Vision T9800HRT
Service Manual
1
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 1
MAINTENANCE PROCEDURE
3
Download from Www.Somanuals.com. All Manuals Search And Download.
MAINTENANCE CHECK LIST
PREVENTIVE MAINTENANCE SCHEDULE
Vision T9800 TREADMILL
Item
Daily
Weekly
Monthly
Quarterly
Biannual
Annual
Console Mounting Bolts
Inspect
Frame
Clean
Inspect
Power Cord
Display Console
Inspect
Inspect
Clean
Clean
Handrail & Handlebar
Inspect
Front Roller
Clean
Clean
Inspect
Inspect
Rear Roller
Emergency Button
Test
Running belt Tension
V Belt
Inspect
Clean
Inspect
Inspect
Inspect &
Re-waxing
Deck Re-waxing
Running Belt
Clean
(Vacuum)
Control Board
Motor
Clean
4
Download from Www.Somanuals.com. All Manuals Search And Download.
TENSIONING THE BELT PROCEDURE
Caution:
Over-tightening of the roller will severely shorten the life of the belt and may cause
further damage to other components.
Frequency: Every 1 months
Running Belt:
If when you plant your foot on the belt, you can feel a slipping sensation then the belt
has stretched and is slipping across the rollers. This is a normal and common
adjustment on a new treadmill. To eliminate this slipping, tension both the rear
rollers Allen bolts 1/4 TURN as shown above. Try the treadmill again to check for
slipping. Repeat if necessary, but NEVER TURN the roller bolts more than 1/4
turn at a time.
5
Perfect Tension of Running Belt: 0.9~1.1 lbs
Download from Www.Somanuals.com. All Manuals Search And Download.
Drive Belt:
If you have tensioned the running belt and are still experiencing a slipping, adjust the
tension screw. Then try the treadmill again to check for slipping.
6
Download from Www.Somanuals.com. All Manuals Search And Download.
DECK RE-WAXING PROCEDURE
Caution:
If deck is not to periodical add the waxing, between the deck and running belt will
produce great friction make the deck and running belt to burn up and cut down the
motor life .
Frequency: Every 1 month
Parts name: Silicon oil set
Parts number: SZTM74SOS
Price (USD): 0.6
Use time : 1
Procedure:
1. Loosen the tension bolts at both ends.
2. Pull the belt with your left hand and apply the silicon in the deck with
your right hand. (The volume of silicon applied is about 40ml)
3. Tighten the tension bolts.
4. Start the treadmill. Step on the treadmill belt to walk the silicon in.
Adjust the belt tension if necessary.
5. With the clamp-on meter, measure the current draw of the motor.
(Clamp on either the red or the black wire.) The current should be less
than 15Amps for 110V model. (less than 7.5Amps for 220V model.)
7
Download from Www.Somanuals.com. All Manuals Search And Download.
CLEAN THE GROOVES PROCEDURE
Caution:
If dirty grooves in the drive belt, motor and roller pulley, there will be noises while
running.
Frequency: Every 3 months
Procedure:
1.Remove the drive belt and check the grooves
in belt for dirt or dust and clean it.
2.Check the grooves in motor pulley for dirt or
dust and clean it
3.Check the grooves in roller pulley for dirt or
dust and clean it.
8
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 2
WIRING DIAGRAM INSTRUCTION
9
Download from Www.Somanuals.com. All Manuals Search And Download.
T9800(TM87) MCB WIRING(FOR 110V / 220V)
P7
J1
P1
P6
P4
J2
P3 P2
‹ P7-------Motor wire
‹ P2--------SAFE SW (install software)
‹ J1--------RS232 (install software)
‹ P4--------Elevation cable
‹ P6------ on/off switch (power)
‹ J2-------Console cable
‹ P1-------Fan power
‹ P3--------Speed sensor (RPM)
10
Download from Www.Somanuals.com. All Manuals Search And Download.
T9800(TM87) MCB WIRING DEFINITION OF PIN
JP1:Elevation cable(6pin/AMP-350762-4)
1
4
5
6
2
3
P4
Pin
1
Name
Definition
ELVR_+5V
Incline place signal test power
2
3
4
5
6
ELVR_POT
ELVR_GND
UP
Incline place signal
Incline place signal test ground
Incline motor does move to up
Incline motor does move to down
Incline motor does turn on power
DOWN
COM
11
Download from Www.Somanuals.com. All Manuals Search And Download.
J2: console cable
20
19
2
1
Pin
1
Definition
Console ground
Motor Current
2
3
ELV REF GND
4
POT Wiper of ELV(0-5V)
ELV REF VOL.+5V
Speed. signal. (0-5V PULSE)
Console ground
5
6
7
8
Console ground
9
Console for MCB of the PWM signal
Console power
10
11
12
13
14
15
16
17
18
19
20
Console power
Console power
Console provide for incline motor UP signal
Console provide for incline motor DOWN signal
E_STOP
TX OUT(RESERVE)
RESERVE
RX IN(RESERVE)
ERR. SIG.
Console ground
12
Download from Www.Somanuals.com. All Manuals Search And Download.
T9800(TM87) CONSOLE WIRING
J15
J16
J1
J14
J13
J11
J5
‹ J13-------Safety Pull Switch
‹ J11-------Safety Push Switch
‹ J5---------Main HR Interface
‹ J14-------Console cable
‹ J15-------CSAFE 1
(Full csafe function)
‹ J16-------CSAFE 2
(Power only port)
‹ J1---------RS232
(install software)
13
Download from Www.Somanuals.com. All Manuals Search And Download.
T8900(TM87) CONSOLE WIRING DEFINITION OF PIN
J14:20-pin console cable
19
20
1
2
J14
Pin
Definition
1
2
Console ground
Motor Current
3
ELV REF GND
4
POT Wiper of ELV(0-5V)
ELV REF VOL.+5V
Speed. signal. (0-5V PULSE)
Console ground
5
6
7
8
Console ground
9
Console for MCB of the PWM signal
Console power
10
11
12
13
14
15
16
17
18
19
20
Console power
Console power
Console provide for incline motor UP signal
Console provide for incline motor DOWN signal
E_STOP
TX OUT(RESERVE)
RESERVE
RX IN(RESERVE)
ERR. SIG.
Console ground
14
Download from Www.Somanuals.com. All Manuals Search And Download.
J13: Safety Pull Switch
J11: Safety Push Switch
J13
J11
2 1
2 1
Pin
1
Name
SS OUT
SS IN
Definition
Safe key
Pin
Name
Definition
1
2
SS OUT
SS IN
Safe key
2
Console ground
Console ground
J5: Main HR Interface
3 2 1
Pin
1
Name
HR2
Definition
Pulse Board signal
2
3
VCC
GND
Console power (+5V)
Console ground
15
Download from Www.Somanuals.com. All Manuals Search And Download.
T9800(TM87) Electrical block diagram for 110V
16
Download from Www.Somanuals.com. All Manuals Search And Download.
T9800(TM87) WIRING DIAGRAM INSTRUCTION for 110V
17
Download from Www.Somanuals.com. All Manuals Search And Download.
T9800(TM87) Electrical block diagram for 220V
18
Download from Www.Somanuals.com. All Manuals Search And Download.
T9800(TM87) WIRING DIAGRAM INSTRUCTION for 220V
19
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 3
CONSOLE FUNCTIONAL FLOW DIAGRAM
20
Download from Www.Somanuals.com. All Manuals Search And Download.
OPERATING T9800
21
Download from Www.Somanuals.com. All Manuals Search And Download.
T9800 OPERATION MANUAL- Engineer mode
1. Press & Hold both “ELEVATION
” and “SPEED ” at the same time
for 5 sec. Then, the display will show
“Engineering Mode”.
2. Press the "ELEVATION UP or
DOWN" to select you want and press the
“SELECT" key enter.
KEY BEHALE FUNCTION
UP
To scroll through the list of setting
To scroll through the list of setting
Add this show parameter of speed
Decrease this show parameter of speed
To Store up the parameter
DOWN
FAST
SLOW
SELECT
Set the data/function Step.
Use the elevation arrow keys to scroll through the available functions press
“SELECT” key enter, press the “SPEED” key to choose the data press
“SELECT” key to save the data/function.
To exit, press “STOP” key
22
Download from Www.Somanuals.com. All Manuals Search And Download.
Engineering Mode Menu
CONFIGURATION
SYSTEM TESTS
AUTO-CALIBRATION
MANUAL CALIBRATION
MAINTENANCE
SOFTWARE VERSION
EXIT
CONFIGURATION
Address
Description
Default Minimum Maximum
Value
Value
Value
P6 T9800HRT
English,0.5-12 Mph,15% Incline for USA
P6 T9800HRT INT
Metric,0.8-20 Kph,15%Incline for ID
English,0.5-12 Mph,15% Incline for ID
P6 T9800S
P24 UNITS
English,0.5-12mph,15% Incline for USA
English/Metric
P7 MAXIMUM
TIME
99
30
5
5
99
99
P22 DEFAULT
TIME
P23 PAUSE TIME
0:20
40
0:05
15
10:00
99
P27 DEFAULT AGE
P8 DEFAULT
WEIGHT
English
Metric
150
68
80
36
400
181
P15 SCROLL
SPEED
3
1
5
P30 Maximum Speed
English
Metric
12.0 20.0
P14 ELEVATION
ERRS—OFF
ON
Reset Novram
EXIT
Exits mode
23
Download from Www.Somanuals.com. All Manuals Search And Download.
MANUAL CALIBRATION
Address
Description
Default Minimum Maximum
Value
Value
Value
P0 PWM MIN
SPD
PWM value at min speed (0.5
mph/0.8kph)
34
1
111
P1 PWM 1/2
MAX
PWM value at 1/2 max speed (6.0
mph/10.0kph)
176
341
40
110
249
27
251
486
71
P2 PWM MAX
SPD
PWM value at max speed (12.0
mph/20.0kph)
P4 ELEVATION
MIN
Value at zero or minimum elevation
P5 ELEVATION
MAX
Value at maximum elevation
218
YES
26
71
228
P13 ELV
DIRECTION
P19 MAGNET
COUNT
1
48
P20 EFF
67.8
30
DIAMETER
P21 PWM
START SPD
1
~
P29 RAMP TIME
EXIT
30
12
40
Exits mode
Remarks:
Do not change the product below parameter , or it may cause malfunction.
Address
Default Value
P13 ELV DIRECTION
P19 MAGNET COUNT
P20 EFF DIAMETER
P29 RAMP TIME
YES
26
67.8
30
24
Download from Www.Somanuals.com. All Manuals Search And Download.
SYSTEM TESTS
HARDWARE TEST
DISPLAY TEST
KEYBOARD TEST
SAFETY SWITCH TEST
IO TEST
BURN-IN TEST
ELEVATION BURN-IN TEST
EXIT
MANUAL CALIBRATION
Address
Description
Default
Value
Minimum
Value
Maximum
Value
P0 PWM MIN SPD
P1 PWM 1/2 MAX
PWM value at min speed (0.5 mph/0.8kph)
34
1
111
PWM value at 1/2 max speed (6.0 mph/10.0kph)
176
110
251
P2 PWM MAX SPD
PWM value at max speed (12.0 mph/20.0kph)
Value at zero or minimum elevation
Value at maximum elevation
341
40
249
27
486
71
P4 ELEVATION
MIN
P5 ELEVATION
MAX
218
71
228
P13 ELV
YES
26
DIRECTION
P19 MAGNET
COUNT
1
48
P20 EFF
67.8 341
30
DIAMETER
P21 PWM START
SPD
1
~
P29 RAMP TIME
EXIT
30
12
40
Exits mode
25
Download from Www.Somanuals.com. All Manuals Search And Download.
MAINTENANCE
Address
Description
Default
Minimum
Value
Maximum
Value
Value
P9 Total HOURS
0
0
0
0
6533.5
65335
P10 TOTAL
DISTANCE
P25
0
0
BELT/MOTOR
HOURS
P26 LIFT
MOTOR HOURS
P16 LUBRICATE
DECK MSG
OFF
P17 CLEAN
0
0
TREADMILL
MSG
ERROR LOG
EXIT
0
Exits mode
Remarks:
If you want to the clean below parameter, please enter engineering mode select “below place”
enter, hold “START” key for 3 sec.
P9 Total HOURS
P10 Total DISTANCE
P25 Belt/Motor HOURS
P26 Lift (Elevation) HOURS
P16 LUBRICATE DECK MSG
P17 CLEAN MSG
TREAMILL MSG
Error Log
26
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 4
MCB LED INSTRUCTIONS
27
Download from Www.Somanuals.com. All Manuals Search And Download.
AC FAN
28
Download from Www.Somanuals.com. All Manuals Search And Download.
Reference
Designator
LED
Description
STATUS
LED 1
LED 2
LED 3
LED 4
Auxiliary Status LED
Auxiliary Status LED
Auxiliary Status LED
Auxiliary Status LED/Digital to Analog Output.
LED 5
Main Status/Error LED.
AC
LED 6
LED 7
LED 8
Indicates if the DC Buss is Energized (Voltage Present).
Indicates if Console Voltage Supply is present.
Indicates if the DSP Power Supply is present.
+VCON
VDSP
DOWN
LED 9
Indicates if the upper console is commanding Elevation
DOWN.
UP
LED 10
LED 11
LED 12
Indicates if the upper console is commanding Elevation UP.
Indicates if Console is commanding speed.
PWM
SPEED
Indicates the motor is moving via the encoder's feedback by
blinking.
NORMAL OPERATION
1. LEDs 1, 2 and 3 Sequence back and forth to indicate the processor is on-line and
operational.
2. LED 4 is used as a discrete/analog signal to the upper console.
3. LED 5 indicates system status/mode. Currently 3 modes are defined safe mode,
stand-by mode and run mode. They are defined as follows:
a) Safe Mode - When the controllers safety relay is not energized and no error
exists, LED 5 remains off.
b) Stand-by Mode - When the safety relay is engaged but the system is not
outputting an active PWM to the motor and no error exists, LED 5 blinks off and
on at a fast rate.
c) Run Mode - When the system outputs an active PWM Control signal to the
motor and no error exists, LED 5 remains ON.
29
Download from Www.Somanuals.com. All Manuals Search And Download.
SECTION 5
TROUBLESHOOTINGS
30
Download from Www.Somanuals.com. All Manuals Search And Download.
T9800 Console Error code
CODE DESCRIPTION
E1
E2
Reverse elevation pot
Elevation out of range
Elevation movement stall
Over-speed
E3
E5
E6
Runaway belt
E7
Speed stall (could be missing speed sensor)
Speed Range (usually caused by calibration)
Stuck key error
E9
E16
E18
E19
Safety Switch Test Failure
NOVRAM failure
Movement related errors can be divided in elevation related errors (E1 – E3) or speed
related errors (E5 – E9).
Elevation Errors
(E1 – E3)
Movement Errors
Speed Errors
(E5 – E9)
System Errors
Operation Errors
31
Download from Www.Somanuals.com. All Manuals Search And Download.
E1 - Reverse Elevation Pot
Step 1. Calibrate Elevation
Calibrate the elevation as outlined in the System Calibration Procedure in below step.
Error 1
Enter engineer mode of
“MANUAL
CALIBRATION”
screen
Check the “P13 ELV
AUTO-
DIRECTION” screen
whether set to “Yes”
Set to “Yes”
Calibration
Enter the “P4 ELEVATION
MINIMUM” screen
whether parameter set is
30̈́2
AUTO-
Calibration
Enter the “P5
ELEVATION
AUTO-
MAXIMUM ” screen
whether parameter set is
240̈́5
Calibration
Step 2. CORRECTIVE ACTION
1.Ensure correct signal is being sent to interface board (MCB) by pressing elevation
up/down keys by observing elevation LED’s correctly corresponding to correct
elevation keys pressed (please refer the 29 page) . If failure occurs for this step check
console cable and then the interface board (MCB).
2.Check failed elevation motor, interface board, console cable with a known good
console.
32
Download from Www.Somanuals.com. All Manuals Search And Download.
E2 – Elevation Out Of Range
Step 1. Calibrate Elevation
Calibrate the elevation as outlined in the System Calibration Procedure in below step.
Error 2
Enter engineer mode of
“MANUAL
CALIBRATION”
screen
Check the “P13 ELV
AUTO-
DIRECTION” screen
whether set to “Yes”
Set to “Yes”
Calibration
Enter the “P4 ELEVATION
MINIMUM” screen
whether parameter set is
30̈́2
AUTO-
Calibration
Enter the “P5
ELEVATION
MAXIMUM ” screen
whether parameter set is
240̈́5
AUTO-
Calibration
Step 2. CORRECTIVE ACTION
1.Check the failed system with a known good console cable. If fixed then
repair/replace the console cable.
2.Check the failed system with a known good elevation motor. If problem fixed then
repair/replace the elevation motor.
3.Check the failed system with a known good interface board. If problem fixed then
repair/replace the interface board (MCB).
4.Check the failed system with a known good console board with current software. If
the problem is fixed then repair/replace the console.
33
Download from Www.Somanuals.com. All Manuals Search And Download.
E3 – Elevation Stall
Step 1. Please refer the below PROBLEM IDENTIFICATION Step.
E3 Error
Check the “P13 ELV
AUTO-
DIRECTION” screen
whether set to “Yes”
Set to “Yes”
Calibration
Enter Hardware Test Screen
Run Elevation Up And Down
N
Treadmill
moves up or
down?
Y
Waiting the Elevation
Motor to cool
Motor
Overheated?
N
Y
Motor Movement Issue
Y
Feedback
Changes
Elevation
AUTO-Calibration
N
Position Feedback Problem
Step 2. CORRECTIVE ACTION
1.Allow elevation motor to cool.
2.Check the failed system with a known good console cable. If fixed then
repair/replace the console cables.
3.Check the failed system with a known good elevation motor. If problem fixed then
repair/replace the elevation motor.
4.Check the failed system with a known good interface board (MCB). If problem
fixed then repair/replace the interface board (MCB).
5.Check the failed system with a known good console board with current software. If
34
the problem is fixed then repair/replace the console.
Download from Www.Somanuals.com. All Manuals Search And Download.
E5 – Over-speed Error
OVERVIEW
If the actual speed from the speed sensor exceeds the system maximum speed by a limit
(currently 2 MPH) an over-speed error occurs (E5).
Step 1. AUTO CALIBRATION
AUTO-Calibration the as outlined in the System Calibration Procedure in below step.
Error 5
Enter engineer mode of
“AUTO
Measured speed <
14 MPH &
displayed speed >
14 MPH
Speed feedback
issue
CALIBRATION”
Please will start Key
held for 3 seconds to
auto calibration
Speed control issue
Speed Feedback Issues – See speed feedback issue trouble shooting guide in the
CORRECTIVE ACTION PROCEDURES – Speed Issues section of this document.
Speed Control Issues – See speed control issue trouble shooting guide in the
CORRECTIVE ACTION PROCEDURES – Speed Issues section of this document.
Step 2 :
1.Record when parameter information with error (please refer the 25 page of P1 / P2 /
P3 place) .
2.Remove Power!!! Carefully check all connections.
3.Check interface board (MCB) with the speed sensor ensure contact are correct and fix.
4. If AUTO CALIBRATION can't finish, please take speed sensor to be close to
magnet and AUTO CALIBRATION again.
5.If repeat over speed errors occur remove the treadmill from service.
35
Download from Www.Somanuals.com. All Manuals Search And Download.
E6 – Runaway Belt Error
OVERVIEW
If the actual belt speed is greater than the target speed by a limit and increasing then an
E6 error is called. E6 errors flag errors that will result in the belt “running away” or not
responding to input.
Step 1 :
Error 6
Before cycling power inspect the
motor controller for error
conditions
Record error code information
Motor Controller Error
from motor controller
Record console error code
parameters recorded with current
error code
Inspect all electrical connections,
ensure that all connections are properly
Speed feedback
Speed control issue
made and there are no shorts to
issue
adjacent conductors
Speed Feedback Issues – See speed feedback issue trouble shooting guide in the CORRECTIVE
ACTION PROCEDURES – Speed Issues section of this document.
Speed Control Issues – See speed control issue trouble shooting guide in the CORRECTIVE ACTION
PROCEDURES – Speed Issues section of this document.
Step 2 :
1.Remove Power!!! Carefully check all connections, interface board and the Reliance Motor
controller setting to ensure all settings are correct.
2. Enter the engineer mode to SERVICE 5, press "START" key to clean "ERROR LOG" and
refer the T5x Engineer mod parameter set SOP to confirm the machine parameter whether is
correct.
3. AUTO CALIBRATION again.
4. If AUTO CALIBRATION can't finish, please take the speed sensor to be close to magnet and
AUTO CALIBRATION again.
36
Download from Www.Somanuals.com. All Manuals Search And Download.
E7 – Speed Stall Error
OVERVIEW
If no belt movement is detected several seconds after commanding belt movement a speed
stall error (E7) is called.
Step 1 :
E7 Error
Enter firmware setup screen
Start PWM 1/2MAX test
N
Belt Moving
Belt drive issue
Y
Allow belt speed to stabilize and measure belt speed
Y
Measured speed different than
displayed speed
Speed Feedback Issue
N
N
N
Measured speed = 6.4
MPH
AUTO CALIBRATION
AUTO CALIBRATION
Y
Displayed speed = 0
Y
Speed feedback missing
Step 2 :
Belt Drive Issues – See belt drive issue trouble shooting section in the CORRECTIVE
ACTION PROCEDURES – Speed Issues section of this document.
Speed Feedback Issues – See speed feedback issue trouble shooting section in the
CORRECTIVE ACTION PROCEDURES – Speed issues section of this document.
Speed Feedback Missing Issues – See speed feedback issue trouble shooting section in the
CORRECTIVE ACTION PROCEDURES – Speed Issues section of this document.
37
Calibration Issues – See speed calibration issue trouble shooting section in the
CORRECTIVE ACTION PROCEDURES – Speed Issues section of this document
Download from Www.Somanuals.com. All Manuals Search And Download.
E9 – Speed Range Error
OVERVIEW
During normal run time operation the value stored during auto calibration is used to initially
set the speed (e.g. target speed = 12 MPH, PWM ticks = Maximum PWM = 363). Once the
speed stabilized the actual speed is monitored and if different than the target speed the PWM
value is adjusted until the actual speed matches the target speed. If the PWM value is
changed by more than the amount of ticks required to change 0.8 MPH and the actual speed
does not match the target speed then an E9 error is flagged. This error indicates the motor
controller system is unable to maintain the target speed.
E9 Error
Before cycling power inspect the
motor controller for error
Record the error
code from the
motor controller
Check for free
movement of
belt roller
Y
Cycle
Power
Run auto
calibration
Motor
controller error
Done
movement
N
Start PWM ½ MAX test
Measure speed and compare
to value displayed in time
window
N
Perform steps outlined in speed
OK
feedback issue
Y
Run Auto Calibration
N
Error
Gone
Perform steps outlined in
speed control issue
Y
38
Done
Download from Www.Somanuals.com. All Manuals Search And Download.
Speed Feedback Issues – See speed feedback issue trouble shooting section in the
CORRECTIVE ACTION PROCEDURES – Speed Issues section of this document.
Speed Control Issues – See speed control issue trouble shooting guide in the CORRECTIVE
ACTION PROCEDURES – Speed Issues section of this document.
Calibration Issues – See speed calibration issue trouble shooting section in the CORRECTIVE
ACTION PROCEDURES – Speed Issues section of this document.
39
Download from Www.Somanuals.com. All Manuals Search And Download.
CORRECTIVE ACTION PROCEDURES – Speed Issues
Speed Feedback Issue
Perform steps in order listed until
problem resolved.
Enter Magnet Count
screen
1.
.Check connections
2.
.Check magnet
orientation (correct
poles)
.Check sensor
mounting
.Replace sensor w/
known good sensor
.Replace interface PCB
with known good PCB
N
Adjust magnet count
to match number of
magnets
3.
4.
5.
Magnet count
= treadmill #
of magnets
Re-run test
Y
Manually rotate belt and check
for only 1 speed pulse on
interface board per magnet
(check all magnets)
N
N
N
N
No pules
for either
magnet
Pulse
only one
magnet
Multiple
pulse per
magnet
OK?
Y
Y
Y
Enter effective
diameter screen
of firmware
Perform steps in order listed
until problem
Perform steps in
Perform steps in order listed until
problem resolved.
order listed
until problem
resolved.
Check magnet
orientation
resolved.
1.
If reed type sensor replace
with Hall type sensor or
correctly orient sensor.
Check connections
setup
1.
2.
Check connections
Check magnet
orientation (correct
poles)
1.
2.
3.
4.
(correct poles)
Check sensor
mounting
Replace sensor
w/ known
Check sensor mounting
Replace sensor w/ known
good sensor
Setup effective
diameter as
described in
system
calibration
section of this
document
3.
4.
5.
Check sensor
mounting
Replace sensor w/
known good sensor
Replace interface
PCB with known
good PCB
2.
3.
good sensor
Y
Problem
Fixed
N
Perform steps in order listed until
problem resolved.
1.
2.
Check connections
Check magnet orientation
(correct poles)
Re-calibrate
system
3.
4.
Check sensor mounting
Replace sensor w/ known good
sensor
Done
5.
6.
Replace interface PCB with
known good PCB
Replace console PCB with
know good PCB
40
Download from Www.Somanuals.com. All Manuals Search And Download.
CORRECTIVE ACTION PROCEDURES – Belt Drive Issues
Belt Drive Issue
Start PWM max test (firmware setup
screens), wait 20 seconds
Check PWM LED on interface PCB
Perform steps in order listed until problem
resolved.
1.
2.
3.
.Replace ribbon cable with
known good ribbon cable.
.Replace interface PCB with
known good interface PCB.
.Replace console PCB with a
known good console PCB.
N
PWM LED
illuminated
Y
Perform steps in order listed until problem resolved.
1.
.Ensure belt and drive is able to turn
freely and are properly mechanically
connected.
2.
3.
4.
.Check all electrical connections
.Verify reliance drive settings
.Replace ribbon cable with a known
good cable
5.
6.
.Replace interface PCB with a known
good PCB
.Replace console PCB with a known
good PCB
41
Download from Www.Somanuals.com. All Manuals Search And Download.
CORRECTIVE ACTION PROCEDURES – Speed Control Issues
Speed Control Issue
Start PWM max test (firmware setup screens), wait
20 seconds or until speed stabilizes
N
See belt drive issue
Belt moving
Y
Measure speed and compare to value displayed in
time window
N
Speed feedback issue
OK
Y
Run Auto Calibration (firmware setup)
Y
Problem Fixed
Done
N
Perform steps in order listed until problem resolved.
1.
.Ensure belt and drive is able to turn freely and are
properly mechanically connected.
2.
3.
4.
5.
6.
.Check all electrical connections
.Verify reliance drive settings
.Replace ribbon cable with a known good cable
.Replace interface PCB with a known good PCB
.Replace console PCB with a known good PCB
42
Download from Www.Somanuals.com. All Manuals Search And Download.
CORRECTIVE ACTION PROCEDURES – Speed Calibration Issue
Speed Calibration Issue
Run auto calibration (firmware setup screen)
Y
Auto calibration
Done
passed
N
Start PWM max test (firmware setup screen),
wait minimum 20 seconds or until sped
stabilizes
Measure speed and compare to value
displayed in time window
N
Check speed feedback
OK
issue
Y
Check speed control issue
43
Download from Www.Somanuals.com. All Manuals Search And Download.
OPERATION ERRORS
E16 – Stuck key error
OVERVIEW
If a key press is detected for more than 45 seconds a stuck key error is flagged. This error is
primarily caused by a faulty keypad but could be caused by other issues (object on the
keypad).
CORRECTIVE ACTION
Reset system power. If error re-occurs replace the keypad with a known good keypad. If
error still occurs replace console PCB with known good console PCB.
E18 – Safety switch test failure
OVERVIEW
If the actual speed exceeds limit set for safety switch test a safety switch test failure error
occurs..
CORRECTIVE ACTION
Re-calibrate system as listed in system calibration section of this document and re-run safety
switch test. If system still fails safety switch test run speed feedback issue and speed control
issue tests in the corrective action procedures section of this document.
E19 – NOVRAM Failure
OVERVIEW
If the values stored in non-volatile memory are out of limits or do not match the safety check
value stored in non-volatile memory a NOVRAM failure occurs. The system attempts to re-
initialize the non-volatile memory three times and if the NOVRAM check fails all three
attempts a NOVRAM failure error (E19) is called.
CORRECTIVE ACTION
An E-19 error indicates the NOVRAM has critically failed and needs to be replaced. If an E19
error occurs the console should be reprogrammed with the current software version and the
power should be toggled. If this does not clear the E-19 error the console PCB will need to be
returned to DCI for repair.
44
Download from Www.Somanuals.com. All Manuals Search And Download.
|