Troubleshooting-ERROR_1_2_T631 Troubleshooting-ERR0R_1_3_T631 Troubleshooting-ERROR_2_1_, ERROR_2_2_T631 Table of Contents (Cont.) 3-11-1. Troubleshooting-ERROR_2_3_T631 3-12-1. Troubleshooting-ERROR_3_1_T631 3-13-1. Troubleshooting-ERROR_8_1_T631 3-14-1. Troubleshooting-ERROR_8_2_T631 3-15-1. Troubleshooting-SERVICE NEEDED-APPLY LUBE-T631 3-16-1. Other Information-Unit Settings and Information-T631 3-17-1. Other Information-Error Messages-T631 4-1-1. 4-2-1. 4-3-1. 4-4-1. 4-5-1. Inspecting and Testing-AC Servo Motor Electrical Open Test-T631 Inspecting and Testing-Incline Zero Switch Test-T631 Inspecting and Testing-Incline Motor Voltage Test-T631 Inspecting and Testing-Motor Thermal Sensor Test-T631 Inspecting and Testing-SAC Motor Encoder Indicator Test-T631 1-1. Product Picture-T631 1-1-1 1-2. Display-T631 1-2-1 1-3. Component Placement-T631 Display 1-3-1 1-3. Component Placement-T631 Display USB/CSAFE board HTR board IPOD board Bridge board 1-3-2 1-3. Component Placement –T631 Drive Board Area 濾波器 AC 升降馬達組 SAC 伺服馬達 1-3-3 驅動器組 1-4. Block Diagram-T631 Cardio board Polarboard board Polar Display board IPOD board Keypad iPod keys Bridge board HTR board iPod earphone jack Safety key board Sensor Sensor AC1 FUSE SW Motor Filter Drive board AC2 Inductor (220v) Encoder Temperature sensor Incline motor Zero switch 1-4-1 To iPod 1-5. Connections-T631 Display Board To telemetry HR receiver To USB/CSAFE board To bridge board (fan) 接至驅動器組 To bridge board (safety key) To bridge board (HTR brd) To bridge board (keys) To iPod board 1-5-1 1-5. Connections-T631 Bridge Board To display board To HTR board To safety key board 1-5-2 1-5. Connections-T631 Drive Board To filter To motor To incline motor To motor thermal sensor To incline zero switch To display board (signal) To display board (power) To encoder 1-5-3 1-6. Indicator LEDs-T631 Display Board Power indicator  Lit indicates display has power. 1-6-1 1-6. Indicator LEDs-T631 Drive Board F1 fuse 15A Encoder indicator Condition indicator  Normal: flashes continuously Incline up (orange) Incline down (green) 1-6-2 1-7. Display Specifications-T631 Details Specification Exterior power Motor Optic sensor Speed range Incline range Illustration Programs Heart rate control program Heart rate 110V / 220V SAC servo motor (with internal thermal sensor) 4.0 HP Magnetic encoder KPH : 0.2 - 20.0(KPH) MPH : 0.1 –12.0(MPH) JAPAN:0.2-16.0(KPH) Power: AC MOTOR (110V or 220V) Incline 0 % -15 % 0-point calibration, time controlled Every 1% = 2sec LED+14-segment LEDs+7-segment LEDs+dot matrix MANUAL, RANDOM, HILL, INTV, FIT TEST, GLUTE CARDIO/ WT LOSS, ZONE TRAINER HTR/telemetry HR 1-7-1 Notes 2-1. Electronics Troubleshooting Chart-T631 Malfunction Safety key malfunction No start up No incline operation Telemetry heart rate Contact heart rate Key (display) Circumstance Inspection and Testing Put safety key in place; there 1. Inspect display bridge board and safety key is no reaction. connections. 2. Replace safety key. Turn on power; display 1. Inspect main fuse. shows no reaction. 2. Inspect drive board fuse. 3. Inspect all cable connections. 4. Inspect display LED and program IC. Press the incline key; incline 1. Inspect incline zero switch. 2. Inspect drive board cable connections. does not operate up or down. 3. Replace drive board. 4. Incline motor malfunction Telemetry heart rate 1. Inspect heart rate transmitter and battery malfunction condition. Replace batteries if they are old. 2. Inspect the heart rate receiver cable connections. 3. Test or replace heart rate receiver. 4. Inspect environment for sources of interference, including speakers and lights. Contact heart rate 1. Inspect HTR cable to the receiver board. malfunction 2. Inspect HTR board indicators. 3. Replace the HTR board. Key does not operate or 1. Replace display key switches operates continuously. or soft keys Key(soft keys) Key does not operate or operates continuously. 1. Inspect bridge board soft key connection. 2. Replace the soft key. 2-1-1 Possible Part Safety key board 1. 2. 3. 4. 1. 2. Main fuse Drive board Cable Display Drive board Zero switch 1. Heart rate transmitter 2. Heart rate receiver 1.HTR board 1. Display keys 2. Soft keys 1.Soft keys Notes ERR0R_1_1_ Servo motor encoder malfunction ERR0R_1_2_ Servo motor thermal sensor excessive heat; motor operates at half speed. ERROR_1_3_ Motor does not rotate ERROR_2_1_ IGBT over current ERR0R_2_2_ IGBT over temperature ERROR_2_3_ Drive board circuit abnormality Incline motor calibration point error ERROR_3_1_ ERROR_3_1_ Incline motor calibration point error 1. If encoder cable connection or encoder is worn, display directly shows ERROR 1_1. 2. Replace the motor Encoder. 1. Inspect the motor for excessive heat. 2. If the motor is not hot, inspect the thermal sensor cable connections. 3. Inspect treadmill walk belt tightness. Adjust or replace walk belt. 1. Motor does not rotate; display shows ERROR_1_3_. 2. Motor has an electrical open. Inspect the motor (red-white-black) wires for a break. 3. Replace the motor. 4. Re-start unit as a test. 5. If issue reoccurs repeatedly, replace SAC drive board. 1. Re-start unit as a test. 2. If issue reoccurs repeatedly, replace SAC drive board. 1. Please replace the drive board. 1. Inspect cable connections. 2. After turning on unit, inspect whether incline motor is hot. If so, the drive board is possibly bad. 1. After turning on unit, inspect whether incline calibrates to 0% position. If not, drive board is possibly bad. 2. Inspect whether incline zero-point switch is normal. 2-1-2 1.Motor encoder 1.Walk belt 1.Motor 1.SAC drive board 1. SAC drive board 1.SAC drive board 1. SAC drive board 2. Incline zero switch 3. Power off Power OFF ERR0R_4_2_ Low voltage error ERROR_4_3_ High voltage error ERROR_8_1_ Communications error at start Communications error after start ERROR_8_2_ Main fuse blew Turn on unit; fuse blows. Main fuse blew Press speed key; motor fuse blows. In use, main fuse suddenly blew. Main fuse blew 1. Re-start unit as a test. 2. If issue reoccurs repeatedly, replace SAC drive board. 1. Power supply voltage is too low. 2. Inspect power supply voltage. Have power supply issue addressed immediately. 3.Re-start unit. Operate. Inspect for safety. 1. Power supply voltage is too high. 2. Re-start unit. If message still appears, power supply voltage is too high. 3. Wait for voltage to drop to protect the treadmill. 1. Cable is not connected. 2. SAC drive board malfunction 1. Inspect for sources of interference in the environment. 2. Inspect power supply ground. 3. Replace SAC drive board. 1. Inspect for electrically “shorted” components. 2. Inspect cable connections for an electrical short. 3. Replace drive board/incline/filter. 1. Inspect motor for abnormality. 2. Replace drive board. 1. Inspect power supply. Is voltage too low? Normal: 110V or 220V +-10%. 2. Inspect walk belt tightness. 3. Inspect walk belt and walk deck for wear. 4. Lubricate the walk belt and walk deck. 5. Replace the SAC drive board as a test. 2-1-3 1.SAC drive board 1.SAC drive board 1. SAC drive board 1.SAC drive board 1.SAC drive board 1.Walk belt 2.SAC drive board SERVICE NEEDED APPLY LUBE Display shows: ”SERVICE NEEDED APPLY LUBE ” Show total distance HTR malfunction FOR ACCURATE HR,HOLD SENSORS FIRMLY WHILE WALKING Every 4000 KM, this message occurs as a prompt to lubricate the walk belt and deck. Follow instructions in the owner manual to lubricate the walk belt and deck. 1. Press key for three seconds to set unit and view total distance, total time, and version numbers of display and drive board firmware. 1. Firmly hold HTR contacts while exercising. 2. If you are holding HTR contacts firmly, inspect HTR contact cable connections. 2-1-4 Troubleshooting Model: T631 Issue: Safety key malfunction Circumstance of malfunction: Put the safety key in place. The display does not operate. Display shows “safety key”. Possible cause: Safety key board malfunction Troubleshooting: 1. Inspect the safety key magnet. 2. Inspect the bridge board cable connections. 3. Test or replace the safety key board. Safety key connection Display board Bridge board Safety key & safety key board Safety key board 3-1-1 Bridge board Troubleshooting Model: T631 Issue: Unit will not start operating. Circumstance of malfunction: Turn power switch on. The display does not light. Possible cause: Inadequate power supply, or component damage. Troubleshooting: 1. Inspect the main fuse and power switch. 2.Inspect all cable connections. 3.Inspect the power switch indicator LED. 4.Inspect the display power indicator LED and main program IC. Cable connection Power indicator Program board Display board Filter AC1 FUSE SW Filter Fuse, switch Drive board AC2 SAC drive board The cable connect to display 3-2-1 Troubleshooting Model: T631 Malfunction: Soft key malfunction (display) Circumstance: Press a key on the display. There is no reaction. Or the key operates continually. Possible causes: 1. Soft keys are not connected. 2. Soft keys are bad. Troubleshooting: 1. Inspect the soft key connections. 2. Replace the soft keys. Soft key connector Keypad Display board Keypad 3-3-1 Troubleshooting Model: T631 Malfunction: Soft key malfunction (display) Circumstance: Press a key on the display. There is no reaction. Or the key operates continually. Possible causes: 1.Soft keys are not connected. 2.Soft keys are bad. Troubleshooting: 1. Inspect the bridge board soft key connections. 2. Replace the soft keys. Soft key connector Display board Bridge board Bridge board Soft key connector Keypad 2 3-3-2 Troubleshooting Model: T631 Issue: No heart rate reading appears. Circumstance: No heart rate reading appears. Possible causes: 1. Heart rate transmitter battery power is insufficient. 2. Heart rate receiver is bad. 3. Environmental noise, such as lights and speakers, interferes with reception. Troubleshooting: 1. Replace transmitter or its batteries. 2. Inspect the telemetry heart rate receiver. 3. Replace the telemetry heart rate receiver. Telemetry heart rate receiver board Red LED is heart rate signal indicator. Heart rate board cable connector Display board Heart rate transmitter (battery location) Heart rate receiver board Transmitter 3-4-1 Troubleshooting HTR Indicators Model: T631 Malfunction: Contact (Heart Touch Rate) malfunction Circumstance: Place hands on heart rate contact sensors. Heart rate values appear to be inaccurate. Possible causes: 1.HTR cable connection 2. HTR board malfunction 3. Display cable connections Troubleshooting: 1. Inspect the display cable connections. 2. Inspect bridge board HTR cable connections. 3. Inspect contact heart rate cable connections. 4. Inspect the HTR board indicator LEDs. 5. Replace the HTR board. LED LED1 Name POLAR LED LED2 HTR contact LED LED3 HTR signal LED LED4 HR output Function Flashing indicates incoming telemetry signal. Lit indicates user is gripping HTR contact. Flashing indicates incoming HTR signal. Each flash indicates a pulse signal output. Display HTR connector Display board HTR Bridge board HTR cable HTR board HTR Sensor-R Sensor-L 3-5-1 HTR contact plate (clean here) Troubleshooting Model: T631 Malfunction: The fuse breaks at start. Circumstance: The fuse breaks as soon as power is turned on. Possible cause: 1. Components have an electrical short. 2. Drive board components are malfunctioning. Troubleshooting: 1. Remove the power cord. Test components for an electrical short. • AC1 to a screw on the frame • AC2 to a screw on the frame 3. Replace the drive board as a test. AC1 FUSE SW Filter Drive board AC2 3-6-1 Troubleshooting Model: T631 Malfunction: The fuse breaks at motor startup. Circumstance: Press the speed up key to start the motor. The fuse breaks. Possible cause: 1. The motor has an internal electrical short. 2. The drive board is malfunctioning. Troubleshooting: 1. Replace the drive board as a test. 2. Replace the motor as a test. 3. Replace the encoder as a test. Display board Encoder Motor SAC drive board Encoder Motor SAC drive board 3-6-2 Troubleshooting Model: T631 Malfunction: The fuse breaks during operation. Circumstance: After a period of use, the fuse breaks. Possible cause: 1.The fuse holder is not connected properly. 2. The walk deck or walk belt is worn. 3. The SAC drive board is malfunctioning. Troubleshooting: 1.Inspect the fuse and fuse holder installation. 2. Inspect mechanical parts: A. Inspect the walk belt and drive belt for wear. Lubricate the walk belt. B. Inspect whether the walk belt is too tight or too lose. 3.Replace the SAC drive board as a test. Motor Display board SAC drive board Encoder Motor 3-6-3 SAC drive board Troubleshooting Model: T631 Malfunction: ERR0R_1_1_ Circumstance: Press the speed key. ERR0R_1_1_ appears. Possible cause: Motor encoder malfunction Troubleshooting: 1. Inspect cable connections. 2. Inspect the encoder signal indicator. If necessary, inspect the encoder for wear. 3. Replace the SAC drive board. Remove motor back cover. Inspect encoder board Encoder indicator Display board 馬達 SAC drive board Encoder Motor 3-7-1 Troubleshooting Model: T613 Malfunction: ERR0R_1_2 Circumstance: ERR0R_1_2 appears. Speed slows to half. Possible cause: 1. Walk deck and belt are worn. 2. Motor thermal sensor is malfunctioning, or there is a poor cable connection. Troubleshooting: 1. Inspect the thermal sensor on the motor. Low temperature: Electrically “closed” circuit. High temperature: Electrically “open” circuit. If not as above, the thermal sensor is bad. 2.When the message appears, if the motor temperature is high, the walk deck and belt are worn. Lubricate the walk deck and belt or replace the walk belt. 3. If the motor is not hot when the message appears, inspect whether the thermal sensor cable is connected. Thermal sensor Display board SAC drive board Motor Thermal sensor 3-8-1 Troubleshooting Model: T613 Malfunction: ERR0R_1_3_ Circumstance: The motor does not rotate. The display shows ERR0R_1_3. Possible causes: 1. The motor is stuck or has an electrical open. Troubleshooting: 1. Re-start the unit. Does the issue reappear? 2. Inspect all cable connections. 3. Inspect whether the motor is stuck. 4. Inspect whether the motor has an electrical open. 5. Inspect whether motor wires (red-black-white) have an electrical open. Display board Motor SAC drive board Motor 3-9-1 Troubleshooting Model: T631 Malfunction: ERR0R_2_1_, ERROR_2_2. Circumstance: Display shows ERR0R_2_1, ERROR_2_2. Possible causes: 1.SAC drive board IGBT excessive heat or excessive current Troubleshooting: 1. Re-start the unit. Test to see whether the message appears again. 2. Stop the unit for ten minutes, and test it again. 3. If the message appears again, please replace the SAC drive board. Display board SAC drive board Fuse 15A (Motor) Motor 3-10-1 SAC drive board Troubleshooting Model: T631 Malfunction: ERR0R_2_3 Circumstance: Display shows ERR0R_2_3_. Possible cause: 1. Drive board internal circuit abnormality. Troubleshooting: 1. Re-start the unit as a test. 2. Replace the SAC drive board. Display board SAC drive board SAC drive board Motor 3-11-1 Troubleshooting Model: T631 Malfunction: ERROR_3_1_ Circumstance: Turn on the treadmill. The incline does not return to the 0% position. Possible cause: 1. Drive board or motor malfunction 2. Incline zero point calibration switch indicator malfunction Troubleshooting: 1. Inspect the incline fuse on the drive board. 2. Inspect the incline UP/DOWN LEDs and measure the voltage to the incline motor. 3. Inspect zero switch operation. 4. Replace the drive board or the incline motor unit. Incline voltage Incline up down Incline LED orange green Incline cable white-black white-red Zero point calibration switch Incline Worm gear 0% Touches switch 1-15% Not touching switch Zero switch on off Zero switch Display board SAC drive board UP LED (orange); DN LED (green) Zero SW AC incline unit 3-12-1 Incline voltage 110V or 220V 110V or 220V Troubleshooting Model: T631 Malfunction: ERROR_8_1_ Circumstance: After turning on the unit, the display shows ERROR_8-1. Possible cause: 1. Signal issue between the SAC drive board and the display program Troubleshooting: 1. After turning on the unit, the display board communicates with the drive board. If communication does not occur, ERROR_8_1_ appears. 2.Inspect whether the SAC drive board can start the unit. 3. Inspect the display/drive board communication signal indicator LED on the drive board. Normally, this LED flashes at a set frequency. 4. Replace the SAC drive board or display board program IC as a test. Display board The cable connect to display (signal) Drive board 3-13-1 Troubleshooting Model: T631 Malfunction: ERROR_8_2_ Circumstance: During operation, the display shows ERROR_8_2_. Possible cause: 1. Interference of communication between the display and drive boards Troubleshooting: 1. Inspect the display-to-drive board data cable connection. 2.After the error message appears, re-start the unit. This may clear the communication issue and thereby clear the error message. 3.If the message does not clear after re-starting the unit, replace the SAC drive board. Display board Drive board The cable connect to display (signal) 3-14-1 Troubleshooting Model: T631 Malfunction: SERVICE NEEDED-APPLY LUBE Circumstance: The message “SERVICE NEEDED-APPLY LUBE” appears, and the unit stops operating. At 4000 km of use, the lubrication service prompt “SERVICE NEEDED-APPLY LUBE” appears. Troubleshooting: 1. Insert the lube applicator tube as shown. 2. Simultaneously press and hold +INCLINE<▲>+INCLINE<▼> for two seconds to activate the lubrication mode. The display counts down (3, 2, 1). The speed window shows 2.0 kph (or 1.3 mph), and the walk belt starts rotating. 3. Squeeze the bottle of lubricant into the applicator tube. Let the unit operate slowly for ten minutes. Allow the lubricant to disperse onto the walk belt. 4. After ten minutes, press the key and remove the lube applicator tube. The display program will clear the lube distance memory. A new lubrication distance will begin to accrue. 5. After lubricating the walk belt, operate the treadmill for ten minutes to let the lubricant disperse. 3-15-1 Other Instructions Model: T631 Item: Unit settings and information: KPH/MPH units, distance, time, display board program, and drive board program versions. Method: 1. Press and hold the key for three seconds to enter the user setting mode. 2. Metric/imperial unit setting: Display shows “UNIT-MPH” (imperial) or “UNIT-KPH” (metric) units. Press the INCLINE<▲> or <▼> keys to toggle between MPH and KPH settings. Then press the <ENTER> key to confirm your choice. 3. Total distance The display shows “DIST-XXXXXXKM, followed by numbers which represent the total the distance of the walk belt rotation. Press the key to proceed to the next setting. 4. Total time The display shows “TIME-XXXXXXHOUR, followed by numbers which represent the total time of use. Press the key to proceed to the next setting. 5. Display program version Press the INCLINE <▲> key to view the display program version, for example, CTL XT631H-1A. Press the ENTER key to exit the program. 6. Drive board program version Press the INCLINE <▼> key to view the drive board program version, for example, DRV –SAC--AF. Press the key to exit the program. 3-16-1 Other Instructions Model: T631 Item: Error messages E1_1 : Servo motor encoder abnormality. Re-start the unit. E1_2 : Servo motor excessive heat warning. Motor operates at half speed. E1_3 : The motor does not rotate; the motor is stuck or has an electrical open. E2_1 : IGBT over current. Turn off unit. Let it sit idle 10 minutes before restarting the unit. E2_2 : IGBT excessive heat warning. Motor operates at half speed. E2_3 : The current sensor on the drive board detects excessive current; the drive board has an issue. E3_1 : Incline motor calibration point abnormality. POWER OFF : Power switch is OFF. E4_2 : Power supply voltage is too low. Wait until voltage returns to normal before starting the unit. E4_3 : Power supply voltage is too high. Wait until voltage returns to normal before starting the unit. E8_1 : Communication abnormality at start up. E8_2 : Communication abnormality during use. 3-17-1 Inspecting and Testing Model: T631 Name: Test for an electrical open on the AC servo motor Method: 1. Disconnect motor wires. Set the voltmeter to the ohm setting. Place red and black probes separately on motor wires as indicated. Normal readings: Motor wires green-black green-white green-red black-white black-red white-red Ohm setting No reaction No reaction No reaction Short Short Short Notes The green wire is the ground wire The green wire is the ground wire The green wire is the ground wire 2.If the black-white, black-red, or white-red wires have an electrical open, the motor has a broken wire. ERRROR 1_3_ will appear. 4-1-1 Inspecting and Testing Model: T631 Name: Incline zero point switch inspection Method: 1. Press the INCLINE<▲> or <▼> key. Inspect the incline and zero point switch operation. 2. Zero point switch operation Incline Zero switch 0% ON (close) 1-15% OFF (open) Incline 0%: zero switch operates Incline 1-15%: zero switch does not operate 4-1-2 Inspecting and Testing Model: T631 Name: Incline zero point switch inspection Method: 1.Turn on power. At 0% incline, the zero switch is touched by the worm gear; The zero switch is on (electrically “closed”). At 1%-15%, the zero switch is not touched by the worm gear; The zero switch is off (electrically “open”). Zero switch Incline Tube Zero switch Picture 4-2-1 0% Touches switch on 1-15% Does not touch switch off Inspecting and Testing Model: T631 Name: Incline motor voltage test Method: 1.Set the voltmeter to the 300 VAC or higher voltage setting. 2.Press INCLINE<▲>/<▼> keys. Incline indicator LEDs on the drive board light. Measure voltage output to the incline motor. Normal readings are shown below. Display Drive board Incline motor cables Incline operates Press <▲> key UP (orange) lights white-black  110V or upward 220V Press <▼> key DOWN (green) lights white-red 110V or downward 220V Up LED (orange); DN LED (green) Display board Black Drive board UP (orange) DOWN (green) Red Incline motor White 4-3-1 Incline voltage cable Inspecting and Testing Model: T631 Name: Motor thermal sensor test Method: 1.When the temperature of the motor is normal, the display operates without any abnormality. Remove the motor thermal sensor cable. The display shows “SERVICE REQUIRED…” 2.When the motor has been used for a long period of time, and the display shows “SERVICE REQUIRED…” touch the motor; The motor surface feels hot. 4-4-1 Inspecting and Testing Model: T631 Name: SAC motor encoder indicator test Method: 1.Turn on power. The display lights. The display shows “ERROR 1_1”. ERROR 1_1 usually indicates an encoder issue. 2. When the motor rotates, the drive board encoder LED flashes. 3. When ERROR 1_1 appears, remove the encoder cover. Inspect whether the encoder board has wear. Remove the motor cover. Inspect whether the encoder board is worn. Encoder indicator 4-5-1