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SportsArt Fitness T645 Repair Manual
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SportsArt Fitness T645 Repair Manual

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T645 Repair Manual (Electronics)
Date: 2014/1/6 V1.0

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Summary of Contents for SportsArt Fitness T645

  • Page 1 T645 Repair Manual (Electronics) Date: 2014/1/6 V1.0...
  • Page 2 Illustration 1-1.Product 1-1-1...
  • Page 3 1-2.Dispaly-T645 1-2-1...
  • Page 4 1-2.Display-T645 1-2-2...
  • Page 5 1-3. Component Placement- T645 Display USB board HTR board Program board Polar board CSAFE board Display Bridge board IPOD key 1-3-1...
  • Page 6 1-3. Component Placement - T645 Drive Compartment AC Servo motor SAC Drive board Lubrication system Inductor (220v) AC Incline motor EUp board Filter 1-3-2...
  • Page 7 1-4. Block Diagram of Electronic Components - T645 USB board Polar board Display CSAFE board Board HTR board IPOD board HTR plate IPOD Bridge Keypad board Ear-phone Volume key Safety-key Motor Fuse / SW. Filter EUP. Speed Sensor SAC Drive Board...
  • Page 8 1-4. Connection-T645 1-4-2...
  • Page 9 1-5. Cable Connections - T645 Display To USB board (UATRT) To Drive board To USB board To HTR board To polar board To keypad To EUp board To IPOD board To bridge board 1-5-1...
  • Page 10 1-5.Cable Connections - T645 Display USB board Bridge board To Display To HTR plate To Fan To Safety-key To lower keypad 1-5-2...
  • Page 11 1-5. Cable Connections - T645 SAC Drive board To motor To thermal sensor To EUp board To incline motor To Display 220V L1,L2 to inductor 110V L1,L2 red wire To Incline Zero switch To incline limit Switch To Display To motor Encoder...
  • Page 12 1-5. Cable Connections - Lubrication system Display Motor & VR unit Speed sensor Lubricant bottle 1-5-4...
  • Page 13 1-5.Cable connections-EUp board To Drive set To Display (LED, Keypad) From Filter 1-5-5...
  • Page 14 1-6.Indicator LEDs - T645 Display Board 1-6-1...
  • Page 15 1-6.Indicator LEDs - T645 Drive Board F1 fuse 15A 1-6-2...

  • Page 16: Troubleshooting

    Troubleshooting Model: T645 Malfunction: Safety key malfunction Circumstance: Put the safety key in place; the display shows no reaction; “Safety key” error message appears. Possible causes: Safety key board malfunction Troubleshooting: 1. Inspect the safety key magnet. Bridge board 2. Inspect the bridge board wire connections.

  • Page 17: Drive Board

    Troubleshooting Model: T645 Malfunction: Unit will not start operating. Cable connection Circumstance: Turn POWER ON; the display does not light. Possible cause: Incoming power issue; component failure. Troubleshooting: 1. Inspect the main fuse and power switch. 2. Inspect all cable connections.
  • Page 18 Troubleshooting Model: T645 Malfunction: The fuse has burnt. Circumstance: Turn on the unit. The fuse breaks. EAC drive board Possible causes: 1. Components have an electrical short. 2. Drive board component malfunction. Troubleshooting: 1. Inspect cable insulation for tears. 2. Remove the power cable and take continuity readings: There should be no continuity between AC1 and frame.
  • Page 19 Troubleshooting Model: T645 Malfunction: The fuse has burnt. Circumstance: Press the SPEED key; the fuse breaks. Possible causes: 1. The motor has an electrical short. 2. Drive board malfunction Troubleshooting: 1. Replace the drive board. 2. Replace the motor as a test.
  • Page 20 Troubleshooting Model: T645 Malfunction: The fuse has burnt. Circumstance: While in operation, the fuse breaks. Possible causes: 1. Fuse holder connection 2. Walk deck or walk belt is worn. 3. EAC drive board malfunction Troubleshooting: 1. Inspect the fuse and fuse holder installation.
  • Page 21 Troubleshooting Model: T645 Malfunction: keypad malfunction Circumstance: Press display board keys. There is no reaction, or keys operate continuously. Possible causes: 1. keypad is bad Troubleshooting: 1. Inspect the keypad connection. 2. Replace the keypad. Display board Keypad keypad 3-4-1...
  • Page 22 Troubleshooting Model: T645 Malfunction: Soft key malfunction Circumstance: Press display board keys. There is no reaction, or keys operate continuously. Connection to Bridge board Possible causes: 1. keypad are not connected properly at the bridge board. 2. Soft keys are bad.
  • Page 23 Troubleshooting Model: T645 Malfunction: Key malfunction – display keys Key cushion Circumstance: Press display keys; there is no reaction; Or keys operate continuously. Possible causes: 1. Display key switch malfunction: 2. Key cushions are out of place. Troubleshooting: 1. Inspect key cushions.

  • Page 24: Display Board

    Troubleshooting Model: T645 Malfunction: Telemetry heart rate malfunction Circumstance: Telemetry heart rate reading does not appear or the value is incorrect. Possible cause: 1. Telemetry heart rate batteries 2. Heart rate receiver 3. Environmental interference, for example, lights and speakers Troubleshooting: 1.
  • Page 25 Troubleshooting Model: T645 Indicator Name Explanation Malfunction: Contact heart rate (Heart touch rate - HTR) LED1 Telemetry heart Flashes to indicate incoming telemetry Circumstance: Place hands on contact heart rate indicator heart rate signal. rate plates; heart rate value is incorrect.
  • Page 26 Troubleshooting Model: T645 Malfunction: Incline will not operate upward or downward. Circumstance: Press incline keys; there is no incline action. Zero switch Possible causes: 1. Zero switch has malfunctioned. Incline Zero switch Drive 2. Cables are not connected. board LED 3.
  • Page 27 Troubleshooting Model: T645 Malfunction: ERR0R_1_1_ Circumstance: Press the SPEED key; ERR0R_1_1_ appears. Possible cause: 1.EAC drive board malfunction 2. Motor sensor malfunction 3. Motor malfunction Troubleshooting: 1. Inspect cable connections. 2. Inspect or replace EAC drive board. 3. Replace the encoder or motor.
  • Page 28 Troubleshooting Model: T645 Malfunction: ERR0R_1_2 Circumstance: Display shows ERR0R_1_2. Speed is reduced to half. Thermal sensor cables Possible cause: 1. Severe walk deck and belt wear 2. Motor thermal sensor malfunction or poor cable connection Troubleshooting: 1. When the error appears, inspect whether the motor is hot.
  • Page 29 Troubleshooting Model: T645 Malfunction: ERR0R_1_3_ Circumstance: Display shows ERR0R_1_3. Possible cause: 1. Motor malfunction Troubleshooting: 1. Re-start unit and inspect for error message. Motor 2. Stop the treadmill ten minutes and test again. 3. Inspect drive belt. 4. Replace the motor as a test.
  • Page 30 Troubleshooting Model: T645 Malfunction: ERR0R_2_1_, ERR0R_2_2_ Circumstance: Display shows ERR0R_2_1. Possible cause: 1. EAC drive board IGBT heat or current is excessive. Troubleshooting: 1. Re-start unit and test again. 2. Stop operating the unit for ten minutes.Then re-test. SAC Drive board 3.
  • Page 31 Troubleshooting Model: T645 Zero switch Malfunction: ERROR_3_1_ Position Incline Zero switch Drive board Circumstance: Turn off unit. Incline does not return to level. Possible cause: 1. When the treadmill starts, the incline lowers, Hits switch activating the zero switch, calibrating the incline.
  • Page 32 Troubleshooting Model: T645 Malfunction: ERROR_4_2, ERROR_4_3 Circumstance: Turn on power switch, and display show “ERR0R_4_2” or “ERROR_4_3” Possible cause: 1. EAC drive board and display CPU signal transmission Error Troubleshooting: 1.ERROR_4_2: Exterior power supply voltage is too high ERROR_4_3: Exterior power supply voltage is too low 2.Estimate the exterior power supply voltage is too high or too low.
  • Page 33 Troubleshooting Model: T645 Malfunction: ERROR_8_1_ Circumstance: Start unit. Display shows ERROR_8-1. Possible cause: 1. EAC drive board and display CPU signal transmission Error Troubleshooting: 1. At start up, the display and drive board communicate. If there is no communication, ERROR_8_1_ appears.
  • Page 34 Troubleshooting Model: T645 Malfunction: ERROR_8_2_ Circumstance: In operation, the display shows ERROR_8_2_. Possible cause: 1. Interference disrupts communication between the display and EAC drive board. Troubleshooting: 1. Inspect cable connections between the display and drive boards. 2. When this error appears, re-start the unit. Sometimes, re-starting the unit restores normal communication and operation.

  • Page 35: Troubleshooting

    Troubleshooting Model: T645 Malfunction item: ERROR_8_3_ Troubleshooting: ERROR_8_3_ on display while using treadmill Possible causes: 1. There is an interference caused SAC board to shut down Troubleshooting: 1. If this occurs occasionally, reset the treadmill to use it again. This is just a drive board’s self-protective function.

  • Page 36: Other Descriptions

    Other descriptions: Model: T645 Item: Error message list ERROR_1_1_ : Serve motor encoder abnormal; power reset to recover ERROR_1_2_ : Serve motor too hot; reduce speed to protect ERROR_1_3_ : Serve motor over loading; power reset to recover ERROR_2_1_ : IGBT over current; recover in 10 minutes ERROR_2_2_ : IGBT too hot;...
  • Page 37 Other descriptions: Model: T645 Item: KPH/MPH switch and total distance, time, control board/drive board software version display Method: 1.Press <CHANGE DISPLAY> key for 3 seconds to enter user preference & settings. A. English and Metric setting The display will show ＂UNIT-MPH (for English) “ or ＂UNIT-KPH (for Metric) ”; press INCLINE<▲><▼> key to select MPH/KPH;...
  • Page 38 Other descriptions: Model: T645 Item: Self-lubrication system operation System: The system is consisting of control board, lubrication motor VR, speed sensor and lubricant bottle Operation process: 1. When the treadmill is in motion, the lubrication control board will track the mileage. When it reaches 1000Km, the program will perform lubrication procedure.
  • Page 39 Other descriptions: Model: T645 Item: Self-lubrication system wiring and block diagram Lubricant hose position Lubrication speed sensor Lubrication control board Lubrication motor & VR Lubricant bottle Lubrication Motor Lubrication control board (From DRV) Lubrication Speed sensor 3-14-2...
  • Page 40 Other descriptions: Model: T645 Item: Lubrication wiring Power in; to drive board To motor gear box To Speed sensor 3-14-3...
  • Page 41 Other descriptions: Model: T645 Item: Lubrication error messages and troubleshooting Troubleshooting: Error messages Malfunction description Possible causes Components replacement suggestion Total distance is not Motor is running, however the total Speed sensor issue 1. Check speed sensor wiring accumulating distance is not accumulating 2.
  • Page 42 Other descriptions: Model: T645 Item: Lubricant bottle replacement Step1.Untighten the screws shown here Step2. Push the metal plate and take Step3.Put the new bottle in with the bottle out existing cap and tighten the screws back to finish. 3-14-5...
  • Page 43 Other descriptions: Model: T645 Item: Energy saving system operation Function: Turn off the power source to drive board and reduce the energy consumption down to under 5W when product is not in use. Operation procedure: 1. When turn on the power, energy saving board will send AC1 /AC2 to drive board and start running the console.
  • Page 44 Other descriptions: Model: T645 Item: Energy saving system wiring To Display board (wakeup signal) Output AC1, AC2 (To DRV) Input AC1,AC2 (From filter) To Display board (wakeup key, LED) Fuse 3-15-2...
  • Page 45 Other descriptions: Model: T645 Item: Bridge board operation Function: 1. Connect the wiring to the lower soft keys, fan, HTR contact plates 2. Coordinate the programming on the drive board to set product model no. Descriptions: Model no. setting: 0 - close，1 - open Model Rep.
  • Page 46 Other descriptions: Model: T645 Item: USB board Function: 1.Changer: Cell phone charging (USB) 2.Data Transfer: Workout data transfer or program update 3.Blue tooth connect: Bluetooth data transmission key & LED indicator 4.Member Card: Member card slot (reserved) USB board To control...
  • Page 47 Other descriptions Model: T645 Item: Language setting Description: 1. Programming language setting procedure; such as German, French… Setting procedure: 1. Press <CHANGE DISPLAY> key for 3 second, it will enter user preference setting. Continuing pressing <ENTER> key until the display shows ”GERMAN ”or “0 MILE H>H” for language setting. See below for all the available languages.
  • Page 48 Inspection and measurement Model: T645 Testing item: AC serve motor circuit breaker inspection Method: 1. Unplug the motor wires and use a volt meter setting at Ohms setting to measure. The reading should be as below: Motor wiring Ohms reading...
  • Page 49 Inspection and measurement Model: T645 Testing item: Incline Zero% limit switch test Method: 1. Turn the power on and start the treadmill, the incline should return to 0% position. At this time, the incline will reach 0% limit switch. 2. If the incline setting is “0%”, then the incline column will touch the zero switch & zero switch will be on (close).
  • Page 50 Inspection and measurement Model: T645 Testing item: Incline motor voltage test Method: 1. Set the volt meter to AC > 300V setting 2. Press INCLINE<▲>/<▼> key; the incline indicator should light up. Measure the incline motor voltage output at this time.
  • Page 51 Inspection and measurement Model: T645 Testing item: Motor temperature switch test Method: 1. When the temperature is normal, there is no abnormality on the display. Unplug the motor temperature switch wiring, the display will show the message of ＂SERVICE REQUIRED…”...
  • Page 52 Inspection and measurement Model: T645 Testing item: Motor Encoder signal test Method: 1. If “ERROR 1_1” message appears when power on, there could be an Encoder issue. Remove the motor cover to see if the Encoder board is damaged. Encoder 2.When the motor is turning, the Encoder indicator on the...