Dyaco AT90E Service Manual Download

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AT90E

NT52

Treadmill

Service Manual

(110~120V & 220~230V)

Summary of Contents for AT90E

Page 1: ...AT90E NT52 Treadmill Service Manual 110 120V 220 230V ...

Page 2: ...D Indicator Locations 6 6 Controller Indicator LED Debugging 6 7 Driver Board Function 7 Product Safety Instructions 7 1 Important Safety Instructions 7 2 Important Electrical Instructions 7 3 Important Grounding Instructions 8 Error Messages and Troubleshooting for Electronic Issues 8 1 Error Message 8 2 Cause of E1 8 3 Circuit diagram 8 4 CALIBRATION PROCEDURE 8 5 Fuse replacement 8 6 Troubles h...

Page 3: ...rts 12 1 Lower Controller Replacement 12 2 Console Replacement 12 3 Motor Replacement 12 4 Breaker Replacement 12 5 AC Power Switch Replacement 12 6 Front Rear Roller Replacement 12 7 Running Deck Belt Cushion Replacement 12 8 Speed Sensor Replacement 12 9 Incline Motor Replacement ...

Page 4: ...S Se er rv vi ic ce e M Ma an nu ua al l 3 1 Treadmill Outlines ...

Page 5: ...S Se er rv vi ic ce e M Ma an nu ua al l 4 ...

Page 6: ...S Se er rv vi ic ce e M Ma an nu ua al l 5 Console Speed adjustment button Hand Pulse Sensor Incline adjustment button Hand Pulse Sensor ...

Page 7: ...S Se er rv vi ic ce e M Ma an nu ua al l 6 Lower Controller Driving Motor Incline Motor ...

Page 8: ...S Se er rv vi ic ce e M Ma an nu ua al l 7 ...

Page 9: ...S Se er rv vi ic ce e M Ma an nu ua al l 8 2 Electronic Parts ...

Page 10: ...S Se er rv vi ic ce e M Ma an nu ua al l 9 2 1 Upper Controllers LCD DISPLAY Hand Pulse Heart Sensors Hand Pulse Heart Sensors Cooling Fan ...

Page 11: ...S Se er rv vi ic ce e M Ma an nu ua al l 10 2 2 Lower Controller and Driver Driver System Motor Controller SPEED SENSOR DC MOTOR Motor Controller INCLINE MOTOR ...

Page 12: ...S Se er rv vi ic ce e M Ma an nu ua al l 11 3 Electrical Configurations ...

Page 13: ...for console incline driver and DC motor driver link the console to output appropriate voltages for motor that control the treadmill functions TREADMILL MOTOR This is a variable speed for DC motor To control the 0 90 120VAC or 0 180 230VAC voltages on the main controller it can to increase or decrease speed of running belt GENERAL INFORMATION CONSOLE Contains Key controls and LCD Display Main contr...

Page 14: ...osition sensor If there is AC voltage on the Red wire UP the incline motor will increase the incline If there is AC voltage on the Black wire DOWN the incline motor will decrease the incline The White wire COM is neutral The green yellow wire is grounding wire NOTICE BEFORE OPERATION The treadmill will increase or decrease speed slowly It means that it will take you a little time to reach the spee...

Page 15: ...S Se er rv vi ic ce e M Ma an nu ua al l 14 4 Product Operation ...

Page 16: ...ce e M Ma an nu ua al l 15 Display Windows LCD Display Hand Pulse Heart Sensors Hand Pulse Heart Sensors FAST SLOW Key UP DOWN Key Safety key INCLINE Quick Keys SPEED Quick Keys ENTER Key PROGRAM Key STOP key START key ...

Page 17: ...S Se er rv vi ic ce e M Ma an nu ua al l 16 LCD Layout ...

Page 18: ...ur DISPLAY range is 0 0 to 99 9 mph km h WORK range is 0 5 to 10 0 mph Press FAST or SLOW to adjust speed each increment and decrement is 0 1 mph kph TIME TIME is either COUNT UP or COUNT DOWN DISPLAY range is 0 00 to 99 99 WORK range is 0 00 to 99 59 In RUN Mode press STOP button to save value of time and enter RUN Mode again that value will continue count up time DISTANCE Display the current dis...

Page 19: ...cations Speed quick keys 3 6 9 FAST Slow Key Adjustment Speed Enter Key Set data function STOP Key end workout Safety Key Emergency function Incline quick keys 3 6 9 PROGRAM Key Choose Program Up Down Key Adjustment incline START Key To workout FAN key Switch FAN ...

Page 20: ...functional UP button If user doesn t enter a setting then this button is non functional DOWN button If user doesn t enter a setting then this button is non functional SPEED RAPID button 3 preset buttons for rapid speed 3 6 9 mph kph INCLINE RAPID button 3 preset buttons for rapid incline 3 6 9 RUN MODE SAFETY KEY When safety key is pulled away from its position the computer will be automatically s...

Page 21: ...S Se er rv vi ic ce e M Ma an nu ua al l 20 SPEED RAPID button Speed will set to 3 6 9 mph kph INCLINE RAPID button Incline will set to 3 6 9 ...

Page 22: ...S Se er rv vi ic ce e M Ma an nu ua al l 21 5 Unit Block Diagrams ...

Page 23: ...S Se er rv vi ic ce e M Ma an nu ua al l 22 Treadmill Configuration ...

Page 24: ...S Se er rv vi ic ce e M Ma an nu ua al l 23 6 Basic Connections and Wiring ...

Page 25: ...S Se er rv vi ic ce e M Ma an nu ua al l 24 6 1 Display Board wire Connections ...

Page 26: ...S Se er rv vi ic ce e M Ma an nu ua al l 25 6 2 Display Board PCB Component Locations PCB Board Top ...

Page 27: ...S Se er rv vi ic ce e M Ma an nu ua al l 26 PCB Board Bottom ...

Page 28: ...S Se er rv vi ic ce e M Ma an nu ua al l 27 6 3 Driver Board Wire Connections ...

Page 29: ...S Se er rv vi ic ce e M Ma an nu ua al l 28 6 4 Driver Board PCB Component Locations ...

Page 30: ...S Se er rv vi ic ce e M Ma an nu ua al l 29 6 5 Driver Board LED Indicator Locations COMMUNICATION STATE NO TWINKLING FAILURE TWINKLING NORMAL POWER DICATOR LIT VCC POWER CIRCUIT ON ...

Page 31: ...rt is pressed Fault condition if start is pressed LED off No input Check fast slow wires of 5PIN 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 120V Replace Fuse Replace controller ...

Page 32: ... l 31 6 7 Driver Board function M 0 90Vdc TO MOTOR BLACK WIRE M 0 90Vdc TO MOTOR RED WIRE TORQUE SPEED SENSOR CONNECTION TO CONSOLE Transformer ACL 120VAC IN ACN 120VAC IN NCLINE VR INCLINE POWER WHITE INCLINE POWER BLACK INCLINE POWER RED ...

Page 33: ...S Se er rv vi ic ce e M Ma an nu ua al l 32 7 Product Safety Instructions ...

Page 34: ... control This part is available through most electrical supply stores Examples Grainger part 1D237 or available online at www squared com part QO120HM 7 3 Important Grounding Instructions This product must be grounded If the treadmill should malfunction or breakdown grounding provides a path of least resistance for electric current reducing the risk of electric shock This product is equipped with ...

Page 35: ...S Se er rv vi ic ce e M Ma an nu ua al l 34 8 Error Messages and Troubleshooting for Electronic Issues ...

Page 36: ...eceive the Safety device signal E1 Display board CPU did not receive the RPM signal ERR Incline failure E2 Over current protection E4 Motor voltage is abnormal or cable is not connected E5 Communication between console and controller is disconnected E6 Controller is defective Prepare Picture Tool name Multi meter ...

Page 37: ...S Se er rv vi ic ce e M Ma an nu ua al l 36 8 1 Error Message E1 Definition Display board CPU did not receive the RPM signal Configuration ...

Page 38: ...n nu ua al l 37 8 2 Cause of E1 The motor doesn t turn E1 appears Explanation The drive board did not sent voltage to the motor so the motor didn t operate And the display board didn t receiver the RPM sensor signal Configuration ...

Page 39: ...S Se er rv vi ic ce e M Ma an nu ua al l 38 LCD show E1 ...

Page 40: ...S Se er rv vi ic ce e M Ma an nu ua al l 39 E1 solution follow chart ...

Page 41: ...S Se er rv vi ic ce e M Ma an nu ua al l 40 Terminals for motor cable Red for M White for M POWER LED ...

Page 42: ...S Se er rv vi ic ce e M Ma an nu ua al l 41 E1 solution follow chart check RPM sensor device procedure ...

Page 43: ...o the motor The speed sensor is small and black with a wire connected to it 3 Make sure the sensor is as close as possible to the pulley without touching it You will see a magnet on the face of the pulley make sure the sensor is aligned with the magnet There is a screw that holds the sensor in place that needs to be loosened to adjust the sensor Re tighten the screw when finished Reed switch RPM S...

Page 44: ...gnal for 8 seconds check the speed sensor cable is in good connection Make sure the good connection for cables The speed sensor didn t detect signal completely Check the gap between speed sensor and magnet To keep the gap distance less than 3 mm E1 message The motor can not move Defective sensor or bad cable connection Check if the sensor and cables are circuit short damaged Change the sensor or c...

Page 45: ... vi ic ce e M Ma an nu ua al l 44 Error Message ERR Definition The console board is not detecting the VR voltage value or the voltage value has exceeded the range INCLINE ERR appears on the display Configuration ...

Page 46: ...S Se er rv vi ic ce e M Ma an nu ua al l 45 LCD show Err ...

Page 47: ...e VR value exceeds the range ERR appears on the display Incline motor isn t operation up or down making the VR value exceed the range After turning on the unit the display board detects that the incline VR voltage exceeds the range so ERR appears Action Flow Chart ...

Page 48: ...res are broken or disconnected Display board 1 Inspect the incline wire and 5 pin cable connections 2 Test whether the VR voltage varies at the incline wire terminal 5 pin cable 1 Inspect the wire connections 2 Inspect whether wires are broken or crimped 3 Replace the wires and test again Driver board Inspect the display board 5 pin connections ...

Page 49: ... 48 Error Message ERR Definition During incline action the display board CPU cannot read the VR value so ERR appears Configuration ...

Page 50: ...s the incline UP and DOWN key The driver board UP or DOWN indicator lights The incline operates moving the VR which changes the VR value The display board CPU reads the incline VR value If there is no VR value change to the CPU the incline is not operating when it should be ERR appears on the display Action Flow Chart ...

Page 51: ...cable is connected well 2 Test by replacing the cable with a good one Driver board Inspect whether the driver board RELAY RY1 RY2 action 1 Press incline UP or DOWN key again making the incline motor return to its position 2 If ERR still appears re calibrate the incline set Incline motor 1 Inspect whether the incline motor is stuck 2 Inspect whether the incline gears are cracked 3 Test whether the ...

Page 52: ... 51 8 3 Circuit diagram ...

Page 53: ...it after pressing PROGRAM button to enter engineering mode Press SET button to choose setting wheel size minimum speed maximum speed or maximum incline level Press SPEED or SPEED to change the value Press START when finish The treadmill starts to calibrate and to exit when calibration is finished ...

Page 54: ...ot 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 FUSE FUSE For AC is 3 15A ...

Page 55: ...roperly 3 Check and make sure motor power is connected properly with correct polarity OK NG 1 Speed sensor by the front roller is not properly connected to the controller or Either the body of speed sensor or the cable is damaged OK NG 2 The body of speed sensor is not properly located must be less than 3 5mm of gap between the sensor and front roller OK NG Motor turns about 10 seconds after press...

Page 56: ... over heated OK NG 1 Check if incline cables connected properly Console shows Err or E3 message Incline malfunction 2 Check if incline mechanism is stuck or defective 3 Is calibration done Is there is still E3 showing after calibration OK NG Console shows E4 message Abnormal voltage between motor terminals 1 Motor cable is not properly connected OK NG Console shows E5 message Communication between...

Page 57: ...ts are faulty 1 Switch the AC switch 2 Insert the safe key on right position 3 Please check the wire and connect again 4 Replace 5 PIN computer cable 5 Replace fuse or controller 6 Replace varistor or controller 7 Replace safety key device 8 Replace console With no safe key but treadmill could display or operate 1 Safety device is broken short 1 Replace the safety key device or console When press ...

Page 58: ... 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 3 Receiver is broken 1 Check for other chest belt use around treadmill 2 Change the position or direction of treadmill 3 Replace with new receiver After pressing START button the treadmill stop immediately Controller was ...

Page 59: ... 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 W WIRE and Console 4 Hand pulse board is broken 1 Two hands hold the hand pulse 2 Connect the cable again 3 Replace with new cable 4 Replace console or Hand pulse board Tread belt does not run in center Tread belt tension not even across tread belt S...

Page 60: ...59 9 Folding Unfolding and Transport ...

Page 61: ...r the unit to the desired position TO FOLD THE TREADMILL Lift the deck until the latch clicks in place TO UNFOLD THE TREADMILL Press the tube with your foot at the yellow sticker To release latch see picture to the right TRANSPORTATION INSTRUCTIONS The treadmill is equipped with four transport wheels that are engaged when the treadmill is folded After folding simply roll the treadmill away ...

Page 62: ...61 10 General Maintenance ...

Page 63: ... dry before using Belt Dust This occurs during normal break in or until the belt stabilizes Wiping excess off with a damp cloth will minimize buildup General Cleaning Dirt dust and pet hair can block air inlets and accumulate on the running belt On a monthly basis vacuum underneath your treadmill to prevent buildup Once a year you should remove the black motor hood and vacuum out dirt that may acc...

Page 64: ...or some belts to drift near one side while the belt is running with no one on it After a few minutes of use the tread belt should have a tendency to center itself If during use the belt continues to move toward one side adjustments are necessary TO SET TREADBELT TRACKING A 10 mm Allen wrench is provided to adjust the rear roller Make tracking adjustments from the left side only Set belt speed at a...

Page 65: ...es can be ordered directly from or your authorized dealer You may also use a Lube n Walk kit that can be purchased through both aforementioned sellers Keeping the deck lubricated at the recommended intervals ensures the longest life possible for your treadmill If the lubricant dries out the friction between the belt and deck rises and places undue stress on the drive motor drive belt and electroni...

Page 66: ...r panel circuit breaker may be tripped 5 Treadmill defect Contact your dealer Tread belt does not stay centered The user may be walking while favoring or putting more weight on either the left or right foot If this walking pattern is natural track the belt slightly off center to the side opposite from the belt movement Treadmill belt hesitates when walked run on See General Maintenance section on ...

Page 67: ...s coming when the user is running on the treadmill with lowest level of incline it could be due to too much pressure with the incline cylinder only in case of the lowest incline level 3 If there is knocking noise during the workout check and make sure all bolts are tightened 4 When there is thumping noise while the belt is running This happens with a brand new treadmill or when the treadmill has n...

Page 68: ...67 11 Installation of the Incline Motor ...

Page 69: ...68 Incline Range must be adjusted to 195mm minimum prior to installation ...

Page 70: ...69 12 Disassembling and Assembling of Parts ...

Page 71: ...70 12 1 Lower Controller Replacement 1 Remove motor cover 2 Disconnect all lower controller wirings 3 Use Phillips head Screwdriver to remove replace with new lower controller and reconnect all wirings ...

Page 72: ...71 12 2 Console Replacement 1 Use M5 L Allen wrench to remove 4 Button Head Socket Bolts from the console support 2 Disconnect console wirings and replace with new console ...

Page 73: ...72 12 3 Motor Replacement 1 Use Phillips head screwdriver to remove 5 Tapping screw securing the motor cover 2 Remove motor grounding wire greenish yellow motor wire red and motor wire black ...

Page 74: ...of disassembly re hook belt readjust belt to be parallel with main frame after re hooking Do not tighten 4 securing screws yet 5 Use 14mm open end wrench to adjust belt tension using tension measuring device Adjust to white LBS area between 70 75LBS Use 14mm T shaped socket wrench to secure and tighten 4 securing screws 6 Connect grounding wires and motor wires red M black M ...

Page 75: ...74 12 4 Breaker Replacement Remove Breaker connection wiring replace part and reconnect wiring ...

Page 76: ...75 12 5 AC Power Switch Replacement 1 Disconnect wiring to AC power switch replace AC power switch and reconnect wiring ...

Page 77: ...76 12 6 Front Rear Roller Replacement 1 Use Phillips head screwdriver to loosen 2 screws on the rear adjustment base 2 Use M6 L Allen wrench to loosen 2 screws on the rear roller ...

Page 78: ...lt tension screw and loosen drive belt 4 Use 13mm wrench to loosen front roller screws remove front and back rollers and replace with new Reassemble in reverse order of disassembly 5 When reassembled running belt tension needs to be adjusted and centered Belt tension also needs to be adjusted refer to 12 3 5 above ...

Page 79: ...ement Please take the cylinder before replacement 1 After running board has been folded use M5 L Allen wrench and 12m m wrench to remove securing screws on cylinder and remove the cylinder 2 Perform step 12 6 and remove front and rear rollers ...

Page 80: ...ad screwdriver to remove the 8 screws securing the running board Remove the running board and replace running board or running belt If cushions need to be replaced remove 6 cushions and replace Reassemble in the reverse order as disassembly 5 When reassembled center and adjust running belt tension Belt tension also needs to be adjusted Refer to step 12 3 5 ...

Page 81: ...Sensor Replacement including the wire 1 First remove motor top cover 2 Remove speed sensor wiring and proceed with parts replacement 3 After replacement a test to check if the sensor registers the magnet is required ...

Page 82: ...oing the incline motor before take it apart from the machine or assemble it onto the frame The zeroing distance is 195mm 1 First remove the motor cover and adjust treadmill to folded position then proceed with old incline motor replacement ...

Page 83: ...82 2 Use 14mm wrench to assemble new incline motor ...

Page 84: ...83 3 Connect incline motor wiring with controller Red wire Connect to UP White wire Connect to COM Black wire Connect to DOWN ...

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Dyaco AT90E, Service Manual

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