T631 Repair Manual (Electronics)

T631 Repair Manual (Electronics)

Table of Contents 1-1-1. Product Picture-T631 1-2-1. Display-T631 1-3-1. Component Placement-T631 Display 1-3-2. Component Placement-T631 Drive Board Area 1-4-1. Block Diagram-T631 1-5-1. Connections-T631 Display Board 1-5-2. Connections-T631 Bridge Board 1-5-3. Connections-T631 Bridge Board 1-6-1. Indicator LEDs-T631 Display Board 1-6-2. Indicator LEDs-T631 Drive Board 1-7-1. Display Specifications-T631 2-1-1. Electronics Troubleshooting Chart-T631 3-1-1. Troubleshooting-Safety Key Malfunction-T631 3-2-1. Troubleshooting-Unit Will Not Start Operating-T631 3-3-1. Troubleshooting-Key Malfunction-T631 3-3-2. Troubleshooting-Key Malfunction-T631 3-4-1. Troubleshooting-Telemetry Heart Rate Malfunction-T631 3-5-1. Troubleshooting-Contact (HTR) Heart Rate Malfunction-T631 3-6-1. Troubleshooting-The Fuse Breaks at Start-T631 3-6-2. Troubleshooting-The Fuse Breaks at Motor Start-T631 3-6-3. Troubleshooting-The Fuse Breaks during Use-T631 3-7-1. Troubleshooting-ERROR_1_1_T631 3-8-1. Troubleshooting-ERROR_1_2_T631 3-9-1. Troubleshooting-ERR0R_1_3_T631 3-10-1. 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. Inspecting and Testing-AC Servo Motor Electrical Open Test-T631 4-2-1. Inspecting and Testing-Incline Zero Switch Test-T631 4-3-1. Inspecting and Testing-Incline Motor Voltage Test-T631 4-4-1. Inspecting and Testing-Motor Thermal Sensor Test-T631 4-5-1. 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 IPOD HTR Bridge 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 驅動器組 1-3-3

1-4. Block Diagram-T631 Polar Polar Display Cardio Keypad IPOD To ipod Safety key HTR Bridge ipod keys ipod earphone jack Sensor Sensor AC1 AC2 FUSE SW Inductor (220v) Filter Drive Motor Encoder Temperature sensor Incline motor Zero switch 1-4-1

1-5. Connections-T631 Display Board To telemetry HR receiver To USB/CSAFE To bridge (fan) 接至驅動器組 To bridge (safety key) To bridge (HTR brd) To bridge (keys) To ipod 1-5-1

1-5. Connections-T631 Bridge Board To display To HTR To safety key 1-5-2

1-5. Connections-T631 Drive Board To filter To motor thermal sensor To motor To incline motor To incline zero switch To display (signal) To display (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 Specification Details Notes Exterior power 110V / 220V Motor SAC servo motor (with internal thermal sensor) 4.0 HP Optic sensor Magnetic encoder Speed range KPH : 0.2-20.0(KPH) MPH : 0.1 12.0(MPH) JAPAN:0.2-16.0(KPH) Incline range Power: AC MOTOR (110V or 220V) Incline 0 % -15 % 0-point calibration, time controlled Every 1% = 2sec Illustration LED+14-segment LEDs+7-segment LEDs+dot matrix Programs MANUAL, RANDOM, HILL, INTV, FIT TEST, GLUTE Heart rate control program CARDIO/ WT LOSS, ZONE TRAINER Heart rate HTR/telemetry HR 1-7-1

2-1. Electronics Troubleshooting Chart-T631 Malfunction Circumstance Inspection and Testing Possible Part Notes Safety key Put safety key in place; there 1. Inspect display bridge and safety key Safety key malfunction is no reaction. connections. No start up No incline operation Telemetry heart rate Contact heart rate Key (display) Turn on power; display shows no reaction. Press the incline key; incline does not operate up or down. Telemetry heart rate malfunction Contact heart rate malfunction Key does not operate or operates continuously. Key(soft keys) Key does not operate or operates continuously. 2. Replace safety key. 1. Inspect main fuse. 2. Inspect drive fuse. 3. Inspect all cable connections. 4. Inspect display LED and program IC. 1. Inspect incline zero switch. 2. Inspect drive cable connections. 3. Replace drive. 4. Incline motor malfunction 1. Inspect heart rate transmitter and battery 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. 1. Inspect HTR cable to the receiver. 2. Inspect HTR indicators. 3. Replace the HTR. 1. Replace display key switches or soft keys 1. Inspect bridge soft key connection. 2. Replace the soft key. 1. Main fuse 2. Drive 3. Cable 4. Display 1. Drive 2. Zero switch 1. Heart rate transmitter 2. Heart rate receiver 1.HTR 1. Display keys 2. Soft keys 1.Soft keys 2-1-1

ERR0R_1_1_ ERR0R_1_2_ Servo motor encoder malfunction Servo motor thermal sensor excessive heat; motor operates at half speed. 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. ERROR_1_3_ Motor does not rotate 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. ERROR_2_1_ IGBT over current 4. Re-start unit as a test. 5. If issue reoccurs repeatedly, replace SAC drive. ERR0R_2_2_ IGBT over temperature 1. Re-start unit as a test. 2. If issue reoccurs repeatedly, replace SAC drive. ERROR_2_3_ ERROR_3_1_ ERROR_3_1_ Drive circuit abnormality Incline motor calibration point error Incline motor calibration point error 1.Motor encoder 1.Walk belt 1.Motor 1.SAC drive 1. SAC drive 1. Please replace the drive. 1.SAC drive 1. Inspect cable connections. 1. SAC drive 2. After turning on unit, inspect whether incline motor is hot. If so, the drive is possibly 2. Incline zero bad. switch 1. After turning on unit, inspect whether incline calibrates to 0% position. If not, drive is possibly bad. 2. Inspect whether incline zero-point switch is normal. 2-1-2 3.

Power off Power OFF 1. Re-start unit as a test. 2. If issue reoccurs repeatedly, replace SAC drive. ERR0R_4_2_ Low voltage error 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. ERROR_4_3_ High voltage error 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. ERROR_8_1_ Communications error at 1. Cable is not connected. start ERROR_8_2_ Communications error after start 2. SAC drive malfunction 1. Inspect for sources of interference in the environment. 2. Inspect power supply ground. 3. Replace SAC drive. Main fuse blew Turn on unit; fuse blows. 1. Inspect for electrically shorted components. 2. Inspect cable connections for an electrical short. 3. Replace drive /incline/filter. Main fuse blew Main fuse blew Press speed key; motor fuse blows. In use, main fuse suddenly blew. 1. Inspect motor for abnormality. 2. Replace drive. 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 as a test. 1.SAC drive 1.SAC drive 1. SAC drive 1.SAC drive 1.SAC drive 1.Walk belt 2.SAC drive 2-1-3

SERVICE NEEDED - APPLY LUBE Display shows: SERVICE NEEDED - APPLY LUBE 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. Show total distance 1. Press <CHANGE> key for three seconds to set unit and view total distance, total time, and version numbers of display and drive firmware. HTR malfunction FOR ACCURATE HR,HOLD SENSORS FIRMLY WHILE WALKING 1. Firmly hold HTR contacts while exercising. 2. If you are holding HTR contacts firmly, inspect HTR contact cable connections. 2-1-4

Troubleshooting 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 malfunction Troubleshooting: 1. Inspect the safety key magnet. 2. Inspect the bridge cable connections. 3. Test or replace the safety key. Safety key connection Display Bridge Safety key & safety key Bridge Safety key 3-1-1

Troubleshooting 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 Display Filter AC1 FUSE SW Filter Fuse, switch Drive AC2 SAC drive The cable connect to display 3-2-1

Troubleshooting 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 Display Keypad Keypad 3-3-1

Troubleshooting 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 soft key connections. 2. Replace the soft keys. Soft key connector Display Bridge Bridge Soft key connector Keypad 2 3-3-2

Troubleshooting 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. Display Telemetry heart rate receiver Red LED is heart rate signal indicator. Heart rate cable connector Heart rate transmitter (battery location) Heart rate receiver Transmitter 3-4-1

Troubleshooting 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 malfunction 3. Display cable connections Troubleshooting: 1. Inspect the display cable connections. 2. Inspect bridge HTR cable connections. 3. Inspect contact heart rate cable connections. 4. Inspect the HTR indicator LEDs. 5. Replace the HTR. Display HTR Indicators LED Name Function LED1 POLAR LED Flashing indicates incoming telemetry signal. LED2 HTR contact LED Lit indicates user is gripping HTR contact. LED3 HTR signal LED Flashing indicates incoming HTR signal. LED4 HR output Each flash indicates a pulse signal output. Display HTR connector Bridge HTR HTR cable HTR HTR HTR contact plate (clean here) Sensor-R Sensor-L 3-5-1

Troubleshooting 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 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 as a test. AC1 AC2 FUSE SW Filter Drive 3-6-1

Troubleshooting 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 is malfunctioning. Troubleshooting: 1. Replace the drive as a test. 2. Replace the motor as a test. 3. Replace the encoder as a test. Display SAC drive Motor Encoder Encoder Motor SAC drive 3-6-2

Troubleshooting 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 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 as a test. Display Motor SAC drive SAC drive Encoder Motor 3-6-3

Troubleshooting 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. Remove motor back cover. Inspect encoder Encoder indicator Display 馬達 SAC drive 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. Display Thermal sensor SAC drive 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 SAC drive Motor Motor 3-9-1

Troubleshooting Malfunction: ERR0R_2_1_, ERROR_2_2. Circumstance: Display shows ERR0R_2_1, ERROR_2_2. Possible causes: 1.SAC drive 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. Display SAC drive Fuse 15A (Motor) SAC drive Motor 3-10-1

Troubleshooting Malfunction: ERR0R_2_3 Circumstance: Display shows ERR0R_2_3_. Possible cause: 1. Drive internal circuit abnormality. Troubleshooting: 1. Re-start the unit as a test. 2. Replace the SAC drive. Display SAC drive SAC drive Motor 3-11-1

Troubleshooting Malfunction: ERROR_3_1_ Circumstance: Turn on the treadmill. The incline does not return to the 0% position. Possible cause: 1. Drive or motor malfunction 2. Incline zero point calibration switch indicator malfunction Troubleshooting: 1. Inspect the incline fuse on the drive. 2. Inspect the incline UP/DOWN LEDs and measure the voltage to the incline motor. 3. Inspect zero switch operation. 4. Replace the drive 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 SAC drive UP LED (orange); DN LED (green) Zero SW AC incline unit 3-12-1 Incline voltage 110V or 220V 110V or 220V

Troubleshooting 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 and the display program Troubleshooting: 1. After turning on the unit, the display communicates with the drive. If communication does not occur, ERROR_8_1_ appears. 2.Inspect whether the SAC drive can start the unit. 3. Inspect the display/drive communication signal indicator LED on the drive. Normally, this LED flashes at a set frequency. 4. Replace the SAC drive or display program IC as a test. Display The cable connect to display (signal) Drive 3-13-1

Troubleshooting Malfunction: ERROR_8_2_ Circumstance: During operation, the display shows ERROR_8_2_. Possible cause: 1. Interference of communication between the display and drive s Troubleshooting: 1. Inspect the display-to-drive 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. Display Drive The cable connect to display (signal) 3-14-1

Troubleshooting 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 <PROGRAM SCROLL>+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 <STOP> 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 Item: Unit settings and information: KPH/MPH units, distance, time, display program, and drive program versions. Method: 1. Press and hold the <CHANGE> 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 <ENTER> 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 <ENTER> 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 program version Press the INCLINE < > key to view the drive program version, for example, DRV SAC--AF. Press the <ENTER> key to exit the program. 3-16-1

Other Instructions 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 detects excessive current; the drive 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 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 Ohm setting Notes green-black No reaction The green wire is the ground wire green-white No reaction The green wire is the ground wire green-red No reaction The green wire is the ground wire black-white Short black-red Short white-red Short 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 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 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 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 light. Measure voltage output to the incline motor. Normal readings are shown below. Display Drive 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 220V downward Up LED (orange); DN LED (green) Incline voltage cable Display Drive UP (orange) DOWN (green) Black Red White Incline motor 4-3-1

Inspecting and Testing 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 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 encoder LED flashes. 3. When ERROR 1_1 appears, remove the encoder cover. Inspect whether the encoder has wear. Remove the motor cover. Inspect whether the encoder is worn. Encoder indicator 4-5-1