T621 Repair Manual (Electronics)

T621 Repair Manual (Electronics)

Table of Contents 1-1-1. Product Picture-T621 1-2-1. Display-T621 1-3-1. Component Placement-T621 Display 1-3-2. Component Placement-T621 Drive Board Area 1-4-1. Block Diagram-T621 1-5-1. Connections-T621 Display Board 1-5-2. Connections-T621 Bridge Board 1-5-3. Connections-T621 Drive Board 1-6-1. Indicator LEDs-T621 Display Board 1-6-2. Indicator LEDs-T621 Drive Board 1-7-1. Display Specifications-T621 2-1-1. Electronics Troubleshooting Chart-T621 3-1-1. Troubleshooting-Safety Key Malfunction-T621 3-2-1. Troubleshooting-Unit Will Not Start Operating-T621 3-3-1. Troubleshooting-Key Malfunction(Display)-T621 3-3-2. Troubleshooting-Key Malfunction-T621 3-4-1. Troubleshooting-Telemetry Heart Rate Malfunction-T621 3-5-1. Troubleshooting-Contact (HTR) Heart Rate Malfunction-T621 3-6-1. Troubleshooting-The Fuse Breaks at Start-T621 3-6-2. Troubleshooting-The Fuse Breaks at Motor Start-T621 3-6-3. Troubleshooting-The Fuse Breaks during Use-T621 3-7-1. Troubleshooting-ERR-1 T621 3-8-1. Troubleshooting-ERR-3 T621 3-9-1. Troubleshooting-ERR-7 T621 3-10-1. Troubleshooting- SERVICE REQUIRED -T621 3-11-1. Other Information-Unit Settings and Information-T621 3-12-1. Other Information-SERVICE NEEDED -T621

3-13-1. Other Information-Error Messages-T621 4-1-1. Inspecting and Testing-Transformer Test T621 4-2-1. Inspecting and Testing-Motor Carbon brush T621 4-3-1. Inspecting and Testing-wheel, speed sensor T621 4-4-1. Inspecting and Testing-Motor voltage T621 4-5-1. Inspecting and Testing-Motor Thermal Sensor Test-T621 4-6-1. Inspecting and Testing-Incline Zero Switch Test-T621 4-7-1. Inspecting and Testing-Incline Motor Voltage Test -T621

1-1. Product Picture-T621 1-1-1

1-2. Display-T621 1-2-1

1-3. Component Placement-T621 Display Telemetry heart rate receiver board Display board 1-3-1

1-3. Component Placement-T621 Display HTR board Bridge board Safety key board Soft keys 1-3-2

1-3. Component Placement T621 Drive Board Area Drive board Speed sensor Temperature sensor DC motor AC incline motor Transformer Filter 1-3-3

1-4. Block Diagram-T621 Polar board Display board Sensor L Sensor R Safety key Keypad HTR board Bridge board AC1 AC2 FUSE SW Transformer Filter Drive board Motor Speed sensor Temperature sensor Incline motor Zero switch 1-4-1

1-5. Connections-T621 Display Board To telemetry HR To bridge board (HTR) To drive board To bridge board (safety key) To bridge board (fan) To bridge board (keypad) To drive board To bridge board 1-5-1

1-5. Connections-T621 Bridge Board To display To HTR board To safety key board 1-5-2

1-5. Connections-T621 Drive Board To incline motor To filter To display To speed sensor To motor To motor temperature sensor To incline zero switch 1-5-3

1-6. Indicator LEDs-T621 Display Board Power indicator Lit indicates display has power. HR indicator 1-6-1

1-6. Indicator LEDs-T621 Drive Board LED4 CUS_UP Indicator Lit = Cushion motor is extended (firm). LED11 I_SENSE Indicator Lit = High current protective function is activated. Transformer fuse LED7 DN Indicator Lit = Incline is operating down. LED3 CUS_DN Indicator Lit = Cushion motor is retracted (soft). Incline fuse LED9 UP Indicator Lit = Incline is operating up. LED5 EMG Indicator Lit = There is voltage to the motor. Not lit = Emergency stop switch is activated. LED10 Motor Thermal Switch Indicator Lit = Motor is overheated; protective function is activated. LED1 SOFT Indicator Lights automatically two seconds after powering up. LED2 POWER Indicator Lit = Power is supplied. LED8 ZERO Indicator Lit = incline is already calibrated. LED6 MC Indicator Flashing indicates motor movement. 1-6-2

1-7. Display Specifications-T621 Specification Details Notes Exterior power supply Motor Speed sensor 110V / 220V DC motor (with internal thermal switch) Has brushes Has heat protection Infrared optic sensor Speed Range Incline Range Display Workout Programs KPH: 0.2-20.0(KPH) MPH: 0.1 12.0(MPH) Power: AC motor (110V or 220V) Incline range: 0 % -15 % 0% setting, time control 1% per 2 seconds LED+16-segment+7-segment LED+dot matrix MANUAL, RANDOM, HILL, INTV, GLUTE, Heart rate control program Heart rate CARDIO, WT LOSS, ZONE TRAINER HTR / Telemetry 1-7-1

2-1. Electronics Troubleshooting Chart-T621 Malfunction Circumstance Inspection and test points Components to Safety key malfunction No start up No start up Telemetry heart rate malfunction Contact heart rate malfunction Put safety key in place. Display has no reaction. Safety key appears on the display. Power on, indicator does not light. Power on, indicator lights but the display does not light. Telemetry heart rate malfunction Contact heart rate malfunction 1. Inspect the cable connections on the lower part of the display and safety key. 2. Inspect the safety key magnet. 3. Inspect the safety key board. 1. Inspect the power cord connection. 2. Inspect all cable connections. 3. Inspect the fuse, the fuse holder, and the power switch. 4. Drive board components have an electrical short. Replace the drive board. 1. Inspect all cable connections, including connector cables. 2. Inspect whether drive board LED2 lights: a. If LED2 lights, inspect and test the transformer fuse. 3. Inspect whether LED1 on the display lights. a. If LED1 does not light, inspect the data cable from the display to the drive board. b. If LED1 does light, inspect the display program IC. Re-install the display IC. 1. Inspect the heart rate transmitter strap and its batteries. Replace batteries if they have not been replaced recently. 2. Inspect the receiver board cables. 3. Test or replace the receiver board. 4. Inspect for environmental interference, for example, from speakers and lights. 1. Inspect the HTR wire connections on the bridge board. 2. Inspect the HTR indicator light. 3. Replace the HTR board. replace Safety key board 1. Fuse, fuse holder 2. Drive board 1. Transformer 2. Drive board 3. Display board program IC 1. Heart rate transmitter 2. Heart rate receiver board 1. HTR board (HTR=heart touch rate = contact heart rate) Notes 2-1-1

Soft key malfunction (display) Soft key malfunction ERR 1 Press soft key, display no rebound, 1. Replace the display soft key. Soft key (display) Key does not operate, 1. Inspect the bridge board soft key connection. or operates continually. 2. Replace the soft key. Motor does not rotate, ERR1 1. There is no power to the motor; the motor appears. cannot operate. 2. Inspect the motor brushes. 3. Measure voltage from the drive board to the motor. If there is no voltage, replace the drive board. If there is voltage, inspect the following: a. transformer voltage b. whether the EMG indicator lights c. whether IGBTs have an electrical short. If so, replace the drive board. 4. Inspect the motor brushes and the commutator. ERR 1 Motor rotate, ERR1 appears, 1. The program did not detect the optic sensor signal. 2. Inspect the CLK indicator on the drive board. If the CLK indicator is not lit, clean or replace the speed sensor. If the CLK indicator lights normally, inspect the data cable from the display to the drive board. Re-install the display program IC. Re-install the display IC. ERR 3 Display speed differs from actual speed. 1. Inspect the KPH/MPH setting. 2. Inspect teeth on the optic wheel. 3. Replace the speed sensor. 4. Replace the drive board. ERR 7 ERR7 appears at startup. 1. Inspect the incline cable connections. 2. Inspect whether incline has calibrated. Soft key 1. Drive board 2. Motor brushes, commutator Speed sensor 1. Speed sensor 2. Drive board 1. Zero calibration switch 2. Drive board 2-1-2

KPH/MPH setting 1. Press the <CHANGE> key three seconds; the display will show UNIT-MPH or UNIT-KPH. 2. Press INCLINE< >/< > to select KPH or MPH. Press <ENTER> to confirm your choice. FOR ACCURATE HR, HOLD SENSORS FIRMLY WHILE WALKING SERVICE REQUIRED TREADMILL SHUTTING DOWN STOPPING SERVICE NEEDED-APPLY LUBE View total distance, total time FOR ACCURATE HR, HOLD SENSORS FIRMLY WHILE WALKING Display shows SERVICE REQUIRED TREADMILL SHUTTING DOWN STOPPING SERVICE NEEDED-APPLY LUBE 1. Hold contact heart rate grips firmly to test the HTR function. 2. If you are already holding grips firmly, inspect the HTR contact wire connections. 1. Motor thermal protection unit is activated. Let the unit rest half an hour or more to cool. 2. If this message often appears, please inspect the treadmill walk belt and deck. Lubricate if necessary. 3. If the walk belt is worn, replace the walk belt. 1. This lubrication prompt appears every 4000 KM. Follow lubrication and maintenance procedures in the owner s manual. 2. Enter lubrication procedure INCLINE < > + INCLINE< >+<0>. 1. Press and hold the INCLINE < > + INCLINE< > + <STOP> keys for 2 seconds. 2. The display will show the total distance and total time 2-1-3

Troubleshooting Malfunction: Safety key malfunction Circumstance: 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. Display board Safety key connection Bridge board Safety key & safety key board Bridge board Safety key board Reed switch Safety key(reed switch test) With safety key Reed switch ON Without safety key Reed switch OFF 3-1-1

Troubleshooting Malfunction: Unit does not operate Circumstance: Turn on unit power; the power indicator does not light. Possible cause: Inadequate incoming power supply or component malfunction. Troubleshooting: 1. Inspect the power cable connection. 2. Inspect cable connections under the motor cover. 3. Inspect the main fuse, fuse holder, and the power switch. 4. Inspect drive board components for signs of burning. Or replace the drive board as a test. Display board Drive board AC1 FUSE SW Filter Drive board Fuse, fuse holder, switch AC2 3-2-1

Troubleshooting Malfunction: No start up. Unit does not operate. Circumstance of malfunction: Turn unit power on; the power indicator LED does not light. Possible causes: 1. Transformer problem. 2. Cables are not connected properly, or the drive board is malfunctioning. Troubleshooting: 1. Inspect all cable connections. 2. Inspect whether LED2 on the drive board lights. A. If LED2 does not light, inspect the transformer fuse and measure transformer input and output voltage. 3. Inspect whether LED1 on the display board lights. A. If it does not light, inspect cable connections from the display to the drive board. B. If it does light, inspect the display IC. Re-install the display IC. Transformer voltage Program IC Power led LED2 power indicator Lit indicates unit is sending 5 VDC power supply to the display. Transformer voltage(ac) AC1 LED Display board (red-red) (blue-blue) 110V (red) 220V(blue) black-black 12.5V white-white 12.5V orange-orange 29V yellow-yellow 11.5V Filter AC2 Transformer FUSE Drive board LED Transformer fuse 3-2-2

Troubleshooting Malfunction: Key malfunction display Circumstance of malfunction: Press display keys; The display shows no reaction. Or keys operate continually. Possible cause: 1. Wires to the display board are not connected properly. 2. Soft keys are bad. Troubleshooting: 1. Inspect soft key connections. 2. Replace the soft keys. Soft key connection Soft key Display board Keypad 3-3-1

Troubleshooting Malfunction: Key malfunction soft key Circumstance: Press the display key; the display shows no reaction, or keys operate continually. Possible cause: 1. Soft key malfunction 2. The bridge board soft key connections are not connected properly. Troubleshooting: 1. Inspect soft key wire connections. 2. Replace the soft keys. Display board Bridge board Bridge board Soft key connector Soft key 3-3-2

Troubleshooting Malfunction: 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 or 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. Heart rate board cable connector Display board Telemetry heart rate receiver board Red LED is heart rate signal indicator. Heart rate transmitter (battery location) Heart rate receiver board 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 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. 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 HTR connector output. Display board Bridge board HTR board HTR HTR HTR contact plate (clean here) HTR cable Sensor-R Sensor-L 3-5-1

Troubleshooting Malfunction: The fuse breaks. Circumstance: Turn on unit. The fuse immediately blows. Possible cause: 1. Components and the frame have an abnormal electrical short. 2. Drive board component malfunction. Troubleshooting: 1. Inspect the power cord. Is the cord insulation broken and creating an electrical short? 2. Replace the drive board as a test. (Drive board malfunctions are the most common source of blown fuses.) 3. Replace the EMI filter. Drive board AC1 FUSE SW Filter Drive board AC2 3-6-1

Troubleshooting Malfunction: The fuse has broken. Circumstance: 1. Press the speed up key. The motor rotates. Then the fuse blows. Possible cause: 1. Motor windings have an electrical short. 2. Drive board malfunction. Troubleshooting: 1. Replace the drive board as a test. 2. Replace the motor as a test. 3. Replace the speed sensor as a test. Drive board Sensor Motor Display board Drive board Sensor Motor 3-6-2

Troubleshooting Malfunction: The fuse has blown. Circumstance: After a period of use, the fuse suddenly breaks. Possible cause: 1. Fuse holder malfunction 2. Deck or belt wear 3. Drive board malfunction Troubleshooting: 1. Inspect the fuse and fuse holder installation. 2. Inspect the mechanics: A. Is the walk belt worn or requiring lubrication? B. Inspect walk belt tightness. Is it too loose? 3. Replace the drive board as a test. 4. Inspect the motor brushes. Display board Drive board Sensor Motor motor 3-6-3

Troubleshooting Malfunction: Error 1 Circumstance: Press the speed key. Speed engages. Before the motor rotates, Error 1 appears. Possible cause: 1. Motor does not rotate. Drive board or motor malfunctions. Troubleshooting: 1. Inspect all cable connections. 2. Inspect the display board IC connection. 3. Measure motor voltage from the drive board. Is there voltage across M+,M-? If not, replace the drive board. If so, (A) inspect transformer output voltage. (B) inspect whether the EMG LED lights. (C) inspect whether IGBTs have an electrical short? 4. Inspect motor brushes and the commutator. Measure M+,M- voltage Display board Transformer Drive board Measure transformer voltage motor Inspect motor brushes. Motor Sensor 3-7-1

Troubleshooting Malfunction: ERR1 Circumstance: Press the speed up key. Motor rotates. ERR1 appears. Possible cause: 1. Motor rotates optic sensor malfunctions Troubleshooting: 1. Inspect all cable connections. 2. Inspect whether the LED6 indicator on drive board flashes. If not, the optic sensor is malfunctioning. Either clean the optic sensor sensor head or replace the optic sensor. 3. If the LED6 indicator lights, inspect the cable connections and main IC connections. Display board Optic sensor LED6 MC indicator Drive board motor Motor Sensor 3-7-2

Troubleshooting Malfunction: ERR3 Circumstance: Display speed and actual speed differ. Possible cause: 1. Optic wheel teeth or optic sensor malfunction 2. Drive board malfunction Troubleshooting: 1. Inspect whether optic wheel teeth are missing. 2. Replace the optic sensor as a test. 3. Replace the drive board. Display board Drive board LED6 MC Sensor Motor Inspect the optic sensor and optic sensor wheel teeth. 3-8-1

Troubleshooting Malfunction: ERR7 Circumstance: The incline never recalibrated; ERR7 appeared. Possible cause: 1. Incline does not operate up or down and calibrate. 2. Drive board is malfunctioning. Troubleshooting: 1. Inspect whether incline UP or DN LEDs light during operation. 2. Drive board voltage follows: Drive board Incline motor voltage LED9 UP lit White-Black 110V or 220V LED7 DOWN lit White-Black 110V or 220V 3. When the incline is at the 0% position, does it touch the zero switch? Does LED8 light? Incline up/down LED Display board Drive board Incline Zero Incline connector motor switch Incline fuse 3-9-1 LED8 zero switch

Troubleshooting Malfunction: The message SERVICE REQUIRED TREADMILL SHUTTING DOWN STOPPING appears. Possible cause: 1. The excessive heat protective function is activated. Troubleshooting: 1. This message indicates that the motor is overheating. Please turn off the unit and allow it to rest for one hour. 2. Inspect whether the motor thermal sensor is normal. 3. If the message appears often, the walk belt might require lubrication or be worn out. Lubricate or replace the walk belt as needed. 4. If these measures aren t effective, replace the walk deck or motor. Temperature sensor wire connector Temperature sensor Tem Display board Drive board Temp sensor Motor 3-10-1

Other Instructions Item: Set KPH/MPH units and view total distance and time. Method: 1. Press and hold the <CHANGE> key for three seconds to enter the user setting mode. 2. The display will show UNIT-MPH (imperial) or UNIT-KPH (metric) units. Press the INCLINE< > or < > key to toggle between MPH and KPH settings. Then press the <ENTER> key to confirm your choice. 3. The display shows DIST XXXXXX KM or DIST XXXXXX MILE. Press the <ENTER> key to proceed and view total time. 4. The display shows TIME XXXXXX HOUR. Press the <ENTER> key to proceed to view more information. 5. Software version numbers for display board and drive boards appear, one after another. After each bit of information appears, press the <ENTER> key to proceed. After the drive board software version appears, pressing the <ENTER> key brings you to the startup banner screen. Item: Clear total distance and time. Method: 1. Press the INCLINE < > + INCLINE < > + <STOP> key. The following prompt appears: PRESS INCLINE UP / DN TO SELECT CLEAR TOTAL TIME AND DISTANCE YES / NO PRESS ENTER 2. Select YES by pressing INCLINE < > / < > keys. Then press the <ENTER> key. 3. Total distance and time will be eliminated. 3-11-1

Other Instructions 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 <0>+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. 3-12-1

Other Instructions Item: Error messages E-1 : Display board main program has not received the optic sensor signal. E-3 : Display setting and actual speed differ. E-7 : Incline motor calibration point abnormality. 3-13-1

Inspecting and Testing Inspection point: Transformer voltage Inspection method: 1. Inspect whether the transformer fuse has blown. 2. Measure transformer voltage. 3. Set the multi-meter to the AC setting. Place probes as follows: Transformer cables Voltage red-red or blue-blue (input voltage) 110V (red)/ 220V(blue) black-black (normal power) 12.5V white-white (normal voltage) 12.5V orange-orange (incline voltage) 29V yellow-yellow (normal voltage) 11.5V Transformer connector Transformer fuse 4-1-1

Inspecting and Testing Inspection point: Motor brushes Inspection method: 1. Inspect motor brushes. A. Inspect brush length. If brushes are shorter than 0.7mm, replace the brushes. B. Inspect the brush surface. It should be smooth. If there are grooves, the commutator might be faulty. C. Inspect whether brush copper wires have changed color. If so, replace the brushes. Motor brushes Brush length should exceed 0.7 mm. This image shows brushes that are too short. Motor brushes If copper wires have changed color, connections are bad. Replace the brushes. Brush ends shown here have scratches, a sign of irregular wear. Replace brushes like these. 4-2-1

Inspecting and Testing Inspection point: Optic wheel, optic sensor Inspection method: 1. Inspect the optic wheel placement. The optic wheel should rotate in the center of the optic sensor. It should not touch the optic sensor. 2. Inspect whether the teeth on the optic wheel have broken. 3. Pull the walk belt to allow the optic wheel to move. Inspect whether LED7 on the drive board flashes. When a tooth of the optic wheel is in the center of the optic sensor, LED7 on the drive board does not light. When a tooth of the optic wheel is not in the center of the optic sensor, LED7 on the drive board lights. 4. The optic sensor includes an infrared transmitter and a receiver. Inspect whether the optic sensor is dirty. If so, wipe it clean. LED6 optic sensor signal indicator Make sure that the optic sensor wheel rotates in the center to the optic sensor. 4-3-1

Inspecting and Testing Inspection point: Motor voltage test at the drive board Inspection method: 1. Select the VDC setting on the multi-meter. Place probes on M+M- connectors on the drive board. 2. Press the SPEED< > key. The motor should operate, allowing you to measure motor voltage. Speed Drive board voltage Motor specifications Highest speed 100-120 VDC 110V Lowest speed 210-230 VDC 220V Place probes on M+M- connectors 4-4-1

Inspecting and Testing Inspection point: Motor thermal sensor test Inspection method: 1. Inspect whether the temperature sensor wire is connected properly. 2. When the motor is not too hot, remove the temperature sensor wire. Drive board LED10 will light. The display will show SERVICE REQUIRED Connect the temperature sensor wire. LED10 on the drive board will not light. 3. When the motor is too hot, LED10 will light and the treadmill will stop operating. Please stop the unit and wait one hour before use. If the same issue occurs again, lubricate the walk belt and deck. Temperature sensor wire connection Temperature sensor indicator LED 4-5-1

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. LED8 lights. At 1%-15%, the zero switch is not touched by the worm gear; The zero switch is off. LED8 does not light. Zero switch Incline 0% 1-15% Tube Touches switch Does not touch switch Zero switch on off Picture Zero switch Incline 0% 1-15% Worm gear Touches zero switch. Does not touch zero switch. Picture Drive board Led 8 light Led 8 no light Led 8 indicator (Zero switch) Led8 zero switch 4-6-1

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 board light. 3. Measure voltage output to the incline motor. Normal readings are shown below. Display Drive board Incline motor cables Incline operates Press < > key Led9 UP lights white-black upward 110V or 220V Press < > key Led7 DOWN lights white-red 110V or 220V downward Display LED9 incline-up Indicator LED7 incline-down Indicator Drive board Black Red Incline motor Incline motor connector LED9 UP LED7 down White Incline fuse 4-7-1