ESPRIT CT80-NT04 Service Manual

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WARNING:
ALWAYS UNPLUG THE TREADMILL FROM THE ELECTRICAL
OUTLET BEFORE SERVICING THE UNIT.
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TABLE OF CONTENTS
Table of Contents...................................................................... 3
Table of Figures ........................................................................ 4
Description................................................................................ 5
A E
LECTRICAL CONFIGURATION
....................................... 5
1. CT80-nt04 Treadmill components............................ 5
1. Console ...................................................................... 6
2. Main controller.......................................................... 6
3. Treadmill motor ........................................................ 6
4. Incline motor............................................................. 6
Operation................................................................................... 8
A W
INDOW DISPLAY MODE
............................................... 8
1. OFF Mode................................................................. 8
2. READY Mode .......................................................... 8
3. RUN Mode................................................................ 8
B F
UNCTION
........................................................................ 9
1. SPEED ...................................................................... 9
2. Incline ....................................................................... 9
3. TIME......................................................................... 9
4. DISTANCE............................................................. 10
5. CALORIES ............................................................. 10
6. PULSE .................................................................... 10
C F
UNCTION BUTTON IN MAIN MODE
............................. 10
1. READY MODE ...................................................... 10
2. RUN MODE ........................................................... 11
D CALIBRATION P
ROCEDURE ................................. 12
1. Calibration............................................................... 12
Troubleshooting ...................................................................... 14
1. General.................................................................... 14
2. Troubleshooting Matrix .......................................... 15
3. controller debugging form ...................................... 22
Diagrams and Schematics ....................................................... 23
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APPENDIX A......................................................................... 27
1. TREADBELT ADJUSTMENT .............................. 27
APPENDIX B ......................................................................... 29
1. TREADMILL LUBRICATION ............................. 29
APPENDIX C ......................................................................... 30
1. RESET SWITCH RESETTING ............................. 30
APPENDIX D......................................................................... 31
1. FUSE REPLACEMENT......................................... 31
APPENDIX E ......................................................................... 32
1. SPEED SENSOR ADJUSTMENT......................... 32
TABLE OF FIGURES
Figure 1 Operational Flowchart ............................................... 7
Figure 2 Console Layout........................................................ 23
Figure 3 Mechanical Layout .................................................. 23
Figure 4 Main Controller information & voltages ................. 24
Figure 5 Function jack connector on Main Controller........... 24
Figure 6 Wiring Diagram........................................................ 26
Figure 8 If Treadbelt slips...................................................... 27
Figure 9 If tread belt shifts too far to the Right ..................... 27
Figure 10 If tread belt shifts too far to the Left...................... 28
Figure 11 Resetting Reset switch............................................ 30
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DESCRIPTION
A E
LECTRICAL CONFIGURATION
Note: Electrical servicing of this treadmill is limited to board
level replacement.
1. CT80-NT04 TREADMILL COMPONENTS
a) Safety key:
To fits on the Console that activate all functions. If no safety key, console can not be controlled.
b) Console:
Interface that controls all functions of the treadmill.
c) Main controller:
The circuit board consist of the DC power supply for consoleincline driver and DC motor driver, link the console to output appropriate voltages for motor that control the treadmill functions.
d) Treadmill motor:
This is a variable speed for DC motor. To control the 0 –90 voltages on the main controller, it can to increase or decrease speed of running belt.
e) Incline motor:
This is an ac motor. User can to control variable
elevation by console within main controller.
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B.
GENERAL INFORMATION
1. CONSOLE
f) Contains touch controls and LCD Display.
2. MAIN CONTROLLER
a) Include power supply motor driver control circuit and
incline control circuit.
3. TREADMILL MOTOR
a) It’s a variable speed on 0-90 volt DC motor.
b) Have three wires red, black and green.
c) If there is DC voltage on the Red wire (M+) the treadmill
motor will turn clockwise.
d) If there is DC voltage on the Black wire (M-) the treadmill
motor will turn counter-clockwise.
e) The higher the voltage the faster the motor turns.
f) The green wire is ground.
4. INCLINE MOTOR
a) This is a 120 volt AC motor.
b) Have four wires, red, black, white and green.
c) Has one 3 pins cable of position sensor.
d) If there is AC voltage on the Red wire (UP) the incline motor
will increase the incline.
e) If there is AC voltage on the Black wire (DOWN) the
incline motor will decrease the incline.
f) The White wire (COM) is neutral.
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Figure 1 Operational Flowchart
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OPERATION
A W
INDOW DISPLAY MODE
1. OFF MODE
a) When user doesn’t insert the SAFETY KEY on the console,
the treadmill enters the OFF Mode and all windows will appear blank.
2. READY MODE
a) When the treadmill is ON and SAFETY KEY is inserted in
console,
b) Press MOED(Program) button to select Program.
c) Press START button to start treadmill on Manual Mode.
3. RUN MODE
a) In RUN Mode, pressing the “STOP” button and removing
the SAFETY KEY will cause the treadmill stop instantly and enter OFF Mode.
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B F
UNCTION
1. SPEED
a) Display the current speed in Kilometer per hour.
b) DISPLAY range is 0.0 to 99.9 km/h.
c) WORK range is 1.0 to 16.0 km/h.
d) Press Speed“FAST” or Speed”SLOW” to adjust speed,
each increment and decrement is 0.1 km/h(mph).
2. INCLINE
a) Display the incline position from 0 to 12.
b) DISPLAY range is 0 to 999.
c) WORK range is 0 to 12.
d) INCLINE preset value is 0 to 12.
e) Press “UP” or ”DOWN” to adjust incline, each increment
and decrement is 1.
3. TIME
a) TIME is either COUNT UP or COUNT DOWN. System
preset is COUNT UP; if user sets the time then timer is COUNT DOWN.
b) DISPLAY range is 0:00 to 99:99.
c) WORK range is 0:00 to 99:59.
d) COUNT DOWN setup range is 10:00 to 99:00.
e) When TIME is set, the count will go to zero.
f) In RUN Mode, press “STOP” button to save value of time
and enter “RUN Mode” again that value will continue count up time.
g)
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h)
4. DISTANCE
a) Display the current distance in kilometer.
b) DISPLAY range is 0.00 to 99.99.
c) WORK range is 0.00 to 99.99.
5. CALORIES
a) Displays the cumulative calories burned at any given time
during your workout.
b) DISPLAY range is 0.0 to 999.0.
c) WORK range is 0.0 to 999.0.
6. PULSE
a) Displays the heart rate beat by using hand pulse or receiver.
When use receiver, a chest belt must be worn.
b) DISPLAY range is 0 to 999.
c) WORK range is 40 to 220.
d) In RUN Mode, if the treadmill doesn’t have a signal for 8
seconds then display value will become “ P ”.
e)
C F
UNCTION BUTTON IN MAIN MODE
1. READY MODE
a) SAFETY KEY: Fit safety key in right position to power on
the computer. When safety key is pulled away from its position, the computer will be automatically shut down.
b) STOP button: Non-function.
c)
START
button: Pressing “
START
” button to start
treadmill, When pressing “
START
” button, there will be 3
second final count down on window display, then machine
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d) Clear/set button: Press “clear/set” button to change each
function. MANUAL can set using time, Pre-set PROGRAM can set using time and speed, Heart Rate Control 1~2 can set time, age and the value of heart rate.
e) Mode(PROGRAM) button: Press Mode(PROGRAM)
button to select manual, program and HRC program.
f) FAST button: If user doesn’t enter a setting then this button
is non-functional.
g) SLOW button: If user doesn’t enter a setting then this button
is non- functional.
h) UP button: If user doesn’t enter a setting then this button is
non- functional.
i) DOWN button: If user doesn’t enter a setting then this
button is non- functional.
j) SPEED RAPID button: 3 preset buttons for rapid speed:
3kph, 6kph, 9kph .
k) INCLINE RAPID button: 3 preset buttons for rapid incline:
3, 6, 9 .
l) FAN button: It can to control ON/OFF for the fan.
2. RUN MODE
a)
SAFETY KEY: When safety key is pulled away from its position, the computer will be automatically shut down.
b) STOP button: press “STOP” button to stop treadmill.
c) START button: non-functional.
d) Mode(Program) button: non-functional.
e) FAST button: Press the button to increase your speed and
each increase is 0.1kph. If button is pressed continuously then speed increases to MAX SPEED quickly.
f) SLOW button: Press the button to decrease your speed and
each decrease is 0.1kph. If button is pressed continuously then speed decreases to MIN SPEED quickly.
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g) UP button: Press the button to raise position and each
increase is 1, the maximum incline position is 12.
h) DOWN button: Press the button to lower position and each
decrease is 1, the minimum incline position is 0.
i) SPEED RAPID button: Speed will set to 3kph, 6kph, 9kph
quickly.
j) INCLINE RAPID button: Incline will set to 3,6,9position
quickly.
k) Fan button: It can to control ON/OFF for the fan.
l)
D
C
ALIBRATION
P
ROCEDURE
1. CALIBRATION
a) Turn on power.
b) Press and hold
“mode(Program)”
button at the same time.
c) Inserts the SAFETY KEY on console, all windows will
appear blank.
d) Press “Clear/Set” to Set wheel size: Press “FAST” or
“SLOW” button to adjust to 47.
e) Press
“Clear/Set”
button to memorize above setting and
enter next section of setting mode.
f) Set Min. speed: Press “FAST” or “SLOW” button to adjust
window to 1.0Kph / 0.5Mph.
g) Press
“Clear/Set”
button to memorize above setting and
enter next section of setting mode.
h) Set high speed: Press “FAST” or “SLOW” button to adjust
window to 18.0Kph / 12mph.
i) Press
“Clear/Set”
button to memorize above setting and
enter next section of setting mode.
j) Set high incline position: Press “UP” or “DOWN” button to
adjust to 12.
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k) Press”Clear/set”
l) Press
“START”
button to memorize all value, the treadmill
will calibrate automatically.
m) After calibrating, treadmill will reset then enter
“READY MODE”.
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TROUBLESHOOTING
WARNING:
ALWAYS UNPLUG THE TREADMILL FROM THE ELECTRICAL
OUTLET BEFORE SERVICING THE UNIT.
1. GENERAL
a) Do a visual check of all wiring and connections looking for
chafed wires or lose connections.
b) Make sure any wiring is safely positioned and/or secured
away from moving parts.
c) If you find a fuse blown on a circuit board replace the circuit
board.
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2. TROUBLESHOOTING MATRIX
Condition Reason Solve
When turn on power, ON/OFF switch isn’t lit.
1 Power cord isn’t plugged into outlet. 2 Power cord isn’t plug into unit. 3 The voltage of outlet is too low. 4 Plug or connector of power cord is open. 5 Connector of power cord is broken. 6 Connecting cable disconnected.
7 Breaker tripped.
8 Breaker is broken. 9 ON/OFF switch is broken.
1 Plug the power cord into outlet. 2 Plug the power cord into unit. 3 Check the voltage of outlet. 4 Replace power cord. 5 Replace power cord. 6 Check if wire is disconnected, connect it
again.
7 Press the small red button to return to
original status.
8 Replace breaker. 9 Replace AC switch.
After turning on power, treadmill has a popping sound.
1 Incorrect input power, varistor is blown broken on controller.
1 Check the voltage of power is110­120V. Replace controller.
When insert safe key, no display on monitor.
1 Haven’t switch ON/OFF switch. 2 Insert the Safe key on wrong position. 3 10 PIN Computer connector not plugged in properly.
4 10 PIN computer cable is broken.
1 Switch the AC switch. 2 Insert the safe key on right position. 3 Please check the wire and connect
again.
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5 Fuse on controller is blown. 6 Varistor on controller is blown. 7 Reed switch of console is broken. (open) 8 Other components are faulty.
4 Replace 10 PIN computer cable. 5 Replace fuse or controller. 6 Replace varistor or controller. 7 Replace reed switch or console. 8 Replace console.
With no safe key but treadmill could display or operate
1 Reed switch of console is broken. (short) 2 Have other magnetic components on console.
1 Replace reed switch or console. 2 Remove magnetic component beside safe
key. When press “START”, treadmill doesn’t start.
1 Motor M+ or M- wire isn’t connected into right position.
2 Controller is broken. (No power to motor)
3 Motor is broken.
4 Treadmill controller shut down and LED would be ON.
1 Please check and plug again.
2 Replace controller or MOSFET IRFP
460 and add the Silicone Heat Sink Paste suitably.
3 Replace motor or check the wire and
connector if it was broken. 4 Turn off the AC switch and turn on power again.
Treadmill stops or shuts off by itself.
1 House breaker tripped. 2 Treadmill breaker tripped.
3 Treadmill controller fuse is broken. 4 Treadmill controller shut down and LED would be ON.
1. Reset it.
2. Reset treadmill breaker.
3. Replace with new fuse
4. Turn off the AC switch and turn on
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power again.
After removing safe key, treadmill can’t stop.
1. Reed switch of console is broken. 1. Replace with new reed switch or console.
LCDs not bright, incomplete or imperfect.
1. LCD light is broken.
2. Power to console too low.
1. Replace with new LCD or console.
2. Check AC power is 110-120V.
3. Check power to console.
4.Replace lower controller.
LCD displays not bright, incomplete or imperfect.
1. LCD displays are broken. 1. Replace with new console and calibrate it.
When press “START” button to start treadmill, running belt isn’t running and window displays “Loss Speed” error message after 8 seconds.
1. Controller experienced unusual shut down; the Shut_D light
will be always bright. (Controller debugging form)
2. Motor wires (red, black) aren’t plugged into controller.
3. Computer cables not connected properly.
4. Computer cables are broken or damaged.
5. Motor belt is broken.
6. Controller is broken.
7. Motor is broken.
8. Console is broken.
1. Turn off power and reset the treadmill.
2. Plug wires again.
3. Plug the wire again on controller, connector and console.
4. Replace with new wires.
5. Replace with new motor belt.
6. Replace with new controller.
7. Replace with new motor.
8. Replace with new console.
SPEED windows display is not 1.0 to 16.0 km
Monitor is not calibrated. Calibrate the console
INCLINE windows display 1 Console is not calibrated.
1 Calibrate the console.
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is not 0 to 12
The speed of the belt doesn’t match console display.
1. Console is not calibrated. 1.Calibrate the console
The incline position doesn’t match console
1 Console is not calibrated.
1 Calibrate the console.
INCLINE ERR window displays “E2”.
1 Position sensor value of incline motor is wrong.
1 Turn off the AC switch and turn on power again.
2. Calibrate the monitor.
INCLINE window displays “----” during training.
1 Position sensor value of incline motor is wrong.
1 Turn off power and reset the treadmill.
INCLINE window displays “----”.
1 Position sensor value of incline motor is wrong.
1.Check the 3 pins cable of the incline
motor.
TIME window display “E3” 1.EEPROM is broken. 1.Replace with new console and calibrate
it.
After pressing “START” button, the treadmill stops immediately.
1 Controller is broken. 1 Turn off the AC switch and turn on power
again. 2 Replace controller and calibrate it.
Erratic pulse display. 1. Another chest belt in use around treadmill.
2. Other magnetic field disturbance.
1. Check for other chest belt use around treadmill.
2. Change the position or direction of
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3. Receiver is broken.
treadmill.
3. Replace with new receiver.
After pressing “START” button, the treadmill stop immediately.
Controller was broken. Replace with new controller and calibrate
it.
FAST/SLOW button of SPEED ADJUSTMENT SWITCH can’t be used.
Speed button just can press FAST, can’t press SLOW.
Speed button just can press SLOW, can’t press FAST.
1 The connector of SPEED CABLE (UPPER) and
CONSOLE not connected properly.
2 The connector of SPEED CABLE (UPPER) and SPEED
ADJUSTMENT SWITCH W/CABLE not connected properly.
3 The connector of SPEED CABLE (UPPER) or
SPEED ADJUSTMENT SWITCH/W/CABLE is damaged.
4. Button of SPEED ADJUSTMENT SWITCH is broken.
5. The connector of SPEED CABLE (UPPER) or SPEED ADJUSTMENT SWITCH/W/CABLE is damaged.
6. The connector of SPEED CABLE (UPPER) or SPEED ADJUSTMENT SWITCH/W/CABLE is damaged.
1. Connect cables again.
2. Connect cables again.
3. Connect cable again.
4. Replace with new buttons.
5. Replace with new cable.
6. Replace with new cable.
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UP/DOWN button of INCLINE ADJUSTMENT SWITCH can’t be used.
Incline button just can press UP, can’t press DOWN. Incline button just can press DOWN, can’t press UP.
1 The connector of INCLINE CABLE (UPPER)
and CONSOLE not connected properly.
2. The connector of INCLINE CABLE (UPPER)
and INCLINE ADJUSTMENT SWITCH W/CABLE not connected properly.
3 The connector of INCLINE CABLE (UPPER) or INCLINE ADJUSTMENT SWITCH CABLE got damage.
4. Button of INCLINE ADJUSTMENT SWITCH is broken.
5. The connector of INCLINE CABLE (UPPER) or
INCLINE ADJUSTMENT SWITCH CABLE got damage.
6. The connector of INCLINE CABLE (UPPER) or
INCLINE ADJUSTMENT SWITCH CABLE damaged.
1 Connect the wires again.
2. Connect the wires again.
3. Replace the cable.
4. Replace buttons.
5. Replace the cable.
6. Replace the cable.
Hand pulse lost its function.
(No pulse displayed on monitor)
1. Hands not on the hand pulse sensors or only one hand on sensor.
2. The connector of HANDPULSE W/WIRE and Console not connected properly.
3. The wires got damaged when connecting the HANDPULSE
1. Two hands hold the hand pulse.
2. Connect the cable again.
3. Replace with new cable.
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W/WIRE and Console.
4. Hand pulse board is broken.
4. Replace console or Hand pulse board.
Wireless lost its function. (No pulse displayed on monitor)
1. Chest belt not worn properly.
2. Distance is too far and exceeds range of receiver.
3. Chest belt battery is weak or dead.
1. Check chest belt has proper contact with skin and is oriented correctly.
2. User chest belt in front of console within 3 feet.
3. Replace with new lithium battery type is CR2032.
Chest belt too close to the treadmill.
Weak battery. Replace with new lithium battery with type
CR2032.
Tread belt does not run in center.
Tread belt tension not even across tread belt.
See treadbelt adjustment
(see Appendix A)
Tread belt hesitates while being stepped on.
Insufficient lubricant on tread belt. Tread belt tension insufficient
See treadbelt lubrication (see Appendix B) Tension Belt (see Appendix A )
Black particles collecting under treadmill.
Drive belt is breaking in. Vacuum under treadmill periodically.
Noise under motor cover. 1. Worn brushes or bearings on motor.
2. Front roller bearings are defective.
3. Drive belt is misadjusted (too tight or too loose).
1. Replace with new motor.
2. Replace with new front roller.
3. Adjust motor position.
Noise in the rear of the treadmill.
1. Rear roller bearings are defective.
2. Rear roller misaligned.
1. Replace with new rear roller.
2. Adjust rear roller position.
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3. CONTROLLER DEBUGGING FORM
Indicator LED
Function Condition Reason Solve
PWM Motor speed
Normal on when start is pressed. Fault condition if start is pressed & LED off.
No input. Check fast/slow wires of 10PIN connector.
Replace controller. Replace console.
POWER Controller power If DC voltage is normal, it would be
always ON. If off, fault condition exists.
Voltage is not correct. Fuse is blown. Transformer is no good.
Check the supply voltage is 110-120V. Replace Fuse. Replace controller.
LIMIT Limit the current of
DC motor.
When current of motor exceed 12A, the LCD will turn on.
If LIMIT light is bright for 3 to 5 seconds, the Shut_D light will turn on.
Loading is too high on belt.
Operation is not correct, motor lock.
Check mechanical drive system is not locked
or jammed. Replace controller. Replace motor.
Shut_D Controller shut down. If controller has unusual shut down,
the Shut_D light will be always bright.
Motor lock, LIMIT light will be bright for 3 to 5 seconds previously.
Turn off power and reset the treadmill.
MOT_DRV Motor Drive Circuit
fault.
If motor Drive Circuit has a fault, LCD ON.
MOSFET is broken. Drive IC was broken.
Replace controller. Replace “Drive IC”.
UP
Motion of incline motor
Motion of incline motor is up. Transistor was broken.
Relay failed.
Replace controller.
DOWN Motion of incline
motor
Motion of incline motor is down. Transistor was broken.
Relay failed
Replace controller.
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DIAGRAMS AND SCHEMATICS
Figure 2 Console Layout
Figure 3 Mechanical Layout
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MOS FET
FAS T DIO DE
M+T O MOTOR (RED WIRE )
M-T O MO TOR (BLACK WI RE)
Jk 2 SP E E D SE NSOR
Jk 1 CONNECTION TO CONSOLE
DETEMINES INCLIV E LE V E
CAPACITO R
FUSE 10 AMP
230 VA C IN
VARIS T OR
INCLINE DOWN (BLCA K WI RE)
NEUTRA L TO INCLINE MOT OR (WHITE WIRE )
INCLINE UP (RED WIRE)
Figure 4 Main Controller information & voltages
Figure 5 Function jack connector on Main Controller
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Figure 6 Wiring Diagram
Figure 7 Schematic Diagram
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APPENDIX A
1. TREADBELT ADJUSTMENT
The treadbelt has been factory pre-adjusted, however if during the operation:
1/4 T U R N
Figure 8 If Treadbelt slips
The treadbelt is too loose: Tighten both rear roller adjusting bolts 1/4 turn clockwise using allen wrench
1/4 TUR N
Figure 9 If tread belt shifts too far to the Right
a) Set the treadmill speed to 3.5 mph/5.6 km. b) Tighten the right adjusting bolt a 1/4 turn clockwise using allen wrench c) Wait 15 seconds: if no change; turn the left adjusting bolt a 1/4 turn counter-clockwise using allen wrench e) Repeat steps b and c until belt is centered
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30
79
31
79
1/4 TU R N
Figure 10 If tread belt shifts too far to the Left
a) Set the treadmill speed to 3.5 mph/5.6 km. b) Tighten the left adjusting bolt a 1/4 turn clockwise using allen wrench c) Wait 15 seconds: if no change; turn the right adjusting bolt a 1/4 turn counter-clockwise using allen wrench e) Repeat steps b and c until belt is centered
IMPORTANT DO NOT OVERTIGHTEN TREADBELT
If treadbelt is overtightened, edges of treadbelt will begin to curl CAUTION!! DO NOT ALLOW ANYONE TO WALK ON
TREADBELT WHILE YOU ARE ADJUSTING.
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9
APPENDIX B
1. TREADMILL LUBRICATION
Your treadmill should require little maintenance other then periodically applying lubricant. Lubricating under the treadbelt will ensure superior performance and extend its life expectancy.
HOW TO CHECK TREADBELT FOR PROPER LUBRICATION
Lift one side of the treadbelt and feel the top surface of the treadboard If the surface is (slick) to the touch, then no further lubrication is required If the surface is dry to the touch, apply one packet of lubricant
HOW TO APPLY LUBRICANT
1. Lift one side of treadbelt.
2. Pour one half of the lubricant bottle under the center of the treadbelt on the top surface of the treadboard
3. Walk on the treadmill at a slow speed for 3 to 5 minutes to evenly distribute lubricant.
NOTE: DO NOT over lubricate treadboard. Any excess lubricant that
comes out should be wiped off.
IMPORTANT: ONLY USE HALF THE BOTTLE OF LUBRICANT PER APPLICATION LUBRICATION SCHEDULE
1. After the first 25 hours of use (2-3 months) apply one half bottle of lubricant
2. Every 50 hours of use (5-8 months) apply one half bottle of lubricant
We recommend that you use: Lube-N-Walk™ Treadmill Lubrication Kit.
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APPENDIX C
Figure 11 Resetting Reset switch
1. RESET SWITCH RESETTING
a) If the red button of reset switch is tripped, it will protrude out from the
face of the switch.
b) Press in the red button of the switch.
c) If the red button of reset switch is not tripped, that means normal.
Tripped
Normal
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APPENDIX D
FUSE 15 AMP
FUSE MO UNT
Figure 12 Fuse replacement
1. FUSE REPLACEMENT
If your treadmill loses power or will not start, check the fuse located on the motor controller.
DANGER: Turn the power switch off and unplug the treadmill to reduce the risk of an electric shock
Remove the motor cover Remove and replace the fuse on the motor controller Replace the motor cover
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APPENDIX E
1. SPEED SENSOR ADJUSTMENT
If the monitor does not display speed or distance the speed sensor and magnet may be misaligned. Follow these steps to check and realign. Remove the motor cover Check the spacing and alignment between the magnet on the right side of the front roller and the speed sensor on the frame. The spacing must be 1/8”. Loosened screw and slide speed sensor in or out of clamp. Retighten screw Replace the motor cover.
SERVICE QUESTION
!
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