Dyaco AT90E Service Manual
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Dyaco AT90E Service Manual

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AT90E
NT52
Treadmill

Service Manual

(110~120V & 220~230V)

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Summary of Contents for Dyaco AT90E

  • Page 1: Service Manual

    AT90E NT52 Treadmill Service Manual (110~120V & 220~230V)

  • Page 2: Table Of Contents

    --------------------------------------Table of Contents------------------------------------------- 1. Treadmill Outlines 2. Electronic Parts 2.1 Upper Controllers 3. Electrical Configuration 4. Product Operation 5. Unit Block Diagrams 6. Basic Connections and Wiring 6.1 Display Board Wire Connections 6.2 Display Board PCB Component Locations 6.3 Driver Board Wire Connections 6.4 Driver Board PCB Component Locations 6.5 Driver Board LED Indicator Locations 6.6 Controller Indicator LED Debugging...
  • Page 3 Disassembling and Assembling of Parts 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: Treadmill Outlines

    1. Treadmill Outlines...
  • Page 6 Console Speed adjustment button+ Hand Pulse Sensor Incline adjustment button+ Hand Pulse Sensor...
  • Page 7 Driving Motor Lower Incline Motor Controller...

  • Page 9: Electronic Parts

    2. Electronic Parts...

  • Page 10: Upper Controllers

    2.1 Upper Controllers DISPLAY Cooling Fan Hand Pulse Hand Pulse Heart Sensors Heart Sensors...
  • Page 11 2.2. Lower Controller and Driver SPEED SENSOR Motor Controller DC MOTOR INCLINE MOTOR Driver System(Motor/Controller)

  • Page 12: Electrical Configuration

    3. Electrical Configurations...
  • Page 13 AFETY KEY O FITS ON THE ONSOLE THAT ACTIVATE ALL FUNCTIONS F NO SAFETY KEY CONSOLE CAN NOT BE CONTROLLED ONSOLE Interface that controls all functions of the treadmill. AIN CONTROLLER The circuit board consist of the DC power supply for console、incline driver and DC motor driver, link the console to output appropriate voltages for motor that control the treadmill functions.

  • Page 14: Treadmill Motor

    Treadmill motor It’s a variable speed on 0-90 volt DC motor.for 120V Have three wires red, black and green. If there is DC voltage on the Red (white) wire (M+) the treadmill motor will turn clockwise. If there is DC voltage on the Black wire (M-) the treadmill motor will turn counter-clockwise. The higher the voltage the faster the motor turns The green wire is ground.

  • Page 15: Product Operation

    4. Product Operation...

  • Page 16: Display Windows

    Display Windows LCD Display SPEED Quick Keys INCLINE Quick Keys FAST/SLOW UP/DOWN PROGRAM Key ENTER Key Hand Pulse Hand Pulse Heart Sensors Heart Sensors STOP key Safety key START key...
  • Page 17 LCD Layout...
  • Page 18 Operation Window Display Mode OFF Mode When user doesn’t insert the SAFETY KEY on the console the treadmill enters the OFF Mode and windows will appear E0 . READY Mode When the treadmill is ON and SAFETY KEY is inserted in console the treadmill enters the READY Mode. Press START button to start treadmill on Manual Mode.
  • Page 19 Function Button Locations Speed quick keys 3/6/9 Incline quick keys 3/6/9 FAST/Slow Key Adjustment Speed Up/Down Key Adjustment incline PROGRAM Key FAN key Choose Program Switch FAN Enter Key Set data function STOP Key end workout START Key To workout Safety Key Emergency function...
  • Page 20 Function Button In Main Mode READY MODE 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. 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 starts running.
  • Page 21 SPEED RAPID button: Speed will set to : 3,6,9 mph(kph) INCLINE RAPID button: Incline will set to : 3,6,9...

  • Page 22: Unit Block Diagrams

    5. Unit Block Diagrams...
  • Page 23 Treadmill Configuration...

  • Page 24: Basic Connections And Wiring

    6. Basic Connections and Wiring...

  • Page 25: Display Board Wire Connections

    6.1 Display Board wire Connections...

  • Page 26: Display Board Pcb Component Locations

    6.2 Display Board PCB Component Locations PCB Board Top...
  • Page 27 PCB Board Bottom...

  • Page 28: Driver Board Wire Connections

    6.3 Driver Board Wire Connections...

  • Page 29: Driver Board Pcb Component Locations

    6.4 Driver Board PCB Component Locations...

  • Page 30: Driver Board Led Indicator Locations

    6.5 Driver Board LED Indicator Locations COMMUNICATION STATE NO TWINKLING ：FAILURE TWINKLING：NORMAL POWER DICATOR LIT：VCC POWER CIRCUIT ON...

  • Page 31: Controller Indicator Led Debugging

    6.6 Controller Indicator LED debugging Indicator Function Condition Reason Solve INFO Motor speed Normal on when start is pressed. No input. Check fast/slow wires of 5PIN Fault condition if start is pressed & connector. LED off. Replace controller. Replace console. POWER Controller power If DC voltage is normal, it would be...

  • Page 32: Driver Board Function

    6.7 Driver Board function M+0~90Vdc TO MOTOR (BLACK WIRE) 120VAC IN 120VAC IN M-0~90Vdc TO MOTOR (RED WIRE) INCLINE POWER WHITE INCLINE Transformer POWER TORQUE INCLINE POWER BLACK NCLINE VR CONNECTION TO CONSOLE SPEED SENSOR...

  • Page 33: Product Safety Instructions

    7. Product Safety Instructions...

  • Page 34: Important Safety Instructions

    7.1 Important Safety Instructions - To reduce the risk of electric shock disconnect your treadmill from the electrical outlet prior to cleaning and/or service work. - To reduce the risk of burns, fire, electric shock, or injury to persons, install the treadmill on a flat level surface with access to a 120-volt, 15-amp grounded outlet with only the treadmill plugged into the circuit.

  • Page 35: Error Messages And Troubleshooting For Electronic Issues

    8. Error Messages and Troubleshooting for Electronic Issues...

  • Page 36: Error Message

    Error code items： ： ： ： Error Message Explain Display board CPU did not receive the Safety device signal. Display board CPU did not receive the RPM signal. Incline failure Over current protection Motor voltage is abnormal or cable is not connected Communication between console and controller is disconnected.
  • Page 37 8.1 Error Message： ： ： ： E1 Definition：Display board CPU did not receive the RPM signal. Configuration：...

  • Page 38: Cause Of E1

    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 LCD show E1...
  • Page 40 E1 solution follow chart...
  • Page 41 Terminals for motor cable, Red for M+, White for M- POWER LED...
  • Page 42 E1 solution follow chart – check RPM sensor device procedure： ： ： ：...
  • Page 43 Is sensor cable connected properly? Checking the speed sensor 1) Remove the motor cover hood. 2) The speed sensor is located on the left side of the frame, right next to the front roller pulley (the pulley will have a belt around it that also goes to the motor). The speed sensor is small and black with a wire connected to it.
  • Page 44 E1 issue troubleshooting form E1 message Possible cause Things to check Solution Possible cause Things to check Solution The monitor hasn't check the speed Make sure the good connection receive any speed signal sensor cable is in for cables for 8 seconds good connection E1 message Check the gap...
  • Page 45 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 LCD show Err...
  • Page 47 Case of Incline 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.
  • Page 48 Troubleshooting Part Troubleshooting 1.Reconnect VR wires. Incline VR 2.Inspect whether the incline wires are broken or disconnected. 1.Inspect the incline wire and 5-pin cable connections. Display board 2.Test whether the VR voltage varies at the incline wire terminal. 1.Inspect the wire connections. 5-pin cable 2.Inspect whether wires are broken or crimped.
  • Page 49 Error Message： ： ： ： ERR Definition：During incline action,the display board CPU cannot read the VR value,so ERR appears. Configuration： -48-...
  • Page 50 Cause of ERR Press the incline UP/DOWN key.The incline doesn’t operate. ERR appears on the display. Explanation Press 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.
  • Page 51 Troubleshooting Part Troubleshooting 1.Press incline UP key.The driver board RELAY #RY2 action.. Display board 2.Press incline DOWN key.The driver board RELAY #RY1 action.. 3.If not as above,inspect the cable and connections. 1.Inspect whether the 5-PIN cable is connected well. 5-pin cable 2.Test by replacing the cable with a good one.

  • Page 52: Circuit Diagram

    8.3 Circuit diagram -51-...

  • Page 53: Calibration Procedure

    8.4 CALIBRATION PROCEDURE Calibration Engineering Mode Pull off the safety key and reinsert 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”...

  • Page 54: Fuse Replacement

    8.5 Fuse replacement FUSE For AC is 3.15A 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 FUSE...
  • Page 55 Err code troubleshooting check list Trouble Diagnosis/Insp. Possible cause/Inspection item 1. External power 1. Check power outlet to the OK□ NG□ problem treadmill. Make sure power switch light is on after turning on the switch. 2. Internal control/Lower 2. Make sure fuse is OK and Console without power controller varistor is free from...
  • Page 56 3. Check if the problem OK□ NG□ persists with a new controller, 1. Make sure safety key is OK□ NG□ placed properly and safety switch mechanism is not Console shows E0 Safety switch loose. message malfunction or 2. Check if the cable for intermittence mileage switch in the OK□...

  • Page 57: Troubles Hooting Procedure Matrix

    8.6 Troubles hooting procedure matrix Condition Reason Solve When turn on power, ON/OFF switch isn’t lit. 1 Power cord isn’t plugged into outlet. 1 Plug the power cord into outlet. 2 Power cord isn’t plug into unit. 2 Plug the power cord into unit. 3 The voltage of outlet is too low.
  • Page 58 When press “START” button to start treadmill, running 1. Motor wires (red, black) aren’t plugged into 1. Plug wires again. belt isn’t running and window displays “E1” error controller. 2. Plug the wire again on controller, connector and console. message after 10 seconds. 2.
  • Page 59 UP/DOWN button of 1 The connector of INCLINE CABLE (UPPER) 1 Connect the wires again. and CONSOLE not connected properly. INCLINE ADJUSTMENT SWITCH can’t be used. 2. The connector of INCLINE CABLE 2. Connect the wires again. (UPPER) and INCLINE ADJUSTMENT Incline button just can press UP, can’t press DOWN.

  • Page 60: Folding/Unfolding And Transport

    9. Folding/Unfolding and Transport...

  • Page 61: Folding Instructions

    FOLDING INSTRUCTIONS Do not attempt to move the unit unless it is in the folded and locked position. Be sure the power cord is secured to avoid possible damage. Use both handrails to maneuver the unit to the desired position. ■...

  • Page 62: General Maintenance

    10. General Maintenance...

  • Page 63: Tread Belt And Deck

    10.1 Tread belt and Deck Your treadmill uses a very high-efficient low-friction bed. Performance is maximized when the bed is kept as clean as possible. Use a soft, damp cloth or paper towel to wipe the edge of the belt and the area between the belt edge and frame. Also reach as far as practical directly under the belt edge.
  • Page 64 Tighten the rear roller bolts only enough to prevent slippage at the front roller. Turn both tread-belt tension adjustment bolts in increments of 1/4 turn each and inspect for proper tension by walking on the belt at a low speed, making sure the belt does not slip. Keep tensioning the bolts until the belt stops slipping.
  • Page 65 ATTENTION: DAMAGE TO THE RUNNING BELT RESULTING FROM IMPROPER TRACKING / TENSION ADJUSTMENTS IS NOT COVERED UNDER THE WARRANTY. BELT/DECK LUBRICATION First, you want to clean between the belt and deck to remove any debris that may be trapped. Use a clean, non-fraying rag, t-shirt, or light towel. Halfway between the end of the treadmill and motor cover, shove the garment under the belt until you can grasp it on both sides of the belt.

  • Page 66: Service Troubleshooting Checklist - Diagnosis Guide

    10.2. Service Troubleshooting Checklist – Diagnosis Guide Before contacting your dealer for aid, please review the following information. It may save you both time and expense. This list includes common problems that may not be covered under the treadmill’s warranty. PROBLEM SOLUTION/CAUSE Display does not light...
  • Page 67 Treadmill will only achieve approximately This indicates motor should be receiving power to operate. Low AC voltage to treadmill. Do not use an extension cord. 10 kph but shows higher speed on display If an extension cord is required it should be as short as possible and heavy duty 16 AWG minimum. Low household voltage. Contact an electrician or your dealer.

  • Page 68: Installation Of The Incline Motor

    11. Installation of the Incline Motor...
  • Page 69 Incline Range must be adjusted to 195mm minimum prior to installation.

  • Page 70: Disassembling And Assembling Of Parts

    12. Disassembling and Assembling of Parts...

  • Page 71: Lower Controller Replacement

    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: Console Replacement

    12.2 Console Replacement Use M5 L Allen wrench to remove 4 Button Head Socket Bolts from the console support Disconnect console wirings and replace with new console.

  • Page 73: Motor Replacement

    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 (3) Use 14mm T-shaped socket wrench to loosen 4 screws, use 14mm open end wrench to loosen 1 belt tension screw, remove motor and replace with new. (4) Reassemble in reverse order of disassembly, re-hook belt (readjust belt to be parallel with main frame after re-hooking). Do not tighten 4 securing screws yet.

  • Page 75: Breaker Replacement

    12.4 Breaker Replacement Remove Breaker connection wiring, replace part and reconnect wiring.

  • Page 76: Ac Power Switch Replacement

    12.5 AC Power Switch Replacement (1) Disconnect wiring to AC power switch, replace AC power switch and reconnect wiring.

  • Page 77: Front/ Rear Roller Replacement

    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 (3) Remove motor cover, use 14mm T-shaped socket wrench to loosen 4 screws. Use 14mm open end wrench to loosen 1 belt 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.

  • Page 79: Running Deck/ Belt & Cushion Replacement

    12.7 Running Deck/ Belt & Cushion Replacement(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 (3) Use Phillips head screwdriver to remove 4 Tapping Screws from the front and back of the foot rail according to the indicating arrows. (4) User Phillips head screwdriver to remove the 8 screws securing the running board. Remove the running board and replace running board or running belt.

  • Page 81: Speed Sensor Replacement

    12.8 Speed 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: Incline Motor Replacement

    12.9 Incline Motor Replacement Zeroing 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 2. Use 14mm wrench to assemble new incline motor.
  • Page 84 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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Nt52

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