T652 Repair Manual (Electronics)

T652 Repair Manual (Electronics)

Table of Contents 1-1-1. Product Illustration T652 1-2-1. Display T652 1-3-1. Component Placement T652 Display 1-3-2. Component Placement T652 Drive Compartment 1-4-1. Block Diagram of Electronic Components T652 1-5-1. Cable Connections - T652 Display 1-5-2. Cable Connections - T652 EAC Drive Board 1-6-1. LED Indicators - T652 Display Board 1-6-2. LED Indicators - T652 Drive Board 1-7-1. Electronic Specifications - T652 2-1-1. Electronic Component Troubleshooting Chart - T652 3-1-1. Troubleshooting Safety Key Malfunction - T652 3-2-1. Troubleshooting Unit Will Not Start - T652 3-3-1. Troubleshooting No Telemetry Heart Rate - T652 3-4-1. Troubleshooting Key Malfunction Soft Keys - T652 3-5-1. Troubleshooting Key Malfunction Display Keys - T652 3-6-1. Troubleshooting Incline Operation Malfunction - T652 3-7-1. Troubleshooting Contact Heart Rate Malfunction - T652 3-8-1. Troubleshooting Fuse Breaks at Start T652 3-8-2. Troubleshooting Fuse Breaks at Speed - T652 3-8-3. Troubleshooting Fuse Breaks in Use - T652 3-9-1. Troubleshooting ERROR_1_1_T652 3-9-2. Troubleshooting ERROR_1_2_T652 3-9-3. Troubleshooting ERR0R_1_3_T652 3-10-1. Troubleshooting ERROR_2_1_T652 3-11-1. Troubleshooting ERROR_3_1_T652 3-12-1. Troubleshooting ERROR_8_1_T652 3-12-2. Troubleshooting ERROR_8_2_T652 3-13-1. Troubleshooting SERVICE NEEDED-APPLY LUBE-T652 3-14-1. Other - KPH/MPH, distance, time, display/drive board program versions - T652 3-15-1. Other Error Message Chart - T652

1-1. Product Illustration 1-1-1

1-2. Display - T652 1-2-1

1-3. Component Placement - T652 Display Telemetry heart rate receiver Display board IPOD earphone board HTR board IPOD audio board Bridge board CARDIO board 1-3-1

1-3. Component Placement - T652 Drive Compartment EAC drive board EAC servo motor (green sticker designates EAC) Inductor AC incline motor Filter 1-3-2

1-4. Block Diagram of Electronic Components - T652 Polar board Polar board Display board Cardio board Keypad ipod board To ipod Safety key board HTR board Bridge board ipod keys ipod earphone jack Sensor Sensor AC1 AC2 Fuse SW Inductor Filter Drive board Motor Speed sensor Thermal switch Incline motor 0% switch 1-4-1

1-5. Cable Connections - T652 Display To telemetry heart rate receiver To bridge board To drive board To ipod board To cardio board To ipod board 1-5-1

1-5. Cable Connections - T652 EAC Drive Board To thermal sensor To motor To filter To incline motor To display 接至電子表組 board To incline 0% switch To motor speed sensor 1-5-2

1-6. Indicator LEDs - T652 Display Board Power indicator LED Indicates display is receiving power. 1-6-1

1-6. LED Indicators - T652 Drive Board F1 fuse 15A 1-6-2

1-7. Electronic Specifications - T652 Item Details Notes Power supply 110V / 220V Motor AC servo motor (includes internal thermal sensor) 5.0 HP Speed sensor Optic encoder KPH: 0.2-24.0 (KPH) Speed range MPH: 0.1 15.0 (MPH) Japanese: 0.2-20.0 (KPH) Power: AC motor (110V or 220V) Incline range: 0 % -15 % Incline range 0% setting, time control 1% per second Display method LED+16-segment+7-segment LED+dot matrix MANUAL, HILL 1 2 3, RANDOM, Program mode GLUTE, INTERVAL, TRACK, FAT BURN Heart rate control CARDIO, WT LOSS, ZONE TRAINER program Heart rate Contact HTR / telemetry heart rate Japanese version limits speed to 18 KPH AC electronic automatic adjustment 1-7-1

2-1. Electronic Component Troubleshooting Chart - T652 Malfunction Circumstance Inspection or test point Replace Notes Safety key operation is malfunctioning Put Safety key in place. There is no reaction from the display. Safety Key error 1. Inspect the cable connections at the bridge board and safety key 2. Replace the safety key. Safety key board No start up No incline operation No telemetry heart rate reception No contact heart rate reception Key malfunction (display) Key malfunction (soft key) message appears. Turn on the power. Display shows no reaction. Press incline keys. The incline does not operate up or down. Telemetry heart rate does not function. Contact heart rate does not function. Keys do not operate or keys operate continuously. Keys do not operate or keys operate continuously. 1. Inspect main fuse. 2. Inspect drive board fuse and LED. 3. Inspect all cable connections. 4. Inspect display LED and program IC. 1. Inspect incline 0% switch. 2. Inspect drive board cable connections. 3. Replace drive board. 4. Incline motor malfunction. 1. Inspect heart rate transmitter strap and battery. Replace the battery if the strap has not been used for a long time. 2. Inspect heart rate receiver board cable connection. 3. Inspect or replace the telemetry heart rate receiver board. 4. Inspect environment for interference, such as speakers and lights. 1. Inspect the HTR cable connection to the bridge board. 2. Inspect the HTR indicator LEDs. 3. Replace the HTR board. 1. Main unit fuse 2. Drive board 3. Cables 4. Display 1. Drive board 2. 0% switch 1. Heart rate transmitter 2. Heart rate receiver 1.HTR board 1. Replace the display key switches. Display board key switches 1. Inspect the soft key cable connection on the bridge Soft keys board. 2. Replace the soft key. 2-1-1

2-1. Electronic Component Troubleshooting Chart - T652, Continued. Malfunction Circumstance Inspection or test point Replace Notes ERR0R_1_1_ Servo motor encoder malfunction ERR0R_1_2_ Servo motor thermal sensor is activated; speed is reduced to half speed. 1. If motor does not rotate, the EAC drive board could be the issue. 2. If the motor rotates and ERROR_1_1_ appears, replace the motor speed sensor. 1. Inspect motor temperature. If it is not hot, inspect the thermal sensor cable connection. 2. Inspect walk belt tightness. 3. Inspect walk belt wear. 4. Lubricate the belt. If lubrication is not effective, replace the walk belt.. ERROR_2_1_ IGBT over current malfunction 1. Re-start the unit as a test. 2. If issue is repeated, replace the EAC drive board. ERR0R_2_2_ IGBT over heat malfunction 1. Re-start the unit as a test. 2. If issue is repeated, replace the EAC drive board. ERROR_3_1_ Incline motor calibration malfunction 1. Inspect cable connections. 2. After starting the unit, feel the incline motor. If hot, the drive board is malfunctioning. 3. After starting the unit, inspect whether incline 0% switch operates. If so, the drive board is malfunctioning. 4. Inspect the 0% switch operation. Power off Power is off. 1. Re-start the unit as a test. 2. If issue is repeated, replace the EAC drive board. ERR0R_4_2_ Low voltage supply 1. Power supply is too low. 2. Measure power supply voltage. If too low, external power supply is insufficient. Please have an electrician address the situation. 3. After fixing the power supply, use the product to confirm its safety. 1. EAC drive board 2. Servo encoder 1. Walk belt 1. EAC drive board 1. EAC drive board 1.EAC drive board 2.Incline 0% switch 1. EAC drive board 2-1-2

2-1. Electronic Component Troubleshooting Chart - T652, Continued. Malfunction Circumstance Inspection or test point Replace Notes ERROR_4_3_ High voltage supply 1. External power supply voltage is too high. 2. Turn off unit. Re-start the unit. If the message still appears, this may be a time period of low voltage use, creating excessive voltage. This issue often occurs in industrial areas. 3. For safety, wait until the power supply voltage drops before using ERROR_8_1_ Communication error at start up ERROR_8_2_ Communication error after start up Main fuse breaks. Main fuse breaks. Main fuse breaks. SERVICE NEEDED - APPLY LUBE Fuse breaks at start up Press the speed key; motor rotates; fuse breaks. During use, main fuse suddenly breaks. Display shows: SERVICE NEEDED - APPLY LUBE the unit. 1. Cables are not connected. 2. EAC drive board is malfunctioning. 1. Inspect for environmental interference. 2. Inspect power supply for an actual ground. 3. Replace the EAC drive board. 1. Inspect components for electrical shorts. 2. Inspect power supply for an electrical short. 3. Replace the drive board/incline/filter. 1. Inspect the motor for abnormalities. 2. Replace the drive board. 1. Inspect the main power supply for low voltage. Normal is 110v (N. America) or 220v (Europe) +-10%. 2. Inspect whether walk belt is excessively tight. 3. Inspect the walk belt and deck for wear. Lubricate the walk belt. 4. Inspect the fuse holder and fuse. 5. Replace the EAC drive board as a test. This lubrication prompt appears every 4000 KM. Follow lubrication and maintenance procedures in the owner s manual. 1. EAC drive board 1. EAC drive board 1. EAC drive board 1. EAC drive board 1. Walk belt 2. EAC drive board 2-1-3

2-1. Electronic Component Troubleshooting Chart - T652, Continued. Malfunction Circumstance Inspection or test point Replace Notes Show total Press the <CHANGE> key three seconds distance to see KM/Miles, total distance, total time, Contact HTR heart rate malfunction FOR ACCURATE HR, HOLD SENSORS FIRMLY WHILE WALKING display IC version, drive board IC version. 1. Hold contact heart rate grips firmly to test HTR function. 2. If you are already holding grips firmly, inspect the HTR contact wire connections. 2-1-4

Troubleshooting Malfunction: Safety key malfunction Circumstance: Put the safety key in place; the display shows no reaction; Safety key error message appears. Possible causes: Safety key board malfunction Troubleshooting: 1. Inspect the safety key magnet. 2. Inspect the bridge board wire connections. 3. Test or replace the safety key board. Display Board Bridge board Safety key board 3-1-1

Troubleshooting Malfunction: Unit will not start operating. Circumstance: Turn POWER ON; the display does not light. Possible cause: Incoming power issue; component failure. Troubleshooting: 1. Inspect the main fuse and power switch. 2. Inspect all cable connections. 3. Inspect drive board power LED. Or replace the drive board as a test. 4. Inspect the display power LED and main IC. Main program IC Cables Display board EAC drive board 組 AC1 AC2 FUSE Power switch Filter Drive board Fuse and power switch Filter 3-2-1

Troubleshooting Malfunction: Telemetry heart rate malfunction Circumstance: Telemetry heart rate reading does not appear or the value is incorrect. Possible cause: 1. Telemetry heart rate batteries 2. Heart rate receiver 3. Environmental interference, for example, lights and speakers Troubleshooting: 1. Replace telemetry heart rate transmitter or its batteries 2. Inspect telemetry receiver board cable connections 3. Replace the telemetry receiver board as a test. Display board Telemetry heart rate receiver board Telemetry HR receiver Telemetry transmitter (battery area) Transmitter 3-3-1

Troubleshooting Malfunction: Soft key malfunction Circumstance: Press display board keys. There is no reaction, or keys operate continuously. Possible causes: 1. Soft keys are not connected properly at the bridge board. 2. Soft keys are bad. Troubleshooting: 1. Inspect the soft key connection at the bridge board. 2. Replace the soft keys. Display board Soft key connector Bridge board Key pad Soft keys 3-4-1

Troubleshooting Malfunction: Key malfunction display keys Circumstance: Press display keys; there is no reaction; Or keys operate continuously. Possible causes: 1. Display key switch malfunction: SW1-SW25. 2. Key cushions are out of place. Troubleshooting: 1. Inspect key cushions. 2. Replace display key switches. Key cushions Display board (CPU) SW25 SW1-SW13 SW1-SW13 SW25 SW14-SW2 SW14-SW24 3-5-1

Troubleshooting Malfunction: Incline will not operate upward or downward. Circumstance: Press incline keys; there is no incline action. Possible causes: 1. Zero switch has malfunctioned. 2. Cables are not connected. 3. Incline motor is not operating. Troubleshooting: 1. Inspect drive board cable connections. 2. Inspect zero switch calibration. 3. Inspect incline signal indicators on the drive board and measure incline output voltage. 4. Listen for the sound of incline gear grinding. 5. Feel the incline motor. Is it hot? If it is hot, the drive board could be malfunctioning. Replace the drive board. Zero switch Incline Zero switch Drive board LED 0% on lit 1-15% off No lit Incline gear box Display board Zero switch EAC drive board AC incline unit Incline voltage Direction Incline Incline Voltage Cables up white-black 110 VAC or 220VAC down white-red 110VAC or 220VAC 3-6-1

Troubleshooting Malfunction: Contact heart rate (Heart touch rate - HTR) Circumstance: Place hands on contact heart rate plates; heart rate value is incorrect. Possible causes: 1. HTR cable is not connected. 2. HTR board malfunction 3. Display cable connections Troubleshooting: 1. Inspect display cable connections. 2. Inspect bridge board HTR cable connections. 3. Inspect contact heart rate cable connections. 4. Inspect HTR board LEDs. 5. Replace the HTR board. Indicator Name Explanation LED1 Telemetry heart rate indicator Flashes to indicate incoming telemetry heart rate signal. LED2 HTR contact indicator Lights to indicate that someone is touching heart rate contact plates. LED3 HTR heart rate signal indicator Flashes to indicate incoming contact heart rate signal. LED4 Heart rate signal output LED Each flash represents an outgoing heart rate signal. HTR Board LEDs Display board HTR connections (Display board) Bridge board HTR board HTR board cable connections SENSOR-R SENSOR-L 3-7-1

Troubleshooting Malfunction: The fuse has burnt. Circumstance: Turn on the unit. The fuse breaks. Possible causes: 1. Components have an electrical short. 2. Drive board component malfunction. Troubleshooting: 1. Inspect cable insulation for tears. 2. Remove the power cable and take continuity readings: There should be no continuity between AC1 and frame. There should be no continuity between AC2 and frame. 3. Check components for signs of electrical shorts. Replace the drive board as a test. 4. Replace the filter as a test. EAC drive board AC1 AC2 FUSE SW Filter Drive board Filter 3-8-1

Troubleshooting Malfunction: The fuse has burnt. Circumstance: Press the SPEED key; the fuse breaks. Possible causes: 1. The motor has an electrical short. 2. Drive board malfunction Troubleshooting: 1. Replace the drive board. 2. Replace the motor as a test. 3. Replace the encoder as a test. Display board EAC Drive Board EAC drive board Encoder (Sensor) Motor Encoder (Speed sensor) Motor 3-8-2

Troubleshooting Malfunction: The fuse has burnt. Circumstance: While in operation, the fuse breaks. Possible causes: 1. Fuse holder connection 2. Walk deck or walk belt is worn. 3. EAC drive board malfunction Troubleshooting: 1. Inspect the fuse and fuse holder installation. 2. Inspect mechanical parts: A. walk belt lubrication and wear B. walk belt tightness 3. Replace the EAC drive board as a test. Display board EAC drive board EAC drive board Motor Encoder (Sensor) Motor 3-8-3

Troubleshooting Malfunction: ERR0R_1_1_ Circumstance: Press the SPEED key; ERR0R_1_1_ appears. Possible cause: 1.EAC drive board malfunction 2. Motor sensor malfunction 3. Motor malfunction Troubleshooting: 1. Inspect cable connections. 2. Inspect or replace EAC drive board. 3. Replace the encoder or motor. (Motor failure would be extremely rare.) Display board EAC drive board EAC drive board Encoder Motor Encoder Motor 3-9-1

Troubleshooting Malfunction: ERR0R_1_2 Circumstance: Display shows ERR0R_1_2. Speed is reduced to half. Possible cause: 1. Severe walk deck and belt wear 2. Motor thermal sensor malfunction or poor cable connection Troubleshooting: 1. When the error appears, inspect whether the motor is hot. If it is hot, walk deck or belt may be worn. Lubricate or replace the walk belt. 2. If not, inspect thermal sensor cable connections. 3. If the motor is not hot, and the cable is connected, the motor thermal sensor could be malfunctioning. EAC drive board Display board EAC Drive Board Thermal sensor cables Thermal sensor Motor 3-9-2

Troubleshooting Malfunction: ERR0R_1_3_ Circumstance: Display shows ERR0R_1_3. Possible cause: 1. Motor malfunction Troubleshooting: 1. Re-start unit and inspect for error message. 2. Stop the treadmill ten minutes and test again. 3. Inspect drive belt. 4. Replace the motor as a test. Motor Display board EAC drive board Motor 3-9-3

Troubleshooting Malfunction: ERR0R_2_1_, ERR0R_2_2_ Circumstance: Display shows ERR0R_2_1. Possible cause: 1. EAC drive board IGBT heat or current is excessive. Troubleshooting: 1. Re-start unit and test again. 2. Stop operating the unit for ten minutes.then re-test. 3. If issue persists, replace the EAC drive board. Display board EAC drive board EAC drive board Motor 3-10-1

Troubleshooting Malfunction: ERROR_3_1_ Circumstance: Turn off unit. Incline does not return to level. Possible cause: 1. When the treadmill starts, the incline lowers, activating the zero switch, calibrating the incline. 2. Drive board or motor malfunction 3. If the incline was at the highest position when it hit the zero switch, but the zero switch didn t react, the zero switch is malfunctioning. Troubleshooting: 1. Touch the incline motor. Is it hot? If so, the drive board is malfunctioning. Replace the drive board. 2. Turn on unit. Does the incline operate downward? If not, the incline and drive board could be defective. 3. Test the zero switch. Does it switch on/off? Zero switch Position Incline Zero switch Drive board LED 0% Hits switch on lit 1-15% Does not hit off not lit switch Zero switch Display board EAC drive board Zero SW AC Incline Unit Incline voltage Incline Cable Incline Voltage up white black 110VAC or 220VAC down white-red 110VAC or 220VAC 3-11-1

Troubleshooting Malfunction: ERROR_8_1_ Circumstance: Start unit. Display shows ERROR_8-1. Possible cause: 1. EAC drive board and display CPU signal transmission Error Troubleshooting: 1. At start up, the display and drive board communicate. If there is no communication, ERROR_8_1_ appears. 2. When ERROR_8_1_ appears, re-start the unit. Sometimes, normal communication and operation resumes. 3. If ERROR_8_1_ still appears, inspect all cable connections, or replace the drive board. Display board EAC drive board 3-12-1

Troubleshooting Malfunction: ERROR_8_2_ Circumstance: In operation, the display shows ERROR_8_2_. Possible cause: 1. Interference disrupts communication between the display and EAC drive board. Troubleshooting: 1. Inspect cable connections between the display and drive boards. 2. When this error appears, re-start the unit. Sometimes, re-starting the unit restores normal communication and operation. 3. If re-starting the unit does not eliminate ERROR_8_2_, replace the EAC drive board. Display board EAC drive board 3-12-2

Troubleshooting Malfunction: SERVICE NEEDED-APPLY LUBE Circumstance: SERVICE NEEDED-APPLY LUBE appears. Unit stops operating. Possible cause: Every 4000 km, the display notifies the user that it is time to lubricate the walk belt. Troubleshooting: 1. Display shows SERVICE NEEDED-APPLY LUBE. 2. Simultaneously press <0>+INCLINE< >+INCLINE< > for two seconds to enter lubrication mode. Time window counts down: 3,2,1. Speed window shows 2.0 kph (or 1.3 mph). The walk belt starts to rotate. 3. Hold the applicator tube in front of the rear roller. Squeeze the lubricant into the applicator tube. Allow the unit to operate for ten minutes, letting the lubricant drip onto the bottom side of the walk belt. 4. After ten minutes, press the <STOP> key to exit the lubrication mode. Re-start the unit. Distance memory will be Cleared and then start accruing again. 5. After applying the lubricant, use the unit for ten minutes to disperse the lubricant. 3-13-1

Other Item: How to select KPH/MPH units of measure and view distance, time, and display/drive board program versions. Method: 1. Press the <CHANGE> key three seconds to enter the user parameter mode. 2. KPH/MPH setting Display shows UNIT-MPH (Imperial standard) or UNIT-KPH (Metric standard). Press the INCLINE< > or < > key to toggle between MPH and KPH settings. Press the <ENTER> key to confirm your choice. 3. Distance Display shows total distance as DIST-XXXXXXKM. Press the <ENTER> key to proceed to the next view. 4. Time Display shows total time as TIME-XXXXXXHOUR. Press the <ENTER> key to proceed to the next view. 5. Display board program version Display shows the display board IC version, for example, CTL T650-1A. Press the <ENTER> key to proceed to the next view. 6. Drive board program version Display shows the drive board IC version, for example, DRV SERVO-1A. Press the <ENTER> key to exit the user parameter setting. 3-14-1

Other Item: Error Message Chart ERROR_1_1_ : Servo motor encoder abnormality; Re-start unit. ERROR_1_2_ : Servo motor high temperature warning. Unit operates at half speed. ERROR_1_3_ : Servo motor excessive current warning. Re-start unit. ERROR_2_1_ : IGBT excessive current warning. Wait 10 seconds for unit recovery. ERROR_2_2_ : IGBT excessive heat. Unit operates at half speed. ERROR_3_1_ : Incline motor calibration abnormality. POWER OFF : Power switch: off. ERROR_4_2_ : Power supply voltage is too low. Re-start unit after power supply stabilizes. ERROR_4_3_ : Power voltage is too high. Re-start unit after power supply stabilizes. ERROR_8_1_ : Communication abnormality at start up. ERROR_8_2_ : Communication abnormality during operation. 3-15-1