Sharp LL-T2000 Service manual

Series 2000 Treadmill
field service manual
PN 409110-004
Revision D
A PART OF THE
MARQUETTE
U N I T Y
NETWORK
NOTE
Due to continuing product innovation,
specifications in this manual are subject to
change without notice.
 Copyright Marquette Medical Systems, Inc. 1998. All rights reserved.
Trademarked names appear throughout this document. Rather than list the names and entities that own the
trademarks or insert a trademark symbol with each mention of the trademarked name, the publisher states that
it is using the names only for editorial purposes and to the benefit of the trademark owner with no intention of
improperly using the trademark.
ACCUSKETCH, AccuVision, APEX , AQUA-KNOT, ARCHIVIST, Autoseq, BABY MAC, CardioServ, CardioSmart,
CardioSys, CardioWindow, CASE, CD TELEMETRY, CENTRA, CHART GUARD, CINE 35, CORO, COROMETRICS,
CRG PLUS, Digistore, Digital DATAQ, E for M, EAGLE, Event-Link, HELLIGE, IMAGE STORE, INTELLIMOTION,
LASER SXP, MAC, MAC-LAB, MACTRODE, MARQUETTE, MARQUETTE MAC, MARQUETTE UNITY NETWORK,
MARS, MAX, MEDITEL, MEI, MEI in the circle logo, MEMOPORT, MEMOPORT C, MINISTORE, MINNOWS,
Monarch 8000, MULTI-LINK, MULTISCRIPTOR, MUSE, MUSE CV, Neo-Trak, NEUROSCRIPT, OnlineABG,
OXYMONITOR, Pres-R-Cuff, PRESSURE-SCRIBE, QMI, QS, Quantitative Medicine, Quantitative Sentinel, Qwik
Connect Spiral, RAMS, RSVP, SAM, SEER, SOLAR, SOLARVIEW, Spectra 400, Spectra-Tel, ST GUARD, TRAM,
TRAM-NET, TRAM-RAC, TRAMSCOPE, TRIM KNOB, UNITY logo, UNITY NETWORK, Vari-X, Vari-X
Cardiomatic, VariCath, VAS, and Vision Care Filter are trademarks of Marquette Medical Systems, Inc.,
registered in the United States Patent and Trademark Office.
12SL, 15SL, AccuSpeak, ADVANTAGE, BAM, BODYTRODE, Cardiomatic, CardioSpeak, CD TELEMETRY®-LAN,
CENTRALSCOPE, Corolation, Corometrics Sensor Tip, DASH, EDIC, HI-RES, IMAGE VAULT, IMPACT.wf,
INTER-LEAD, IQA, LIFEWATCH, MARQUETTE MEDICAL SYSTEMS, MARQUETTE® RESPONDER, MENTOR,
MicroSmart, MMS, MRT, MUSE CardioWindow, O2 SENSOR, OMRS, Premium, RAC, SILVERTRACE, SMARTPAC, SMARTLOOK, Spectra-Overview, Trimline, UNITY, and Universal are trademarks of Marquette Medical
Systems, Inc.
T-2
Series 2000 Treadmill
409110-004
Revision D
22 July 1998
Contents
1
Introduction ................................................ 1-1
Manual Information ..................................................................
Revision History .................................................................................
Manual Purpose .................................................................................
Conventions .......................................................................................
1-3
1-3
1-3
1-4
Safety Information ....................................................................
Responsibility of the Manufacturer ....................................................
General ...............................................................................................
Equipment Symbols ...........................................................................
Warnings and Cautions ......................................................................
1-5
1-5
1-5
1-6
1-7
Service Information .................................................................. 1-9
Service Requirements ........................................................................ 1-9
Equipment Identification .................................................................... 1-9
Revision D
Series 2000 Treadmill
409110-004
i
2
Equipment Overview ..................................... 2-1
General Description ..................................................................
Intended Use ......................................................................................
Motor Drive System ...........................................................................
Elevation System ................................................................................
Bed Assembly ....................................................................................
Electronic Assembly ...........................................................................
Block Diagram ....................................................................................
2-3
2-3
2-3
2-3
2-3
2-3
2-4
Preparation for Use ................................................................... 2-5
Safe Handling Guidelines ................................................................... 2-5
Equipment Assembly ......................................................................... 2-6
Handle Set ............................................................................ 2-6
Emergency Stop Switch ........................................................ 2-7
Connector Locations .......................................................................... 2-8
Operating Instructions ............................................................... 2-9
Electrical Safety Tests ........................................................................ 2-9
Operating Controls ............................................................................. 2-9
Power Switch ....................................................................... 2-9
Emergency Stop Switch ........................................................ 2-9
Controlling the Treadmill .................................................................. 2-10
Emergency Stop Switch Check ........................................................ 2-10
3
Maintenance ............................................... 3-1
Introduction
...................................................................... 3-3
Recommended Maintenance .............................................................. 3-3
Inspection Report ................................................................. 3-3
Required Tools and Supplies ............................................................. 3-3
Inspection and Cleaning .............................................................
Visual Inspection ................................................................................
Exterior Cleaning ................................................................................
Interior Cleaning ................................................................................
3-4
3-4
3-4
3-4
Domestic Electrical Safety Tests ................................................... 3-5
AC Line Voltage Test .......................................................................... 3-5
120 VAC, 50/60 Hz ............................................................... 3-5
240 VAC, 50/60 Hz ............................................................... 3-5
Leakage Tests .................................................................................... 3-6
Leakage Test Diagrams ...................................................................... 3-7
ii
Series 2000 Treadmill
409110-004
Revision D
Test #1 ............................................................................................... 3-7
Ground-Wire-Leakage-to-Ground ......................................... 3-7
Test #2 ............................................................................................... 3-7
Chassis-Leakage-to-Ground (Exposed Chassis) ................... 3-7
Test #3 ............................................................................................... 3-8
Patient-Cable-Leakage-to-Ground ......................................... 3-8
Test #4 ............................................................................................... 3-8
Patient Cable-Leakage-into-Patient Leads-from 120 VAC ..... 3-8
Ground Continuity Test ...................................................................... 3-9
Self-Calibration ..................................................................... 3-10
When to Calibrate ............................................................................. 3-10
Activating Self-Calibration ................................................................ 3-10
Belt Tracking Adjustments .........................................................
When to Adjust ................................................................................
Check Treadmill Level ......................................................................
Adjust Pulley Screws .......................................................................
3-11
3-11
3-11
3-12
Miscellaneous Maintenance Forms ............................................... 3-13
4
Troubleshooting ........................................... 4-1
Power PCB Theory .................................................................... 4-3
General Description ............................................................................ 4-3
Power Distribution/Isolation .............................................................. 4-3
STOP Circuitry ................................................................................... 4-3
Frequency-to-Voltage Converter/Amplifier ......................................... 4-3
Start/Stop Circuitry ............................................................................ 4-4
Elevation Relays ................................................................................. 4-4
Drive Connector ................................................................................. 4-4
Hall Feedback ..................................................................................... 4-4
Power Inlet, Drive Power Outlet, and Mains ....................................... 4-4
Control Board Connector ................................................................... 4-4
Elevation Sensor ................................................................................ 4-5
Isolation Transformer ........................................................................ 4-5
Power Supplies .................................................................................. 4-5
Isolated Serial Link ............................................................................. 4-5
Debug/Serial Link ............................................................................... 4-5
ESD and EMI Compatibility ................................................................ 4-6
Power Supply Requirements .............................................................. 4-6
Precautions ...................................................................................... 4-12
Initial Board Conditions .................................................................... 4-12
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Series 2000 Treadmill
409110-004
iii
Control PCB Theory ..................................................................
General Description ..........................................................................
Power Distribution ...........................................................................
Clock Generator ...............................................................................
Reset Generator ...............................................................................
Temperature Sensor ........................................................................
Processor Circuitry ..........................................................................
Analog Inputs ...................................................................................
Speaker Output ................................................................................
Analog Outputs ................................................................................
Analog Supplies ...............................................................................
Supplies ...........................................................................................
ESD and EMI Compatibility ..............................................................
4-13
4-13
4-13
4-13
4-13
4-14
4-14
4-14
4-14
4-15
4-15
4-15
4-15
Brushless DC Drive Theory .........................................................
General Description ..........................................................................
Phases and Power Switches ............................................................
Motor Torque ...................................................................................
Motor Speed ....................................................................................
4-16
4-16
4-16
4-16
4-16
Drive Motor Control Box Description .............................................
Power Board ....................................................................................
Control Board ...................................................................................
LED Functions ..................................................................................
User Inputs/Outputs .........................................................................
Electrical Requirements ...................................................................
4-17
4-17
4-17
4-17
4-19
4-21
General Fault Isolation ............................................................. 4-22
Visual Inspection .............................................................................. 4-22
Power Down ....................................................................... 4-22
Shroud Removal .............................................................................. 4-23
Parts Locations ................................................................................ 4-24
Power Supply Voltage Checks .......................................................... 4-25
Speaker Check ................................................................................. 4-25
Service Port ..................................................................................... 4-25
Drive Control Fault LEDs .................................................................. 4-26
DC Motor Replacement ............................................................. 4-27
Replacement Instructions ................................................................ 4-27
Front Roller Replacement .......................................................... 4-29
Replacement Instructions ................................................................ 4-29
Walking Belt and Board Replacement ............................................ 4-30
Walking Belt Replacement Instructions ............................................ 4-30
Walking Board Replacement Instructions ........................................ 4-31
Motor Drive Belt Replacement and Adjustments ............................... 4-32
Tension Adjustments ....................................................................... 4-32
Tracking Adjustments ...................................................................... 4-33
iv
Series 2000 Treadmill
409110-004
Revision D
Elevation Motor Replacement ..................................................... 4-34
Replacement Instructions ................................................................ 4-34
Electronics Box Replacement ...................................................... 4-35
Replacement Instructions ................................................................ 4-35
Drive Motor Control Box Replacement ........................................... 4-36
Replacement Instructions ................................................................ 4-36
5A
Parts Lists and Drawings for Configuration
without CE ................................................. 5A-1
Ordering Parts ..................................................................... 5A-3
Introduction ..................................................................................... 5A-3
Field Replaceable Units For Product CodeY5 (non-CE) ........................ 5A-4
5B
Rev R
Upper-Level Assembly ......................................... 5A-5
900433-001G
Full Handrail Kit................................................. 5A-6
900367-001T
Treadmill Assembly ............................................ 5A-7
900418-101B
Electronics Box Assembly ................................... 5A-14
88380-006B
Stop Switch Assembly........................................ 5A-16
Parts Lists and Drawings for Configuration
with CE ..................................................... 5B-1
Ordering Parts ..................................................................... 5B-3
Introduction ..................................................................................... 5B-3
Field Replaceable Units for Product Code Y5 w/CE ............................ 5B-4
Revision D
Rev R
Upper-Level Assembly ......................................... 5B-5
900444-00XG
50/60 Hz Full Handle Assembly............................... 5B-6
900433-001G
Full Handrail Kit................................................. 5B-6
900367-002T
Treadmill Assembly w/CE ..................................... 5B-7
900418-102B
Electronics Box Assembly w/CE ............................ 5B-14
88380-006B
Stop Switch Assembly........................................ 5B-16
Series 2000 Treadmill
409110-004
v
6
PCB Assemblies ........................................... 6-1
800320-001H
Control PCB ....................................................... 6-3
SD800320-001G Control PCB Schematic ......................................... 6-6
800334-003A
Power PCB ....................................................... 6-12
SD800334-003A Power PCB Schematic ......................................... 6-16
Appendices
Appendix A: Abbreviations ............................... A-1
Standard Abbreviations .............................................................. A-3
Appendix B: Technical Description ...................... B-1
Technical Specifications ............................................................ B-3
vi
Series 2000 Treadmill
409110-004
Revision D
1
Introduction
Manual Information ..................................................................... 3
Manual Purpose ..................................................................................... 3
Conventions ........................................................................................... 4
Safety Information ....................................................................... 5
General ................................................................................................... 5
Equipment Symbols ............................................................................... 6
Warnings and Cautions .......................................................................... 7
Service Information ..................................................................... 9
Equipment Identification ........................................................................ 9
Revision D
Series 2000 Treadmill
409110-004
1-1
1-2
Series 2000 Treadmill
409110-004
Revision D
Introduction: Manual Information
Manual Information
Revision History
Each page of the document has the document part number followed by
a revision letter at the bottom of the page. This letter identifies the
document’s update level. The latest letter of the alphabet corresponds
to the most current revision of the document.
The revision history of this document is summarized in the table below.
Table 1-1. Revision History PN 409110-004
Revision
Date
Comment
A
30 January 1997
Initial release of manual. This manual covers the Y% product code (Thor controller). This
replaces the -003 and includes RS232 port. There are two parts lists chapters for CE and non-CE.
B
21 February 1997 Changed page 2-8 due to product label correction of the fuse. F2 is 0.5ASB.
C
6 June 1997
Added “Intended Use” and recommendations on use of rails and emergency stop switch from
American Heart Association.
D
22 July 1998
Removed CE page, updated parts lists and technical specifications.
Manual Purpose
Revision D
This manual supplies technical information for service representatives
and technical personnel so they can maintain the equipment at the
assembly and subassembly level. It is intended to function primarily as a
guide for maintenance and electrical repairs considered field repairable.
The manual includes: maintenance and troubleshooting guides, parts
lists, illustrations of assembly parts, and some schematics.
Series 2000 Treadmill
409110-004
1-3
Introduction: Manual Information
Conventions
These are the conventions used in this manual.
Safety Messages
DANGER safety messages indicate an imminently hazardous situation
which, if not avoided, WILL result in death or serious injury.
WARNING safety messages indicate a potentially hazardous situation
which, if not avoided, COULD result in death or serious injury.
CAUTION safety messages indicate a potentially hazardous situation
which, if not avoided may result in minor or moderate injury.
NOTE messages provide additional user information.
Definitions
■
Items shown in Black text are keys on the keyboard, text to be
entered, or hardware items such as buttons or switches on the
equipment.
■
Items shown in Italicized text are software terms which identify
menu items, buttons, or options in various windows.
■
To perform an operation which appears with a plus (+)sign
between the names of two keys, you press and hold the first key
while pressing the second key once. This is called a keystroke
combination.
For example, “Press Ctrl+Esc” means to press and hold down
the Ctrl key while pressing the Esc key.
1-4
■
When instructions are given for typing a precise text string with
one or more spaces, the point where the spacebar must be
pressed is indicated as: <Space>. The purpose of the < >
brackets is to ensure you press the spacebar when required.
■
Enter means to press the “Enter” or “Return” key on the
keyboard. Do not type “enter”.
Series 2000 Treadmill
409110-004
Revision D
Introduction: Safety Information
Safety Information
Responsibility of the
Manufacturer
General
Marquette Medical Systems, is responsible for the effects of safety,
reliability, and performance only if:
■
Assembly operations, extensions, readjustments, modifications,
or repairs are carried out by persons authorized by Marquette.
■
The electrical installation of the relevant room complies with
the requirements of the appropriate regulations.
■
The equipment is used in accordance with the instructions for
use.
To ensure patient safety, use only parts and accessories manufactured
or recommended by Marquette Medical Systems.
Contact Marquette Medical Systems for information before connecting
any devices to this equipment that are not recommended in this
manual.
The use of ACCESSORY equipment not complying with the equivalent
safety requirements of this equipment may lead to a reduced level of
safety of the resulting system. Consideration relating to the choice shall
include:
Revision D
■
use of the accessory in the PATIENT VICINITY; and
■
evidence that the safety certification of the ACCESSORY has
been performed in accordance to the appropriate IEC 601-1
and/or IEC 601-1-1 harmonized national standard.
Series 2000 Treadmill
409110-004
1-5
Introduction: Safety Information
Equipment Symbols
The following symbols appear on the equipment.
This symbol means that you must pay attention to the documents delivered with this
equipment. It calls attention to the things to which you must pay special attention
during operation and when the equipment is operated in conjunction with other
equipment.
In Europe, this symbol means dangerous or high voltage. In the United States, this
symbol represents the caution notice below:
CAUTION
To reduce the risk of electric shock,
do NOT remove cover (or back).
Refer servicing to qualified
personnel.
M15287-16A
Type B equipment. Type B equipment is suitable for intentional external and internal
application to the patient, excluding direct conductive connection to the patient’s
heart.
Alternating current (AC)
Equipotential (This is the ground lug.)
Protective earth (ground)
M13495, M13504, M13864, M13571, M13574, M13573
1-6
Series 2000 Treadmill
409110-004
Revision D
Introduction: Safety Information
Warnings and Cautions
DANGER
WARNING
Do NOT use in the
presence of flammable
anesthetics.
M15287-1B
Total system leakage
current must not
exceed 300
microamperes.
M15287-76A
WARNING
Replace only with the
same type and rating
of fuse.
M15287-2B
WARNING
Wait until treadmill belt
is moving before
placing feet on belt.
M15287-11B
WARNING
WARNING
This is Class I
equipment. The mains
plug must be connected
to an appropriate power
supply.
Keep hands, hair,
jewelry, and loose
clothing away from
moving parts.
M15287-26B
M15287-5C
WARNING
WARNING
Keep leakage current
within acceptable limits
when connecting
auxiliary equipment to
this device.
Do not place feet under
treadmill during
elevation changes.
Otherwise, serious
injury could result.
M15287-7C
M15287-36A
WARNING
WARNING
Do NOT contact unit or
patient during
defibrillation.
M15287-8C
Revision D
Series 2000 Treadmill
409110-004
Route the AC power
cable away from
moving parts.
M15287-64A
1-7
Introduction: Safety Information
WARNING
WARNING
Verify proper operation
of the stop switch
assembly, pn 88380-006,
every month.
M15287-065A
1-8
Series 2000 Treadmill
409110-004
Operate the treadmill
with 6 feet of clearance
at the rear (end opposite
the motor).
M15287-066A
Revision D
Introduction: Service Information
Service Information
Service Requirements
Refer equipment servicing to Marquette Medical Systems’ authorized
service personnel only. Any unauthorized attempt to repair equipment
under warranty voids that warranty.
It is the user’s responsibility to report the need for service to Marquette
Medical Systems or to one of their authorized agents.
Failure on the part of the responsible individual, hospital, or institution
using this equipment to implement a satisfactory maintenance schedule
may cause undue equipment failure and possible health hazards.
Regular maintenance, irrespective of usage, is essential to ensure that
the Series 2000 treadmill will always be functional when required.
Equipment Identification
Every Marquette Medical Systems device has a unique serial number for
identification. The serial number appears on the product label on the
base of each unit.
A
B
C
I
H
G
F
E
MD1113-022B
D
Table 1-2. Equipment Identifications
Item
Name
Description
A
name of device
Series 2000 treadmill
B
manufacturer
Marquette Medical Systems
C
serial number
Unique identifier
D
device characteristics
One or two letters that further describe the unit, for example: P = prototype not
conforming to marketing specification; R = refurbished equipment; S = special
product documented under Specials part numbers; U = upgraded unit
E
division
F = Cardiology
F
product sequence number
Manufacturing number (of total units manufactured.)
G
product code
Two-character product descriptor Y5 = Treadmill
H
year manufactured
6 = 1996, 7 = 1997, 8 = 1998, (and so on)
I
month manufactured
A = January, B = February, C = March, D = April, E = May, F = June, G = July,
H = August, J = September, K = October, L = November, M = December
Revision D
G = Monitoring
Series 2000 Treadmill
409110-004
J = GW Labs
1-9
Introduction: Service Information
1-10
Series 2000 Treadmill
409110-004
Revision D
2
Equipment Overview
General Description ..................................................................... 3
Intended Use .......................................................................................... 3
Motor Drive System ............................................................................... 3
Elevation System .................................................................................... 3
Bed Assembly ........................................................................................ 3
Electronic Assembly ............................................................................... 3
Block Diagram ........................................................................................ 4
Preparation for Use ...................................................................... 5
Equipment Assembly ............................................................................. 6
Handle Set ................................................................................6
Emergency Stop Switch ............................................................7
Connector Locations .............................................................................. 8
Operating Instructions .................................................................. 9
Operating Controls ................................................................................. 9
Power Switch ...........................................................................9
Emergency Stop Switch ............................................................9
Controlling the Treadmill ...................................................................... 10
Emergency Stop Switch Check ............................................................ 10
Revision D
Series 2000 Treadmill
409110-004
2-1
2-2
Series 2000 Treadmill
409110-004
Revision D
Equipment Overview: General Description
General Description
Standard features include the emergency stop switch, a full handrail set,
and a long, 60-inch walking surface. Designed for simplified
serviceability, the Series 2000 Treadmill has fewer moving parts than
other treadmills, built-in self-calibration, and easy-to-replace
assemblies.
Intended Use
The Series 2000 Treadmill is intended for use with any one of the several
Marquette Medical Systems exercise testing systems or the MTC-1
(manual treadmill controller) for administering a controlled exercise
load during a diagnostic stress test.
The emergency stop switch is intended for emergency situations where
immediately stopping the treadmill is required to deliver appropriate
emergency care to the patient or health care provider, as implied by the
American Heart Association “Guidelines for Clinical Exercise Testing
Laboratories” (1995). It is not intended for routinely stopping the
treadmill.
Motor Drive System
The 3 HP, brushless, DC motor is controlled by a separate control box,
and it connects directly to the front roller with a drive belt. An 11-pound
flywheel, attached to the motor’s drive shaft, keeps “footfall” variance to
a minimum. An “adjustment plate” between the motor and the
treadmill frame contains two bolts for adjusting the drive belt tension.
The increase of horsepower raises the weight capacity from 350 lbs. for
previous treadmills to 450 lbs.
Elevation System
The elevation system uses a rack and pinion operation to raise and
lower the treadmill rather than jack screws and chains. The elevation
motor attaches to a small gearbox that connects to the pinion shaft.
The upper- and lower-limit switches ride along one of the pinion “legs,”
making them easy to reach and adjust. Replacing the elevation motor
only requires the removal of the three mounting bolts and detaching the
motor from the pinion shaft coupling.
Bed Assembly
Electronic Assembly
Revision D
The one-piece bed assembly, with side rails and struts welded together,
enables quick parts replacement for field service personnel.
An isolated “electronics box” contains the power supply PCB and the
control PCB. The box is instantly accessible with the shroud removed
and can be replaced as a complete assembly.
Series 2000 Treadmill
409110-004
2-3
2-4
Series 2000 Treadmill
409110-004
WALL OUTLET:
NEMA 6-20R
20 AMP
POWER
CABLE
POWER
INPUT
200-240 V
50/60 Hz
2 -2 .5 KVA
SERVICE
COVER
J3
5V
J4 SELF–CAL
U12
OPTOCOUPLER
OPTOCOUPLERS
U10, U11
TXCOMM
RXCOMM
FUSES
F6, F7
POWER
INLET
LIGHTED
SWITCH
CB1
20ASB
-7.5 V
16.5 V
AEROVOX EMI
FILTER MODULE
(International
Units w/CE)
DOMESTIC UNITS
TEMP SENSOR
U12, U16
U9
78310
PROCESSOR
800320-00X CONTROL BOARD
5V
ELEVATION MOTOR
CONTROL RELAYS
K1, K2, K4
U10
SRAM
62256
SPEAKER
LS1
(located on
Power PCB)
U13
8K X 8
EEPROM
U2
SPEAKER
DRIVER
U5,U6
FREQ TO
VOLT
SPEED/0-10V
CONV/
AMPL
STOP-PB
J1/J9 - CPU I/F
U1, U3, U7, U8, U12
ANALOG OUTPUTS
RS-232 AND
VOLTAGE
DOUBLERS
(–7.5 V and +16.5 V)
T1
XFMR
J7
J8
J6
800334-00X POWER BOARD
L-C FILTERS
FL 1
TB1-4
EMI
FL 2
TB1-5
FILTER
30 M
TB1-6
(3) 10M Ohm
SCREW
BLEED–OFF
TERMINALS
RESISTORS
5 V distributed
throughout
U9
5 VOLT
both PCBs
J5
POWER
HALLS
SUPPLY
1, 2, 3, 4, 5
U1
J12
5 VOLT
U7
ISOLATED
TACH_A HALLS
POWER
4, 5
SUPPLY
TACH_B
K3
STOP RELAY
FUSES
F4, F5
CHASSIS
GND
L1
L2
RT1
LIMITER
J2
DEBUG/ANA OUT
9-PIN "D"
SERVICE PORT
E - STOP
REMOTE
(OPT)
OR
PCB
J1
STRESS
SYSTEM ISOLATED PLASTIC
9
PIN
“D”
RS - 422
OPTION
F1
EXTERNAL
0.5ASB
FUSES
F2
ISOLATED
RS - 232
8 - PIN
800334-003 MINI-DIN
TB1-1
TB1-2
TB1-3
ELECTRONICS BOX
10 µF MOTOR
RUN CAP
(mounted to
chassis)
RIBBON
PULSED
320V
1TB
CHASSIS
DRIVE ROLLER
LOW LIMIT SWITCH
HIGH LIMIT SWITCH
INSULATED
COUPLING
ELEVATION RACKS
INSULATED
DRIVE BELT
ELEVATION FEEDBACK
5 - TURN POT
ELEVATION MOTOR
1/8 HP
220 V 50/60 HZ
ELEVATION SYSTEM
3.0 HP BRUSHLESS
MOTOR
DRIVE SYSTEM
POWER BOARD
(located behind
other PCBs)
DRIVE MOTOR
CONTROL BOX
INSULATED SPACERS
“FLOATING GROUND”
HALLS
1 THRU 5
2TB
3TB
SCREWS
TERMINALS
Equipment Overview: General Description
Block Diagram
MD1129-007E
Revision D
Equipment Overview: Preparation for Use
Preparation for Use
Safe Handling
Guidelines
The Series 2000 Treadmill ships preset with an approximate 2% grade.
This slight elevation provides for free wheel movement and prevents the
shroud from scraping the floor.
If you are moving the treadmill after it has been in operation, use the
controlling equipment to set the grade to approximately 7%. Then
remove power and disconnect all cables to the treadmill before moving
the unit.
Follow the steps below to move the treadmill. We recommend that two
people work together since the treadmill may be too heavy for some
individuals to lift and lower safely.
1. Lift the end of the bed assembly to about knee height, keeping
knees bent and backs straight as you lift.
2. Rotate the treadmill in the direction you want to go (the
treadmill will pivot on its wheels) and push forward.
3. When you have maneuvered the treadmill into its new location,
gently lower the end of the bed assembly to the floor.
Lift up
MD1128-022
Revision D
Series 2000 Treadmill
409110-004
2-5
Equipment Overview: Preparation for Use
Equipment Assembly
The Series 2000 Treadmill ships completely assembled except for the
handle set and the emergency stop switch. Attach the handle set and
emergency stop switch before applying power to the unit.
NOTE
As recommended by the American Heart
Association Exercise Standards (Special
Report, Vol 82, No 6), the treadmill
should have front and side rails installed
for patients to steady themselves. An
emergency stop switch must be visible
and readily accessible.
Handle Set
1. Insert the wood front handrail into the metal side rails, then
align the predrilled holes and screw in the two Phillips screws on
both sides. Assemble the optional side rails in the same way.
2. Place the assembled front handrail into the metal mounting
brackets on the front corners of the shroud. Using the supplied
Allen wrench and four bolts, secure the handrail to the brackets.
3. Place the assembled side rails into the side mounting holes and
screw in the two bolts on each side.
1
Wood Front Handrail
Screw
Metal Front Rail
Side Rail
Mounting Hole
Wood Side Handrail
Left Side
Right Side
Notch
Screw
Notch
2
3
Front Handrail
Mounting Bracket
Metal Side Rail
Right Side
Notch
Right Side
Notch
Notch Represents
Right Side
MD1128-003C
2-6
MD1128-004B
Series 2000 Treadmill
409110-004
Revision D
Equipment Overview: Preparation for Use
4. Attach the side rails to the front rail with the mated T-brackets.
Tighten the two T-bracket bolts with the Allen wrench.
Bolts
2 Places
T-bracket
Align the side rails to the
predrilled guide holes in the
front rails.
Nuts
2 Places
Typical two places
MD1128-005C
Emergency Stop Switch
1. Attach the two clamp pieces to the assembled, latching
emergency stop switch.
Emergency Stop
Switch Assembly
Cable
Handrail
Clamp
MD1128-006A+
2. Position the clamps around the treadmill front handrail and
secure with the supplied screw and nut.
3. Connect the cable from the emergency stop switch to the
mating connector on the treadmill’s rear connector panel.
4. Use the cord clips to attach the cable along the front handrail.
Revision D
Series 2000 Treadmill
409110-004
2-7
Equipment Overview: Preparation for Use
Connector Locations
The illustration below shows the various input connectors on the rear
panel of the treadmill. Attach the appropriate controller cable from the
stress system or MTC-1 and the AC power cable.
WARNING
Route the AC power
cable away from
moving parts.
M15287-64A
SERIES
t
r
e
a
d
m
i
l
F1 0.5ASB
250V
F2 0.5ASB
250V
WARNING: FOR CONTINUED
PROTECTION AGAINST RISK OF
FIRE REPLACE ONLY WITH FUSE
OF SAME TYPE AND RATING.
CAUTION: ELECTRICAL SHOCK HAZARD.
DO NOT REMOVE COVER. REFER
SERVICING TO QUALIFIED PERSONNEL.
CAUTION: DO NOT USE BOTH
CONNECTORS AT THE SAME TIME.
RS-232
SERIAL CONT
RS-232 Port
(Connection to: CardioSys, MAC VU,
MAX-1, MAX Personal)
RS-422
SERIAL CONT
RS-422 Serial Port
(Connection to: MTC-1, CASE 15,
CENTRA)
STOP
Emergency Stop Switch Connection
Service Port
SERVICE
ON/OFF Power Switch
Equipotential (ground lug)
AC Power Connection
(220–240V, 50–60Hz, 20A)
220-240V~ 50-60Hz 16A
MD1128-001E
2-8
Series 2000 Treadmill
409110-004
Revision D
Equipment Overview: Operating Instructions
Operating Instructions
Electrical Safety Tests
The electrical safety of this installation is the responsibility of the
customer, not Marquette Medical Systems. In hospitals, contact your inhouse biomedical technician, electrician, or technically qualified
personnel. Outside of hospitals, contact your hospital affiliation for
these services. Otherwise, contact Marquette Medical Systems and open
a customer-billable service call.
Before using the treadmill, perform the tests listed below.
■
AC line voltage test to verify the power outlet is properly wired.
■
Ground continuity test to verify all exposed metal is properly
grounded.
■
Leakage tests to verify the equipment passes all applicable
leakage tests.
Your in-house biomedical technician, electrician, or technically
qualified personnel can find instructions for performing these tests in
chapter 3, “Maintenance.”
Operating Controls
Power Switch
Emergency Stop Switch
Revision D
The treadmill has two operating controls, the power switch and the
emergency stop switch. The power switch is located on the rear panel,
and the emergency stop switch is on the front handrail.
The power switch controls the AC power to the treadmill. The on
position (1) applies power. The off position (0) removes power.
The emergency stop switch is a safety device for use in emergency
situations to stop the treadmill. Press the “STOP” push-button and the
treadmill promptly stops but the belt will not lock, allowing for removal
of foreign objects. To release the emergency stop switch, turn the pushbutton 1/4-turn in either direction.
Series 2000 Treadmill
409110-004
2-9
Equipment Overview: Operating Instructions
Controlling the Treadmill
■
Turn the power switch on (1).
■
Use the controlling equipment to start the treadmill, adjust the
treadmill speed and grade, proceed through the exercise phases,
terminate the exercise session, and turn off the treadmill.
WARNING
Wait until treadmill belt
is moving before
placing feet on belt.
M15287-11B
WARNING
Do not place feet under
treadmill during
elevation changes.
Otherwise, serious
injury could result.
M15287-36A
WARNING
Keep hands, hair,
jewelry, and loose
clothing away from
moving parts.
M15287-26B
Emergency Stop Switch
Check
2-10
■
With the belt moving at a relatively high speed, press the
emergency stop switch. The treadmill belt will stop promptly
but the belt will not lock, allowing for removal of foreign objects.
To release the switch, turn the button 1/4-inch turn in either
direction.
■
Use the controlling equipment to terminate the exercise session
and turn off the treadmill.
Series 2000 Treadmill
409110-004
Revision D
3
Maintenance
Introduction ............................................................................... 3
Recommended Maintenance .................................................................. 3
Inspection Report .....................................................................3
Required Tools and Supplies ................................................................. 3
Inspection and Cleaning ................................................................ 4
Visual Inspection .................................................................................... 4
Exterior Cleaning .................................................................................... 4
Interior Cleaning .................................................................................... 4
Domestic Electrical Safety Tests ...................................................... 5
AC Line Voltage Test .............................................................................. 5
120 VAC, 50/60 Hz ...................................................................5
240 VAC, 50/60 Hz ...................................................................5
Leakage Tests ........................................................................................ 6
Leakage Test Diagrams .......................................................................... 7
Test #1 ................................................................................................... 7
Ground-Wire-Leakage-to-Ground .............................................7
Test #2 ................................................................................................... 7
Chassis-Leakage-to-Ground (Exposed Chassis) .......................7
Test #3 ................................................................................................... 8
Patient-Cable-Leakage-to-Ground ............................................8
Test #4 ................................................................................................... 8
Patient Cable-Leakage-into-Patient Leads-from 120 VAC .........8
Ground Continuity Test .......................................................................... 9
Self-Calibration ........................................................................ 10
When to Calibrate ................................................................................. 10
Activating Self-Calibration .................................................................... 10
Belt Tracking Adjustments ........................................................... 11
When to Adjust .................................................................................... 11
Check Treadmill Level .......................................................................... 11
Adjust Pulley Screws ........................................................................... 12
Miscellaneous Maintenance Forms ................................................. 13
Revision D
Series 2000 Treadmill
409110-004
3-1
3-2
Series 2000 Treadmill
409110-004
Revision D
Maintenance: Introduction
Introduction
Recommended
Maintenance
Inspection Report
A regular equipment maintenance program helps prevent unnecessary
equipment and power failures and also reduces possible health hazards.
This chapter contains instructions for the following recommended
maintenance:
■
Inspecting and cleaning the unit
■
Power source integrity test
■
Leakage safety tests
■
Resistance measurements
■
Self-calibration
■
Belt tracking adjustments
To help you establish a systematic maintenance routine, Marquette
Medical Systems recommends that, every six months, you perform the
maintenance checks and test procedures on the “Preventive
Maintenance Inspection Report,” included at the end of this chapter.
(Make extra copies of the report form to use as an inspection check-off
list.)
NOTE
Unless
you
have
an
Equipment
Maintenance Contract, Marquette Medical
Systems does not in any manner assume
the responsibility for performing the
recommended maintenance procedures.
The sole responsibility rests with the
individual or institution using the equipment.
Marquette
Medical
Systems
service
personnel may, at their discretion, follow the
procedures provided in this manual as a
guide during visits to the equipment site.
Required Tools and
Supplies
Revision D
To maintain and repair the treadmill, you will need the following:
■
Standard hand tools
■
DVOM
■
Leakage current tester PN MT-1216-01 (for 120 V), PN MT-121602 (for 240 V), or equivalent
■
Anti-septic cleaner
■
Dust remover (compressed air)
Series 2000 Treadmill
409110-004
3-3
Maintenance: Inspection and Cleaning
Inspection and Cleaning
Visual Inspection
Regularly inspect the AC power cord and all other cords and cables for
fraying or other damage. Perform safety tests on any repaired line cords.
Inspect all plugs, cables and connectors for bent prongs or pins. Verify
that all cords, socketed components, and connectors are securely
seated.
Inspect the following for excessive wear or damage:
■
Walking belt
■
Drive belt
■
Handrail and hardware
Test the stop switch assembly monthly.
3-4
Exterior Cleaning
Turn the treadmill system off. Clean the exterior surfaces with a clean,
soft cloth and a mild dishwashing detergent diluted in water. Wring out
the excess water from the cloth and take care not to drip solutions on
the keyboard or writer assembly. (Use anti-septic cleaner on the
handrails and walking belt.) Avoid contact with open vents, plugs or
connectors. Dry the surfaces with a clean cloth or paper towel.
Interior Cleaning
Complete any pre-service procedures prior to opening the unit or
performing any interior cleaning. Clean the unit as needed, but at least
once per month.
Series 2000 Treadmill
409110-004
Revision D
Maintenance: Domestic Electrical Safety Tests
Domestic Electrical Safety Tests
AC Line Voltage Test
120 VAC, 50/60 Hz
This test verifies that the domestic wall outlet supplying power to the
equipment is properly wired. For international wiring tests, refer to the
internal standards agencies of that particular country.
Use a digital voltmeter to check the voltages of the 120-volt AC wall
outlet (dedicated circuit recommended). If the measurements are
significantly out of range, have a qualified electrician repair the outlet.
The voltage measurements should be as follows:
1. 120 VAC (± 10 VAC) between the line contact and neutral and
between the line contact and ground.
2. Less than 3 VAC between neutral and ground.
❶
NEUTRAL
❷
LINE
❶
MD1128-011
GROUND
240 VAC, 50/60 Hz
Use a digital voltmeter, set to measure at least 300 VAC, to check the
voltages of the NEMA 6-20R, AC wall outlet (dedicated circuit
recommended). If the measurements are significantly out of range, have
a qualified electrician repair the outlet. The voltage measurements
should be as follows:
1. 120 VAC (± 10 VAC) between either “hot” contact and ground.
2. 210 to 230 VAC between the two “hot” contacts.
❷
HOT
❶
❶
GROUND
Revision D
Series 2000 Treadmill
409110-004
HOT
MD1128-012
3-5
Maintenance: Domestic Electrical Safety Tests
Leakage Tests
The leakage tests are safety tests to ensure that the equipment poses no
electrical health hazards. Use the table below to determine which tests
apply to the unit under test and the maximum allowable leakage
currents. For international leakage limits, refer to the internal standards
agencies of that particular country.
If the unit under test fails the leakage tests, do not allow the customer to
use the equipment. Call Tech Support for assistance. (See the “How to
Reach Us” page in the front of the manual.)
Marquette Medical Systems recommends that you perform these tests:
■
Before applying power for the first time
■
Every 6 months as part of routine maintenance
■
Whenever internal assemblies are serviced
NOTE
The accuracy of the leakage tests depends
on a properly-wired wall outlet. Do not
proceed until you verify the integrity of the
power source.
WARNING
Total system leakage
current must not
exceed 300
microamperes.
M15287-76A
Table 3-1. Leakage Tests and Maximum Allowable Leakage Currents
Test
Applies To
Maximum Current (µA)
1
Ground-wire-leakage-to-ground
MAX-1 stress system
300
2
Chassis-leakage-to-ground
MAX-1 stress system
300
3
Patient-cable-leakage-to-ground
Acquisition module
10
4
Patient-cable-leakage-into-patient-leads-from-120 V ac
Acquisition module
20
3-6
Series 2000 Treadmill
409110-004
Revision D
Maintenance: Domestic Electrical Safety Tests
Leakage Test Diagrams
These diagrams show only a representation of how a typical leakage
current tester functions. Follow the instructions provided with the
leakage current tester that you use.
Test #1
Ground-Wire-Leakage-to-Ground
“To be tested” power connector on back of
tester (may not be labeled on some testers).
Line
Tester
power
cord
Tester
Polarity
Norm
Line
UUT
power
cord
Neutral
Unit
under
test
(UUT)
Neutral
Gnd
Rvs
Gnd
1K
Meter
connectors
V
M13052-001E
Test #2
Chassis-Leakage-to-Ground
(Exposed Chassis)
Apply line voltage to the UUT chassis for this test.
“To be tested” power connector on back of
tester (may not be labeled on some testers).
Line
Tester
power
cord
Tester
Polarity
Norm
Line
Neutral
Neutral
Rvs
Gnd
UUT
power
cord
Unit
under
test
(UUT)
Gnd
1K
Probe to
exposed chassis
Meter
connectors
V
M13052-002E
Revision D
Series 2000 Treadmill
409110-004
3-7
Maintenance: Domestic Electrical Safety Tests
Test #3
Patient-Cable-Leakage-to-Ground
“To be tested” power connector on back of
tester (may not be labeled on some testers).
Line
Tester
power
cord
Tester
Polarity
Norm
Line
UUT
power
cord
Neutral
Unit
under
test
(UUT)
Neutral
Rvs
Gnd
Gnd
1K
Meter
connectors
Patient cable
V
Patient
cable connectors
M13052-003E
Test #4
Patient Cable-Leakage-intoPatient Leads-from 120 VAC
During this test, line voltage is applied to the patient cable connectors.
To prevent erroneous readings, don not allow the leadwires to contact
conductive materials such as metal handles, and do not place the
leadwires on the floor.
“To be tested” power connector on back of
tester (may not be labeled on some testers).
Line
Tester
power
cord
Tester
Polarity
Norm
Line
UUT
power
cord
Neutral
Unit
under
test
(UUT)
Neutral
Rvs
Gnd
Gnd
1K
Meter
connectors
Patient cable
V
Patient
cable connectors
M13052-004E
3-8
Series 2000 Treadmill
409110-004
Revision D
Maintenance: Domestic Electrical Safety Tests
Ground Continuity Test
This test verifies that there is continuity (less than 100 mΩ resistance)
between all the exposed metal surfaces, which have the potential to
become energized, and the ground prong on the mains AC power cord.
If the metal surfaces are anodized or painted, scrape off a small area in
an inconspicuous area on the aluminum casting for the probe to make
direct contact with the metal.
Use a digital multimeter to check all the metal surfaces of the
equipment as illustrated below. Make adjustments for any resistance in
the test leads.
If the measurements are significantly out of range, check for breaks in
the power cord or in the internal connections within the unit.
<0.1Ω
MD1128-007A+
Revision D
Series 2000 Treadmill
409110-004
3-9
Maintenance: Self-Calibration
Self-Calibration
When to Calibrate
Activating
Self-Calibration
Marquette Medical Systems recommends that you activate the
self-calibration feature every time you replace a major assembly or a
circuit board.
To activate the Series 2000 Treadmill self-calibration feature, do the
following:
1. Remove the plate covering the service port on the rear panel of
the treadmill.
2. Remove controlling device (MAX-1, CASE, CENTRA, MTC-1)
cable or turn off the controlling device.
3. Below the service port are two prongs (pins). Place a screwdriver
between the two self-calibration prongs to short the circuit and
activate the self-calibration software.
The software calibrates the speed and grade from the minimum
points to the maximum points.
3-10
Series 2000 Treadmill
409110-004
Revision D
Maintenance: Belt Tracking Adjustments
Belt Tracking Adjustments
WARNING
Keep hands, hair,
jewelry, and loose
clothing away from
moving parts.
M15287-26B
When to Adjust
The treadmill walking-belt tension is set at the factory. However, you
should test the belt tracking every time the treadmill is moved. Run the
treadmill for several minutes with no one exercising. If the belt tracks to
one side or the other, then you must adjust the belt tracking.
It is not unusual for the treadmill belt to move slightly off center while a
person with a heavy gait is exercising. A properly adjusted belt recenters
itself when the person steps off the treadmill. If the belt does not
recenter, check the treadmill level and adjust the belt tracking as
described.
Check Treadmill Level
1. Use the controlling equipment to set the treadmill elevation to
0.0%.
2. Check the treadmill level with a carpenter’s level.
3. If the treadmill is uneven, adjust the feet at the rear of the
treadmill until it is stable.
For stability, use one shim of the right thickness (rather than
several thin shims) to achieve the proper level.
If necessary, use longer shims to accommodate the maximum
treadmill elevation. The treadmill wheels must not roll off the
shims. Verify that the shim lengths exceed the wheel movement
when the treadmill is fully elevated.
4. If you cannot level the treadmill safely with shims, move the
treadmill to another location.
Revision D
Series 2000 Treadmill
409110-004
3-11
Maintenance: Belt Tracking Adjustments
Adjust Pulley Screws
1. Use the controlling equipment to set the belt speed to 4 or 5
miles per hour (7 or 8 kilometers per hour).
2. To correct a belt that tracks to the right, turn the right pulley
adjustment screw CLOCKWISE in 1/8-turn increments until the
belt tracks in the center. Wait 2 or 3 minutes between each 1/8turn to allow the belt position to stabilize.
To correct a belt that tracks to the left, turn the left pulley
adjustment screw CLOCKWISE in 1/8-turn increments until the
belt tracks in the center. Wait 2 or 3 minutes between each 1/8turn to allow the belt position to stabilize.
NOTE
Make adjustments to the pulley screws in
small increments. Over-adjustments and
repeated tightening of the screws can cause
too much tension on the belt.
3. If either adjustment in step 2 results in an over-adjustment of
the belt tracking, loosen the pulley screw that was tightened and
wait several minutes for the treadmill belt position to stabilize.
Then tighten the other pulley adjustment screw.
Pulley Screws
MD1129-016B
3-12
Series 2000 Treadmill
409110-004
Revision D
Maintenance: Miscellaneous Maintenance Forms
Miscellaneous Maintenance Forms
Marquette Medical Systems recommends that every six months you
perform the maintenance checks and test procedures on the
“Preventive Maintenance Inspection Report” (see following page).
These maintenance procedures can be performed more often if
indicated.
Revision D
Series 2000 Treadmill
409110-004
3-13
Maintenance: Miscellaneous Maintenance Forms
3-14
Series 2000 Treadmill
409110-004
Revision D
Series T2000 Treadmill
DPMFRM-003B
31 July 1998
Preventive Maintenance Inspection Report
Page 1 of 3
Customer______________________________ Customer Number______________________ Date___________
FE ___________________________________ FE ID________ Call Number______________________________
Equipment Serial Number_________________ Software Revision _________
Configuration ()
___ Emergency Stop Switch installed
Tools
1. Leakage tester
2. Multimeter
3. Standard hand tools
4. Service Manual (p/n 409110-001)
5. ESD Mat and Wrist Strap
Visual Inspection ()
Inspect the following for excess wear and/or any visual signs of damage.
1. ___ Walking belt
3. ___ Connectors
2. ___ Interface cable
4. ___ AC power cord
5. ___ Handrail hardware
6. ___ Drive belt
Cleaning ()
1. ___ Handrails
2. ___ Shroud
3. ___ Walking belt
Calibration ()
1. ___ Speed calibration (2 mph = 10 revolutions in 38 seconds +/- 2 seconds)
2. ___ Grade calibration (@ 10% +/- .75 inches)
Electrical Safety Checks ()
Refer to PM Application Form XPMAPP-001-4 class B for leakage standards for specific voltages.
1. ___ Wall Receptacle Test
2. ___ Ground Continuity (Impedence of protected connection)Test(≤ .1Ω or ≤.2Ω w/power cord)
3. Leakage
Ground(Earth) wire leakage to ground test
Chassis(Enclosure) leakage to ground test
Normal
___
___
Open
Reversed
___
___
Closed
Normal
Reversed
NA
NA
___
___
Checkout Procedure ()
1. Perform the applicable checkout procedure(s) listed below using the FRU Checkout Procedure document, after a major
assembly is replaced.
1.____ Increase and decrease speed from minimum to maximum using controlling unit(MAX-1, CASE 15, etc.) to
verify operation.
2.____ Raise and lower elevation from 0% to 25% using controlling unit(MAX-1, CASE 15, etc.) to verify operation.
3.____ Depress emergency stop switch(if installed) while unit running at 3 m.p.h. to confirm operation.
4.____ Monitor walking belt tracking at 3 m.p.h. Adjust, if necessary, using procedure in Field Service manual.
5.____ Verify speed calibration, 2 m.p.h. = 10 revolutions in 38 seconds.
6.____ Verify elevation calibration. Adjust, if necessary, using calibration procedure in Field Service manual.
7.____ Monitor drive belt for slipping, squeaking and mis-alignment. Adjust, if necessary, using procedure in Field
Service manual.
8.____ Perform Self-Calibration procedure. Refer to Field Service Manual for details.
Template Revision C
DPMFRM-003B
Page 2 of 3
Comments
Briefly describe all repairs/adjustments made and list all parts replaced:
___________________________________________________________________________________________________
___________________________________________________________________________________________________
Additional comments:
___________________________________________________________________________________________________
___________________________________________________________________________________________________
Template Revision C
FRU Checkout Procedure
FRU
Description*
Tools
Visual
Inspection
Drive Controller Box(Thor)
Control(CPU) Pcb
Power Pcb
Drive Belt
Walking Belt
Walking Board
3 HP Speed Motor
Elevation Motor
Front Roller
Rear Roller
Software
Hardware Upgrades
(Including Firmware)
Supplies
1,4
1,4
1,4
4
4
4
4
-
-
Non-Listed FRU’s
Cleaning
Calibration
Electrical
Safety Tests
Checkout
Procedure
3
3
2
3
3
-
1,3,8
1,3,8
1,3,8
1,7
1,4
1,4
1,5,8
2,6,8
1,4,5,7
1,4,5,7
1,2,8
1
1,2
1,2
1
2
Perform complete PM
Perform applicable Checkout Procedure(s)
Perform complete PM
Perform applicable Checkout Procedure(s)
No Parts Replaced
* The FRU Checkout procedure for any listed FRU also applies to it’s internal PCB’s and parts.
Template Revision C
4
Troubleshooting
Power PCB Theory ....................................................................... 3
General Description ................................................................................ 3
Power Distribution/Isolation .................................................................. 3
STOP Circuitry ....................................................................................... 3
Frequency-to-Voltage Converter/Amplifier ............................................. 3
Start/Stop Circuitry ................................................................................ 4
Elevation Relays ..................................................................................... 4
Drive Connector ..................................................................................... 4
Hall Feedback ......................................................................................... 4
Power Inlet, Drive Power Outlet, and Mains ........................................... 4
Control Board Connector ....................................................................... 4
Elevation Sensor .................................................................................... 5
Isolation Transformer ............................................................................ 5
Power Supplies ...................................................................................... 5
Isolated Serial Link ................................................................................. 5
Debug/Serial Link ................................................................................... 5
ESD and EMI Compatibility .................................................................... 6
Power Supply Requirements .................................................................. 6
Precautions .......................................................................................... 12
Initial Board Conditions ........................................................................ 12
Control PCB Theory .................................................................... 13
General Description .............................................................................. 13
Power Distribution ............................................................................... 13
Clock Generator ................................................................................... 13
Reset Generator ................................................................................... 13
Temperature Sensor ............................................................................ 14
Processor Circuitry .............................................................................. 14
Analog Inputs ....................................................................................... 14
Speaker Output .................................................................................... 14
Analog Outputs .................................................................................... 15
Analog Supplies ................................................................................... 15
Supplies ............................................................................................... 15
ESD and EMI Compatibility .................................................................. 15
Brushless DC Drive Theory ........................................................... 16
General Description .............................................................................. 16
Phases and Power Switches ................................................................ 16
Motor Torque ....................................................................................... 16
Motor Speed ........................................................................................ 16
Revision D
Series 2000 Treadmill
409110-004
4-1
Drive Motor Control Box Description ............................................... 17
Power Board ........................................................................................ 17
Control Board ....................................................................................... 17
LED Functions ...................................................................................... 17
User Inputs/Outputs ............................................................................. 19
Electrical Requirements ....................................................................... 21
General Fault Isolation ............................................................... 22
Visual Inspection .................................................................................. 22
Power Down ...........................................................................22
Shroud Removal .................................................................................. 23
Parts Locations .................................................................................... 24
Power Supply Voltage Checks .............................................................. 25
Speaker Check ..................................................................................... 25
Service Port ......................................................................................... 25
Drive Control Fault LEDs ...................................................................... 26
DC Motor Replacement ............................................................... 27
Replacement Instructions .................................................................... 27
Front Roller Replacement ............................................................ 29
Replacement Instructions .................................................................... 29
Walking Belt and Board Replacement .............................................. 30
Walking Belt Replacement Instructions ................................................ 30
Walking Board Replacement Instructions ............................................ 31
Motor Drive Belt Replacement and Adjustments ................................. 32
Tension Adjustments ........................................................................... 32
Tracking Adjustments .......................................................................... 33
Elevation Motor Replacement ....................................................... 34
Replacement Instructions .................................................................... 34
Electronics Box Replacement ........................................................ 35
Replacement Instructions .................................................................... 35
Drive Motor Control Box Replacement ............................................. 36
Replacement Instructions .................................................................... 36
4-2
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: Power PCB Theory
Power PCB Theory
General Description
The 800334-002 power board and the 800320-001 control board
function together as part of the electronics box to control the Series 2000
Treadmill. The power board contains the following:
■
Mains components
■
Isolation transformer
■
Elevation and drive interface circuitry
■
Speaker (for error codes)
■
Serial control links
The serial control links receive inputs from a stress system controller
along with feedback from the treadmill sensors, send the inputs to the
control board, and then receive the control signals for the drive and
elevation motors.
Power Distribution/
Isolation
The power board receives 185 V to 265 VAC power (nominal 220V). The
isolation transformer supplies 5 V to both the isolated communication
link and the control board.
Bypass caps are distributed across the board to minimize EMI and
power supply noise. All other supplies are created on the 800320-001
control board.
STOP Circuitry
When the belt is moving, pushing the normally-closed STOP switch
activates (and latches) the dynamic braking on the drive system. This
takes place as soon as the stop relay K3 is released. The K3 relay also can
be released with a processor RESET* or when the +5 voltage drops too
low.
When a stop occurs, the 4538 timer and frequency-to-voltage converter
disables the output speed (0-10 .3V) for 2.2 seconds and signals the
processor that a stop occurred, even if the switch was only momentarily
depressed.
Frequency-to-Voltage
Converter/Amplifier
Revision D
The 4538 receives variable frequency (0–2 kHz) pulses from the
processor timer and converts them to 470 µs pulses. The 470 µs pulses
are applied to a low-pass filter/integrator (output 0–5 volt) and passed
through a noninverting op amp (Gain=2) to produce a 0–10.3 volt drive
signal. The drive signal is sent to the drive system as an analogrequested speed voltage. The circuitry can be disabled for 2.2 seconds
by a system RESET*, a BRAKE* signal, or by releasing the stop relay. This
permits the watchdog timer to maintain a zero-speed command to the
drive during system power-up and guarantees a zero-speed command
during stop conditions.
Series 2000 Treadmill
409110-004
4-3
Troubleshooting: Power PCB Theory
Start/Stop Circuitry
When COAST* and BRAKE* are not active (low), the START pulse
command can engage the drive system. These signals are level
converted from CMOS/TTL (0–5 V) levels to (-15 V–0 V) logic by the
74HC14 drivers and level shifting transistors. The 750-ohm resistors
limit the maximum current to 27 mA (+5V -(-15V) /750) and the typical
current to 5.7 mA (+5V - (0.7V) /750). The diodes limit the output voltage
to 0.7 volts. These drivers are connected to the opto-couplers within the
drive system.
The COAST* and BRAKE* signals override the START pulse.
Elevation Relays
Drive Connector
Hall Feedback
A direction control and an enable relay control the elevation motor. A
change in direction should only occur when the elevation motor is
stopped. The enable relay is disabled by the normally-closed limit
switches at the end of travel to prevent damage to the motor. The
LIMIT* signal goes low when a limit switch is activated in a particular
direction.
Inputs from the brushless motor hall sensor and the control signals are
combined to provide signals to run the drive system. The drive system
provides fault output, which is reset by pulsing the COAST* signal.
Five hall sensors monitor the position and speed of the drive motor. The
drive control uses the three primary sensors (HALL1, HALL2, HALL3) to
commutate the three-phases of the DC motor. The other two hall
sensors (HALL4 & HALL5) provide speed and direction feedback by
quadrature to the drive and to the control. HALL1and HALL3 provide
about 4 pulses per revolution and HALL4 and HALL5 provide about 30
pulses per revolution. The higher frequency HALL4 and HALL5 signals
maintain better speed regulation at low motor speeds.
These 5-volt hall signals are squared-up by 74HC14, which is protected
by filter caps, limiting resistors, and Zener diodes.
Power Inlet, Drive Power
Outlet, and Mains
Control Board Connector
4-4
The power comes in on the terminal block, gets fused and filtered, and is
distributed to the isolation transformer and out to the drive system.
Externally accessible 0.5ASB fuses are provided for the control portion
of the circuitry. The 20 Amp internal fuses are for the drive section and
are intended to protect the wiring from major faults within the drive
system. Spacings for creepage and isolation are critical in this whole
section.
The control board connector provides 0.5-inches of stand-off spacing
for the rear entry connector on the 800320-001 board.
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: Power PCB Theory
Elevation Sensor
Isolation Transformer
Power Supplies
The elevation sensor is a 5-turn pot that is coupled to the elevation rack.
The voltage on pin 2 should be proportional to elevation. That is, low
voltage should be low elevation, increasing voltage should indicate
increasing elevation. During self-calibration, the offset and gain remain
in software memory. Initially, the limit switch positions are the
reference for self-calibration. Once the offset and gain are adjusted, the
pot position determines the elevation.
The isolation transformer provides isolation for two secondaries. The
220 VAC primary is stepped down and isolated from the two 12 VCT
secondaries. Each of the secondaries provide unregulated power for a
5-volt switching supply.
There are two identical power supplies. One is for the control power, the
other is for the isolated serial link. The isolated serial link supply
provides a maximum of 2 amps of 5-volt power to operate a manual
controller.
Unregulated power comes from the center-tapped isolation
transformer, through the full-wave bridge to the switching regulator.
The switching regulator is a step-down, buck PWM-type that switches at
about 100 KHz. It also has an internal current limit of 4 amps. The 5-volt
regulators are configured to produce about 5.1 volts.
Isolated Serial Link
Debug/Serial Link
This circuitry provides an isolated, RS-422/232 link back to the
controlling system. It also provides up to 2 amps of 5 V power for an
external manual controller.
The debug/serial link connector is covered by a removable plastic plate.
This connector sends/receives the analog outputs, the manual analog
inputs, and the RS-232 (debug) signals.
NOTE
These outputs are accessed through the
SERVICE connector and are referenced to
DIGITAL ground which is NOT connected to
CHASSIS
ground.
Analog
isolation
amplifiers may be required to protect
externally connected equipment.
Revision D
Series 2000 Treadmill
409110-004
4-5
Troubleshooting: Power PCB Theory
ESD and EMI
Compatibility
The I/O connectors on the power board have current-limiting resistors,
Zener diodes, or filtering capacitors wherever possible to prevent EMI
from escaping the board. These components also limit rise-time and
voltages which may come from ESD or other noise sources.
Power Supply
Requirements
Table 4-1. Output Requirements
4-6
Voltage
Nominal Voltage
Test Range
Maximum Current
Ripple P-P
+5 V
+5.1 VDC ±5%
0.0–3.0 A
4.0 A
0.5 V
+5 V–ISO
+5.1 VDC ±5%
0.0–2.0 A
4.0 A
0.5 V
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: Power PCB Theory
Table 4-2. J2 Debug/Analog Control
PIN #
NAME
TYPE
IN/OUT
FREQ
COMMENT
J2-1
SPEEDV
ANA
OUT
DC
Current Speed
1V/5MPH (±2%
TOLERANCE)
J2-2
TXSERVICE
(NOT WORKING)
232
OUT
10KHZ
RS-232
DEBUG T
J2-3
RXSERVICE
(NOT WORKING)
232
IN
10KHZ
RS-232
DEBUG RX
J2-4
MANELEV
ANA
IN
5HZ
MAN ELEV IN 0-5V
(RATIOMETRIC)
J2-5
GND
GND
COM
DC
Digital Ground
J2-6
MANSPD
ANA
IN
5HZ
MAN SPEED IN 05V (RATIOMETRIC)
J2-7
MANRUN
CMOS
IN
LEVEL
Signal to Start MAN
CNTRL
J2-8
+5V
PWR
OUT
DC
+5V POWER OUT
250ma
J2-9
GRADEV
ANA
OUT
5HZ
Current Grade
1V/5% (±2%
TOLERANCE)
Table 4-3. J5 Drive Connector
PIN #
NAME
TYPE
IN/OUT
FREQ.
COMMENTS
J5-1
SHLD-GND
GND
COM
DC
Digital Ground
J5-2
STARTPB
-15V
OUT
PULSE
Drive Start Pulse
J5-3
DRVGND
GND
COM
DC
Digital Ground
J5-4
STOPPB
-15V
OUT
PULSE
Drive Stop (Brake)
Pulse
J5-5
ESTOPPB
-15V
OUT
PULSE
Drive EStop (Coast)
Pulse
J5-6
SPEED/010V
ANA
OUT
5HZ
Speed command
J5-7
FAULT*
OC5V
IN
LEVEL
Drive Fault output
J5-8
HALL1
OC5V
OUT
10KHZ
Hall sensor 1
J5-9
HALL2
OC5V
OUT
10KHZ
Hall sensor 2
J5-10
HALL3
OC5V
OUT
10KHZ
Hall sensor 3
J5-11
DRV5V
PWR
PWR
DC
Hall sensor power
J5-12
TEMP1
15V
I/O
LEVEL
OverTemp cutout
Revision D
Series 2000 Treadmill
409110-004
4-7
Troubleshooting: Power PCB Theory
Table 4-3. J5 Drive Connector (Continued)
J5-13
TEMP2
15V
I/O
LEVEL
OverTemp cutout
J5-14
HALL5
OC5V
OUT
10KHZ
Hall sensor 5
/Tach B
J5-15
HALL4
OC5V
OUT
10KHZ
hall sensor 4/Tach A
J5-16
SHLD-GND
GND
COM
DC
Digital Ground
Table 4-4. J6 Elevation Motor
PIN
NAME
TYPE
IN/OUT
FREQ.
COMMENTS
COLOR
J6-1
220VUP
PWR
OUT
50/60
MOTOR RUN
CAP
BLK
J6-2
NC
J6-3
220VDN
PWR
OUT
50/60
MOTOR RUN
CAP
BLK
J6-4
220VUP
PWR
OUT
50/60
MOTOR BLAC
BLK
J6-5
NC
J6-6
220VDN
J6-7
NC
NC
NOT
CONNECTED
J6-8
NC
NC
NOT
CONNECTED
J6-9
NC
NC
NOT
CONNECTED
J6-10
20VELEV
J6-11
NC
J6-12
MOT20AGND
NC
NOT
CONNECTED
NC
PWR
PWR
OUT
OUT
NOT
CONNECTED
50/60
50/60
NC
GND
COM
MOTOR RED
MOTOR BLUE
RED
BLU
NOT
CONNECTED
DC
MOTOR BROWN
BRN
Table 4-5. J7 Elevation Feedback
4-8
PIN #
NAME
TYPE
IN/OUT
FREQ.
COMMENTS
COLOR
J71
+5V
PWR
OUT
DC
SENSOR
SUPPLY
RED
J72
ELEVFB
ANA
IN
5HZ
SENSOR
OUTPUT 05V
GRN
J73
GND
GND
COM
DC
Digital Ground
BLK
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: Power PCB Theory
Table 4-6. J9 CPU Board Interface–I/O and Power
PIN #
NAME
TYPE
IN/OUT
FREQ.
COMMENTS
J9-1
GND
GND
COM
DC
Digital Ground
J9-2
+5V
PWR
OUT
DC
+5V SUPPLY
J9-3
GND
GND
COM
DC
Digital Ground
J9-4
+5V
PWR
OUT
DC
+5V SUPPLY
J9-5
START
CMOS
IN
PULSE
Belt START pulse
(latched)
J9-6
BRAKE*
CMOS
IN
PULSE
Belt (FAST) STOP
pulse
J9-7
UP/DOWN*
CMOS
IN
LEVEL
Elevation Direction
J9-8
COAST*
CMOS
IN
PULSE
Belt COAST &
FAULT RESET
J9-9
EN-ELEV
CMOS
IN
LEVEL
Elevation Motor
RUN
J9-10
DRIVE-EN
CMOS
IN
LEVEL
NOT USED
J9-11
SETSPEED
CMOS
IN
2KHZ
0-2 KHZ DRIVE
SPEED CMD
J9-12
RESET*
CMOS
IN
LEVEL
CPU RESET signal
J9-13
TXCOMM
CMOS
IN
10KHZ
RS422 TX signal
J9-14
GND
GND
COM
DC
Digital Ground
J9-15
RXCOMM
CMOS
OUT
10KHZ
RS422 RX signal
J9-16
GND
GND
COM
DC
Digital Ground
J9-17
TACH-A
CMOS
OUT
10KH
QUAD-DRV SPEED
& DIR FB
J9-18
GND
GND
COM
DC
Digital Ground
J9-19
TACH-B
CMOS
OUT
10KHZ
QUAD-DRV SPEED
& DIR FB
J9-20
GND
GND
COM
DC
Digital Ground
J9-21
LIMIT*
CMOS
OUT
LEVEL
Elev Limit Switch
reached
J9-22
GND
GND
COM
DC
Digital Ground
J9-23
ESTOPSW
CMOS
OUT
LEVE
ESTOP SWITCH/
RELAY active
J9-24
SPEAKER
ANA
IN
10KHZ
To 8-ohm Speaker
J9-25
ESTOPTRP
CMOS
OUT
PULSE
ESTOP/POWER
insanity 1sho
J9-26
SPEAKER
ANA
IN
10KHZ
To 8-ohm Speaker
Revision D
Series 2000 Treadmill
409110-004
4-9
Troubleshooting: Power PCB Theory
Table 4-6. J9 CPU Board Interface–I/O and Power (Continued)
4-10
J9-27
SELF-CAL
CMOS
OUT
LEVEL
Signal to Start
SELFCAL
J9-28
TXSERVICE
232
IN
10KHZ
RS232 DEBUG TX
J9-29
MANRUN
CMOS
OUT
LEVEL
Signal to Start MAN
CNTRL
J9-30
RXSERVICE
232
OUT
10KHZ
RS232 DEBUG RX
J9-31
FAULT*
CMOS
OUT
LEVEL
BELT DRIVE FAULT
J9-32
GND
GND
COM
DC
Signal Ground
J9-33
GND
GND
COM
DC
Signal Ground
J9-34
-7.5V
PWR
IN
DC
Power for OP AMP
J9-35
GND
GND
COM
DC
Signal Ground
J9-36
+16.5V
PWR
IN
DC
Power for OP AMP
J9-37
GND
GND
COM
DC
Signal Ground
J9-38
GRADEV
ANA
IN
5HZ
Current Grade
1V/5% (2%)
J9-39
GND
GND
COM
DC
Signal Ground
J9-40
SPEEDV
ANA
IN
5HZ
Current Speed
1V/5MPH (2%)
J9-41
GND
GND
COM
DC
Signal Ground
J9-42
MANELE
ANA
OUT
5HZ
MAN GRADE IN
0-5V (RATIO)
J9-43
GND
GND
COM
DC
Signal Ground
J9-44
MANSPD
ANA
OUT
5HZ
MAN SPEED IN
0-5V (RATIO)
J9-45
GND
GND
COM
DC
Signal Ground
J9-46
ELEVFB
ANA
OUT
5HZ
ELEV POSITION FB
(RATIO)
J9-47
GND
GND
COM
DC
Signal Ground
J9-48
+5V
PWR
OUT
DC
+5V SUPPLY
J9-49
GND
GND
COM
DC
Signal Ground
J9-50
+5V
PWR
OUT
DC
+5V SUPPLY
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: Power PCB Theory
Table 4-7. J12 Hall Sensor Interface
PIN #
NAME
TYPE
IN/OUT
FREQ.
COMMENTS
COLOR
J12-1
DRVGND
GND
COM
DC
Digital Ground
BLK
J12-2
DRV5V
PWR
PWR
DC
Hall sensor
power
RED
J12-3
HALL3
OC5V
IN
10KHZ
Hall sensor 3
ORG
J12-4
HALL2
OC5V
IN
10KHZ
Hall sensor 2
YEL
J12-5
HALL4
OC5V
IN
10KHZ
Hall sensor 4
/Tach A
GRN
J12-6
HALL5
OC5V
IN
10KHZ
Hall sensor 5/
Tach B
BLU
J12-7
HALL1
OC5V
IN
10KHZ
Hall sensor 1
WHT
J12-1
SHLD
GND
COM
DC
Digital Ground
SHLD
Revision D
Series 2000 Treadmill
409110-004
4-11
Troubleshooting: Power PCB Theory
Precautions
The Board must be powered before signals are applied to it.
The circuitry is static sensitive as are all HC, AC, and MOS ICs.
Therefore, when removing or installing boards, the power should be off.
The circuit board should not be supplied with a VCC over 5.5 volts on
the +5V supply. The power sections should not be supplied with
voltages over 265VAC.
Initial Board Conditions
4-12
Apply power supply conditions as stated in Table 4-1, “Output
Requirements.”
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: Control PCB Theory
Control PCB Theory
General Description
The 800320-001 control board and the 800334-002 power board
function together to control the Series 2000 Treadmill. The control
board contains the following:
■
Micro-controller CPU circuitry (78310)
■
Memory (EEROM code/calibration/history data, SRAM)
■
Temperature sensor
■
Speaker driver
■
Some of the I/O circuitry
The I/O circuity receives inputs from a stress system controller along
with feedback from the treadmill sensors to control the elevation and
drive systems located on the 800334-002 power board.
Power Distribution
Revision D
The control board receives 5 volts of power from the power board.
Bypass caps distributed across the board minimize EMI and power
supply noise. Other analog supplies are created from the 5-volt supply
to the board with voltage doublers.
Clock Generator
A 12 MHz crystal provides the processor clock. Sharp clock edges are
controlled by the 100-ohm series termination resistors to minimize EMI.
Reset Generator
The Reset/Watchdog generator resets the CPU under any one of three
conditions:
■
Upon receipt of a “BREAK” signal over the RS-422 port, the 100
K/0.33µF RC will discharge, creating the PBRESET* and RESET*
signal.
■
If the 5 V (±5%) supply falls below 4.5 V, RESET* is activated.
■
If the CPU fails to reset the watchdog timer for 1.2 seconds, the
RESET* is activated. The software has the watchdog control
software “threaded” through its task-switcher to help guarantee
that all processor tasks are running.
Series 2000 Treadmill
409110-004
4-13
Troubleshooting: Control PCB Theory
Temperature Sensor
The processor monitors temperature and saves peak temperature in
EEROM data storage for use by field service. The sensor outputs
10 mV/Deg C. The op amp provides a gain of 4.92.
The 78310 A/D converter produces the following outputs
■
In hardware: A/D value = Temp(Deg C) * 10mV/DegC * GAIN *
256(max A/D counts) / VREF
■
In software: Readout Temp = (A/D value) * 4 / 10
For example:
At 25 Deg C ==>
A/D value = 25 * 0.01 * 4.92 * 256 / 5.1 = 62 (Dec)
Readout Temp = 62 * 4 / 10 = 24.8
At 100 Deg C ==>
A/D value = 100 * 0.01 * 4.92 * 256 / 5.1 = 247 (Dec)
Readout Temp = 247 * 4 / 10 = 98.8
Processor Circuitry
The 78310 runs at 12 Mhz. Its code is stored in the 8K X 8 EEROM. It can
be reprogrammed through the RS-422 serial port. The code must be
initially installed by the manufacturing test fixtures. The 78310 accesses
memory through its multiplexed address/data bus. An 8-bit address
latch (HC573) separates the address from the data. An EP330 decodes
the proper chip select from the address. The EP330 can select the SRAM,
the EEROM, or a UART (unused) at the appropriate address. It also
generates the special WRITE gate signals to write to EEROM.
The processor handles all the I/O, including one serial channel, 4 analog
inputs, and digital inputs and outputs, to control the treadmill grade
and speed.
4-14
Analog Inputs
Elevation feedback (from the pot), manual speed, and manual elevation
analog inputs are designed to take ratiometric voltages referenced to +5
VREF as inputs to the processor.
Speaker Output
One of the timer outputs is used to create sound through the ACcoupled audio amplifier. A 2.5 V pseudo-ground is built using one-half
of the op amp. The other half is configured as an AC-coupled bandpass
amplifier referenced to the 2.5 V pseudo-ground.
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: Control PCB Theory
Analog Outputs
Two analog outputs are derived from the two PWM (pulse-width
modulation) output channels. The 8-bit register for the PWM pulses are
used to control an analog switch which provides precise 1.235 V pulses
to an integrator. The output of the integrator is buffered through two op
amps (gain=4.17 ±2%).
Output voltage = (PWM-value) * 1.235 * 4.17 / 255
PWM
Output
0
0.000 V
±20mV typical unadjusted offset
1
0.02020 V
~20mV resolution
255
5.15 V
±2% typical unadjusted gain error
These outputs are used to provide two treadmill analog outputs:
GRADE at 1 volt per 5% grade and SPEED at 1 volt per 5 MPH.
NOTE
These outputs are accessed through the
SERVICE connector and are referenced to
DIGITAL ground which is NOT connected to
CHASSIS
ground.
Analog
isolation
amplifiers may be required to protect
externally connected equipment.
Analog Supplies
Revision D
The +16.5 V and –7.5 V supplies for the analog output and RS-232
circuitry are supplied by the +5 V supply. Capacitor voltage doublers
and inverters are used to get these unregulated supplies from the
LT1133 and the 7660.
Supplies
The EMI filter inductor normally has about a 100 to 200 mV voltage drop
across it (load dependent). +5 VREF is typically at about 5.1 VDC. The
+5V supply is typically at about 4.9 to 5.0 VDC.
ESD and EMI
Compatibility
The one and only connector on this PCB has current limiting resistors
and filtering capacitors on almost every signal to prevent EMI from
escaping this board. These components also limit rise-time and voltages
which may come from ESD or other noise sources.
Series 2000 Treadmill
409110-004
4-15
Troubleshooting: Brushless DC Drive Theory
Brushless DC Drive Theory
General Description
A brushless DC motor consists of permanent magnets that create a static
magnetic field and electromagnets that, when energized, provide
motion. The magnets attach to a shaft to form a rotor with an even
number of magnetic poles. One or more electromagnets are wound on a
laminated steel stator to form the motor phases. Typically, brushless DC
motors have four, six, or eight magnetic poles with three winding phases.
With multiple motor phases, there is always one of the phases that can
be energized to provide rotational torque—regardless of the rotor
position with respect to the stator. Energizing the phases in the proper
sequence and polarity provides constant unidirectional torque.
Transistors have replaced brushes to accomplish phase switching.
Sensors determine the rotor position and turn on the correct motor
phase. These position sensors are typically Hall-effect devices because
of their low cost and immunity from environmental conditions.
Phases and Power
Switches
The most common arrangement of phases and power switches is the threephase, Y-connected windings with six power switches. Each phase consists
of two windings in series, spaced 120 electrical degrees apart. Each phase
can be energized in either direction by turning on two of the six power
devices. This arrangement of switches and motor windings is identical to
an AC motor drive. The number of electrical cycles per mechanical
revolution is equal to the number of rotor poles divided by two.
Motor Torque
To control motor torque, it is necessary to control the current through
the motor windings since torque is directly proportional to motor
current. Rapidly switching the power devices on and off limits the
effective voltage applied to the motor winding. Using a feedback loop, a
voltage command controls the motor current. This is called the current
loop or inner loop of the drive.
Motor Speed
Control of motor torque is only half of the motor control process, since
the ultimate goal of a motor drive is to provide an adjustable motor
speed. The simplest speed control loop consist of a summing junction
to determine the difference between the desired motor speed and the
actual motor speed, along with a gain block that feeds into the current
loop. The current loop may be considered a single block with voltage as
an input and motor current as an output. The overall feedback loop is
called the velocity loop or outer loop of the drive. While this system
controls motor speed, it cannot control the exact motor speed since
some error signal is required to drive the current loop. The actual motor
speed is dependent on the speed command, the load, the error gain, and
the characteristics of the motor itself.
Adding an integrator to the error amplifier allows exact speed control.
Any speed error results in an output from the integrator that builds with
time and causes an output to the current loop. This loop, therefore, will
seek zero speed error. This is the type of velocity loop used in the
Marquette Series 2000 Treadmill drive.
4-16
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: Drive Motor Control Box Description
Drive Motor Control Box Description
Power Board
The treadmill drive motor control consists of two PC boards and a
power IGBT module. The power board is located on the heat sink and
contains the input bridge rectifier, the DC bus capacitors, the logic
power supplies, and the IGBT gate drivers. The IGBT module attaches to
the heat sink in the center of the power board.
NOTE
All the circuitry on this board is referenced to
the common of the DC bus which puts it at or
near line potential.
Control Board
The control board is located on the cover above the power board. This
board contains the logic to decode the motor hall sensors, the current
loop, the velocity loop, and five status LEDs.
NOTE
This board is at line potential with the
exception of the small area between the
terminal block and the row of opto-isolators.
LED Functions
Over-Temperature
This LED lights if the heat sink thermostat opens.
Fault
This LED lights when a fault condition occurs. The following conditions
can cause a fault: AC line under voltage, AC line over voltage, motor over
current, power supplies low, heat sink over temperature, auxiliary
temperature switch open, motor stalled, or personality module missing.
Once a fault occurs, you cannot start the drive until you correct the fault
and open the ESTOP switch.
Ilimit (Current Limit)
This LED lights when the controller is supplying maximum current to
the motor. Although it usually remains off, it may flash with a heavy
load. If this LED is on continuously, check the drive and belt. If the
motor stalls for more than 5 seconds with the current limit LED on, the
drive will fault-out.
Revision D
Series 2000 Treadmill
409110-004
4-17
Troubleshooting: Drive Motor Control Box Description
Power (Power Supplies OK)
This LED lights when the main ± 15-volt power supplies are within the
required range.
Tach loss
This LED lights to indicate the tachometer circuits in the motor are not
active.
4-18
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: Drive Motor Control Box Description
User Inputs/Outputs
User inputs and outputs are available at the 15-pin, D-connector
located at the top of the drive. See figure for a list of the functions and
pin numbers. Signal functions are as follows:
HALL1, HALL2, HALL3
These signals originate from the commutation hall sensors in the DC
motor and are used to decode the rotor position so that the correct
phase is energized. They are 5-volt, square waves, displaced 90 electrical
degrees apart. You can check the signals with a voltmeter while slowly
rotating the motor by hand and verifying the +5 volt and near-zero volt
levels.
HALL4, HALL5
These signals originate from the auxiliary hall sensors in the DC motor,
and they supply a tachometer signal to the drive for speed regulation.
These are 5-volt, square waves, displaced approximately 90 degrees
from each other. You can check the signals with a voltmeter while slowly
rotating the motor by hand and verifying the +5 volt and near-zero volt
levels.
+5ISOL
This signal is the power for the motor hall sensor.
GNDISOL
This is the common for all of the user I/O.
VIN
This is a 0–10.3 volt signal that controls the speed of the drive.
START
This is a normally-open switch input. Connecting this input to
GNDISOL starts the drive unless there is a fault condition or the STOP or
ESTOP contacts are open. The signal is pulled down to –15V ISOL.
STOP
This is a normally-closed switch input. Opening this switch signals the
drive to power to a stop with full braking. The drive brakes until it
reaches zero speed unless a fault occurs or the ESTOP switch is open.
The signal is pulled down to –15V ISOL.
ESTOP
This is a normally-closed switch input. Opening this switch signals the
drive to coast to a stop. This also clears any faults that have been latched
unless the fault condition still exists. The signal is pulled down to –15V
ISOL.
Revision D
Series 2000 Treadmill
409110-004
4-19
Troubleshooting: Drive Motor Control Box Description
FAULT
This is an open collector output that is pulled low when a fault condition
is latched.
TEMP1, TEMP2
These terminals can be connected to an external thermal switch such as
the motor over-temperature switch. The switch should be normally
closed. Opening the contact causes a fault condition.
D-connector Inputs/Outputs
D- Connector Pin #
1
4-20
Signal Name
--
2
GNDISOL
3
ESTOP
4
FAULT
5
HALL2
6
+5ISOL
7
TEMP2
8
HALL5
9
START
10
STOP
11
VIN
12
HALL1
13
HALL3
14
TEMP1
15
HALL4
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: Drive Motor Control Box Description
Electrical Requirements
The two black wires that exit the side of the enclosure supply power to
the drive. The power source should be single phase, 208/240 VAC. If the
line voltage dips below 170 VAC or exceeds 264 VAC, the drive faults.
Maximum input current is 16A.
Fuses should be KTKR 20 only. Substituting a different fuse type may
cause a fire or safety hazard.
The orange wire from the side of the enclosure is connected to the sheet
metal enclosure and should be connected to the designated terminal on
the power terminal block. Do not connect this wire to the treadmill
frame which would cause a safety hazard.
The motor wires exit through the flexible conduit on the left side of the
enclosure. These wires carry the pulsed 320 V to the motor. Be sure to
observe proper phasing when connecting these wires. The drive will not
operate with incorrect phasing.
NOTE
If the motor is disconnected, do not let the
motor wires short to each other or any other
point. If it rotates, the motor will function as a
generator, and it may be damaged or cause
a shock hazard. The ground strap from the
flexible conduit should be connected to the
motor frame. Make sure this connection is
secure.
Revision D
Series 2000 Treadmill
409110-004
4-21
Troubleshooting: General Fault Isolation
General Fault Isolation
Visual Inspection
A thorough visual inspection of the equipment can save time. Small
things—disconnected cables, foreign debris on circuit boards, missing
hardware, loose component—can frequently cause symptoms and
equipment failures that may appear to be unrelated and difficult to
track.
Take the time to make all of the recommended visual checks (refer to
the visual inspection chart on the next page) before starting any detailed
troubleshooting procedures.
NOTE
Before performing any maintenance or repair
on the equipment, take precautions against
electrostatic discharge damage. See
“Controlling Electrostatic Discharge” in
chapter 3.
NOTE
Solder multilayer and surface mount PCB
assemblies at your own risk! Improper repair
methods can damage the PCB assemblies
even further. Only qualified service
personnel with the proper equipment should
attempt to repair PCBs.
Power Down
Set the treadmill’s power switch to off (0). Disconnect the power cord
from the AC wall outlet.
WARNING
Unplug unit before
performing the
following procedure.
M15287-28B
4-22
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: General Fault Isolation
Table 4-8. Visual Inspection List
Area
Look for the following problems:
I/O Connectors and Cables
• Fraying or other damage.•
• Cracked housing.•
Fuses
• Type and rating. Replace as necessary.
Interface Cables
• Excessive tension or wear.•
• Strain reliefs out of place.
Circuit Boards
• Moisture, dust, or debris (top and bottom).•
Loose or missing components.
• Burn damage or smell of over-heated•
Socketed components not firmly seated.
components.•
PCB not seated properly in edge connectors.
• Solder problems: cracks, splashes on board,
incomplete feed through, prior modifications or
repairs.
Ground Wires/Wiring
• Loose wires or ground strap connections.•
• Wires pinched or in vulnerable position.
Mounting Hardware
• Loose or missing screws or other hardware, especially fasteners used as connections to ground
planes on PCBs.
Power Source
• Faulty wiring, especially AC outlet.•
Circuit not dedicated to system.
(Power source problems can cause static discharge, resetting problems, and noise.)
Shroud Removal
Bent prongs or pins.
Loose screws in plugs.
Loose connection.
Faulty wiring.
To remove the treadmill shroud for the internal visual inspection or for
service:
■
Disconnect the power cord from the rear connector panel.
■
Remove the screws on the back panel of the shroud and remove
the back panel.
■
Remove the 2 bolts on each side of the shroud.
■
Lift off the shroud from the front.
Back Panel
Shroud Side Bolts
MD1129-012C
Revision D
Series 2000 Treadmill
409110-004
4-23
Troubleshooting: General Fault Isolation
Parts Locations
chassis ground
WARNING
Electrical shock hazard
between chassis ground
and isolated (“floating”)
ground when power is
applied. Unplug unit from
power source before
M15287-61A
proceeding.
isolated ground
Electronics Box
Connector Panel
Elevation Pot
(under Electronics Box)
Fly Wheel
Elevation Motor
Motor Control Box
MD1129-013C
Brushless DC Motor
DC Motor Drive Belt
Electronics Box
MD1129-014C
4-24
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: General Fault Isolation
Power Supply Voltage
Checks
With the power on, remove the side panel on the electronics box to
measure the system’s supply voltages as follows:
■
On the control board, PN 800320-001, check the voltages on
pins 2, 34, and 36 in reference to digital ground (see illustration).
The control board is mounted on the power board.
■
On the power board, PN 800334-002, check for +5 V-ISO across
diode VR5.
Pin 36
+16.5 VDC
Pin 34
-7.5 VDC
Pin 2
+5 VDC
Pin 1
Digital Ground
800320-001E
Speaker Check
Service Port
Revision D
With the shroud removed, listen for the speaker output during powerup. There should be 2 short beeps to indicate “system OK”.
The self-diagnostic software is not available at this time.
Series 2000 Treadmill
409110-004
4-25
Troubleshooting: General Fault Isolation
Drive Control Fault LEDs
Use a hand-held mirror to view fault indicator LEDs.
Over temp
Fault
Ilim
Power
Tach loss
MD1129-023A
4-26
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: DC Motor Replacement
DC Motor Replacement
Replacement
Instructions
1. Turn the power switch off, disconnect the power cord from the
wall outlet, and remove the shroud.
2. Unscrew the 6 screws on the electronics box side panel and
remove the panel.
3. Disconnect the speed feedback cable from the power board,
illustrated below.
Inside of Electronics Box
J12
Disconnect
Speed Feedback Cable
Power Board
Main CPU Board
MD1128-008C
4. Cut and remove all tie wraps on the speed feedback cable back
to the motor.
5. Remove 4 screws from power cable access box on top of motor.
6. Cut but-splice connectors, unscrew ground strap, remove
conduit lockdown nut. Remove conduit cable from access box.
Revision D
Series 2000 Treadmill
409110-004
4-27
Troubleshooting: DC Motor Replacement
7. Lift the treadmill up on end. This treadmill position offers the
best access for replacing the DC motor.
8. Use a 1/2-inch wrench to remove the 4 nuts that hold the motor
in place (2 each side).
Mounting Nuts
4 Places
Drive Belt Tension
Adjustment Bolts
2 Places
DC Motor
Mounting Bracket
MD1129-015C
9. Remove the 2 drive belt tension adjustment bolts.
10. Remove the DC motor mounting bracket.
11. Swap motors and re-assemble in reverse order. Remember to
replace the tie wraps.
12. Adjust the drive belt tension and tracking. See “Motor Drive Belt
Replacement and Adjustments” in this chapter.
13. Activate the self-calibration feature as instructed in chapter 3,
“Maintenance.”
4-28
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: Front Roller Replacement
Front Roller Replacement
Replacement
Instructions
1. Turn the power switch off, disconnect the power cord from the
wall outlet, and remove the shroud.
2. Loosen the walking belt tension bolts on the end of the
treadmill.
Tension Bolts
MD1129-016B
3. On the drive-belt side of the treadmill, locate the roller bolt
access hole. Remove the 9/16-inch bolt (one of two that hold the
roller in position).
Roller Bolt
2 Places
MD1129-017B
4. While supporting the free end of the roller, remove the
9/16-inch bolt on the opposite side of the treadmill.
5. Lift the roller up and slide it out of the belt.
6. Install the new roller in reverse order, then adjust the walking
belt tension.
7. Activate the self-calibration feature as instructed in chapter 3,
“Maintenance.”
Revision D
Series 2000 Treadmill
409110-004
4-29
Troubleshooting: Walking Belt and Board Replacement
Walking Belt and Board Replacement
Walking Belt
Replacement
Instructions
1. Turn the power switch off, disconnect the power cord from the
wall outlet, and remove the shroud. You do not have to remove
the roller to replace the belt.
2. Remove the right end cap from the end of the treadmill and
loosen the tension bolt on the left end cap.
3. Lift up the left side of the treadmill and place the end cap that
you just removed under the left foot.
Loosen Left Tension Bolt
MD1129-018B
4. On the front right side of the treadmill, remove the eight, 1/2inch bolts that hold the frame’s sliding bracket in place.
Sliding Bracket
Slide lower end
of belt off first.
Sliding Bracket Bolts
8 Places
MD1129-019B
4-30
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: Walking Belt and Board Replacement
5. Slide the bracket into the frame.
6. Slide the belt off the walking board, lower end first.
7. Replace the belt in reverse order.
NOTE
The wax material on the walking board acts
as a lubricant for the belt. We recommend
that you replace the board every time you
put on a new belt to ensure the belt absorbs
the required amount of lubricant.
Walking Board
Replacement
Instructions
1. Remove the walking belt as instructed in the previous steps.
2. Remove the eight, 5/32-inch Allen-head, counter-sunk screws
on from the top of the walking board. (There are no nuts on the
underside of the board.)
3. Secure the new walking board to the bed assembly with the 8
screws.
4. Replace the walking belt and adjust the tension.
5. Activate the self-calibration feature as instructed in chapter 3,
“Maintenance.”
Revision D
Series 2000 Treadmill
409110-004
4-31
Troubleshooting: Motor Drive Belt Replacement and Adjustments
Motor Drive Belt Replacement and Adjustments
Tension Adjustments
1. Turn the power switch off, disconnect the power cord from the
wall outlet, and remove the shroud.
2. To replace the drive belt, first remove the front roller as
instructed in this chapter under “Front Roller Replacement.”
Slide the old belt off, put a new belt on the sprockets, and
replace the front roller.
3. There are two belt-tension adjustment bolts above the DC
motor. Tighten these 1/2-inch bolts to make a course
adjustment to the drive belt tension (clockwise to tighten).
Drive Belt Adjustment Bolt
2 Places
MD1129-021C
4. Re-apply power to the treadmill and run the unit, slowly at first,
to check the belt tension and tracking.
4-32
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: Motor Drive Belt Replacement and Adjustments
5. Fine tune the belt tension with the adjustment bolts so that you
can push in the belt approximately 1/2-inch on one side.
NOTE
Excessive tension will cause undue stress
on the motor shaft.
With firm pressure applied to belt midway between
pulleys, distance must be at least 1/2 inch between top
of belt and 12 inch (minimum) length straight edge.
MD1129-024A
6. Activate the self-calibration feature as instructed in chapter 3,
“Maintenance.”
Tracking Adjustments
Revision D
The motor is mounted at a very slight angle so that the belt meshes
quietly with the sprockets. Because of this design, the belt will always
track to one side of the top sprocket. However, you may have to make
slight adjustments to the top sprocket’s 3/32-inch Allen screws to align
the top sprocket with the lower sprocket so the belt tracks evenly on the
lower sprocket.
Series 2000 Treadmill
409110-004
4-33
Troubleshooting: Elevation Motor Replacement
Elevation Motor Replacement
Replacement
Instructions
1. Turn the power switch off, disconnect the power cord from the
wall outlet, and remove the shroud.
2. Disconnect the elevation motor power cable and remove all tie
wraps on the cable.
3. Place the treadmill on its side so the elevation motor is on top.
NOTE
The elevation motor supports the treadmill.
To prevent the treadmill from falling, only
replace the elevation motor with the treadmill
on its side.
4. Remove the two visible mounting bolts on the elevation motor.
Mounting Bolt
3 Places
MD1129-020C
5. Remove the third mounting bolt behind the rubber coupling. If
the treadmill stopped at 0% elevation, you may have to remove
the wheel to reach the third mounting bolt.
6. Remove the elevation motor from its coupling and replace with
a new motor in reverse order.
7. Replace the tie wraps and activate the self-calibration feature as
instructed in chapter 3, “Maintenance.”
4-34
Series 2000 Treadmill
409110-004
Revision D
Troubleshooting: Electronics Box Replacement
Electronics Box Replacement
Replacement
Instructions
1. Turn the power switch off, disconnect the power cord from the
wall outlet, and remove the shroud.
2. Unscrew the 6 screws on the electronics box side panel and
remove the panel.
3. Disconnect the power ring terminals and communication
connectors from the PCB, as illustrated, and the ground clip (E2)
from the electronics box.
Ring terminals
J5
J12
J7
J8
J6
1
Remove the two fast-ons
to the large capacitor, located
to the left of the board. (The
cap is not polarized.)
MD1129-011C
4. Remove the two, 3/8-inch nuts on both the top and bottom of
the box.
5. Pull the electronics box out and replace it with a new box in
reverse order.
6. Activate the self-calibration feature as instructed in chapter 3,
“Maintenance.”
Revision D
Series 2000 Treadmill
409110-004
4-35
Troubleshooting: Drive Motor Control Box Replacement
Drive Motor Control Box Replacement
Replacement
Instructions
1. Turn the power switch off, disconnect the power cord from the
wall outlet, and remove the shroud.
2. Unscrew 6 screws on the electronics box side panel and remove
the panel.
WARNING
Unplug unit before
performing the
following procedure.
M15287-28B
3. Disconnect the L1 BLK, L2 BLK and GND ORG power ring
terminals from the power pcb assembly.
4. Disconnect the communication cable from the top of the drive
motor control box.
5. Remove the 4 screws from power cable access box on top of
motor.
6. Cut butt-splice connectors, unscrew ground strap, remove
conduit lock down nut. Remove conduit cable from access box
7. Remove the 2 mounting nuts on top of the motor control box
and the 2 mounting nuts on the bottom of the box.
8. Pull the motor control box out and replace it with a new box in
reverse order.
9. Activate the self-calibration feature as instructed in chapter 3,
“Maintenance.”
4-36
Series 2000 Treadmill
409110-004
Revision D
5A
Parts Lists and Drawings for
Configuration without CE
Ordering Parts ......................................................................... 3
Introduction ........................................................................................... 3
Field Replaceable Units For Product CodeY5 (non-CE) ............................ 4
Revision D
Rev R
Upper-Level Assembly ............................................. 5
900433-001G
Full Handrail Kit..................................................... 6
900367-001T
Treadmill Assembly ................................................ 7
900418-101B
Electronics Box Assembly ....................................... 14
88380-006B
Stop Switch Assembly ........................................... 16
Series 2000 Treadmill
409110-004
5A-1
5A-2
Series 2000 Treadmill
409110-004
Revision D
Parts Lists and Drawings for Configuration without CE: Ordering Parts
Ordering Parts
Introduction
This chapter contains the current parts lists, drawings, some
schematics, and any kits for the standard treadmill configurations
available at the time of the manual release date. The upper-level parts
list appears first, followed by the assembly parts. The upper-level parts
list specifies all the items that ship with the equipment such as upgrade
kits, software disks, power cords, and manuals.
These parts lists and drawings supply enough detail for you to order
parts for the assemblies considered field serviceable. See chapter 6 for
component-level drawings and part numbers. To order parts, contact
Service Parts at the address or telephone number on the page, “How to
Reach Us...,” provided at the beginning of the manual.
Revision D
Series 2000 Treadmill
409110-004
5A-3
Parts Lists and Drawings for Configuration without CE: Field Replaceable Units For Product CodeY5 (non-CE)
Field Replaceable Units For Product CodeY5 (non-CE)
The following items may not be assigned separate manufacturing part
numbers because they are normally part of a larger assembly. Since they
are considered field replaceable units (FRUs), they have specific service
part numbers so they can be ordered and replaced by service
technicians
NOTE
Verify part numbers before ordering service
parts. See the tech memo series for this
product for changes or additions to this list.
Table 5A-1. Field Replaceable Units
Item
5A-4
Part Number
WALKING BELT
3602-006
WALKING BOARD
56944-009
DRIVE BELT
408913-001
DRIVE MOTOR 3.0 H.P.
408893-002
DRIVE MOTOR CONTROLLER
408891-002
ELEVATION MOTOR
408890-001
POWER PCB
800334-002
CONTROL PCB
800320-001
Series 2000 Treadmill
409110-004
Revision D
Parts Lists and Drawings for Configuration without CE: Upper-Level Assembly Rev R
Upper-Level Assembly
Item
1
2
3
4
5
7
8
9
10
11
12
23
25
26
27
28
39
40
41
42
43
Revision D
Rev R
Description
2000 TRDML W/FULL HNDL DOM
2000 TRDML W/FULL HNDL INTL
2000 TRDML W/EMI FULL HNDL DOM
2000 TRDML W/EMI FULL HNDL INT
CABLE TRDML/CASE INTCON
MTC-1 REHAB/STRESS MPH T2000
MTC-1 REHAB/STRESS KPH T2000
MTC-1 EXER MPH T2000
MTC-1 EXER KPH T2000
MTC-I FIELD SERVICE CE
T2000 FIELD SERVICE
CAB 8P MINI DIN 20FT
REWORK 2000 TRDML, W/FULL HNDL
REWORK 2000 TRDML W/FULL HNDL
REWORK T2000 EMI FULL HNDL DOM
REWORK 2000 TRDML W/EMI FH INT
REWORK MTC-1 REHAP/STRESS MPH
RWK MTC-1 REHAB/STRESS KPH
REWORK MTC-1 EXER MPH T2000
RWK MTC-1 EXER KPH T2000
CABLE TREADMILL TO STRESS SYS
Series 2000 Treadmill
409110-004
Part Number
900444-001
900444-002
900444-003
900444-004
80690-001
9563-501
9563-502
9563-503
9563-504
407143-003
409110-004
400073-001
900444-001R
900444-002R
900444-003R
900444-004R
9563-501R
9563-502R
9563-503R
9563-504R
700609-001
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5A-5
Parts Lists and Drawings for Configuration without CE: Full Handrail Kit 900433-001G
Full Handrail Kit
900433-001G
Item
1
2
3
4
10
11
13
19
5A-6
Description
SOCKET ALLEN 3/16 HEX
HANDLE-T
SCREW SKT 1/4-20 X 3/4
SCREW SKT 1/4-20 X 1.63
BOX MAILER 11.75L 11.00W 2.88H
KIT TEE HANDLE LH-RH
NUT ESNA 1/4-20
KIT HANDRAIL FULL-PACKAGING
Series 2000 Treadmill
409110-004
Part Number
400056-001
400093-001
407236-001
407236-002
9924-101
408912-003
4521-311
412562-001
Qty
1
1
2
2
2
2
4
1
Revision D
Parts Lists and Drawings for Configuration without CE: Treadmill Assembly 900367-001T
Treadmill Assembly
Item
1
2
3
4
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Revision D
900367-001T
Description
BELT WALKING 1800/1900/2000
SCREW SKT 1/4-20 X 1.00L
EXTRUSION SIDE RAIL T2000
MOTOR ELEVATION 185-265V .13HP
MOTOR 3HP 4000 RPM DC-QUIET
CLAMP HANDRAIL TERM TO BASE
ROLLER ASSEMBLY FRONT
ROLLER ASSEMBLY REAR
RACK STL 10P 14.5 DEG PRESS
GEAR PINION 11T 10P
BRACKET HEAD TO FRAME
SUPPORT FRAME TO CASTING
WELD FRAME TREADMILL T2000
SPROCKET 25T 5MM P .62 BORE
SPROCKET 90T 5MM P
FLYWHEEL 8.00DIA X 1.00W
BASE HEAD CASTING
TOWER FABRICATION
KIT END CAP LH-RH
ELEVATION BLOCK RH
ELEVATION BLOCK LH
SHROUD TMILL-2000
ENDPLATE ELEVATION BLOCK
ENDPLATE SW MTG ELEVATION BL
SPACER DELRIN TWR MNT
SPACER DELRIN EBOX MNT
BELT DRIVE 5MM P 20MM W
BSHG 1.0 OD X .625 ID X .50 W
FOOT FRAME
FOOT HEAD
PIN DOWEL .2502D X 1.000L
SW LEVER SPST NO 3A 250VAC
LABEL BLANK 2 X 3/4
KEY WOODRUFF 3/16 X 5/8
SCR TRILOBE PH FLTHD #10X.50
TUBE TYGON 3/16ID X 5/16OD
REAR PANEL TREADMILL 2000
SHAFT ELEVATION
COUPLING ISOLATION ELE MTR
Series 2000 Treadmill
409110-004
Part Number
3602-006
407236-003
413690-001
408890-001
408893-002
408894-001
408895-001
408896-001
408897-001
408898-001
408899-001
408900-001
413689-001
408902-001
408903-001
408904-001
408905-001
408906-002
408907-003
408908-001
408908-002
408909-001
408910-001
408910-002
408911-001
408911-002
408913-001
408914-001
408915-001
408915-002
408916-001
408918-001
404525-001
408920-001
408921-001
408922-001
408924-001
408925-001
408926-101
Qty
1
8
2
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
12
8
1
2
2
2
2
2
1
2
10
0.06
1
1
1
5A-7
Parts Lists and Drawings for Configuration without CE: Treadmill Assembly 900367-001T
Item
41
42
43
44
45
47
48
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
5A-8
Description
PANEL POT ISO FROM TOWER
BRKT DRIVE MTR MOUNTING
LABEL 2000T SHROUD
CONTROL BOX DRIVE MOTOR CE MRK
KEY 3/16 X 3/16 X 7/16
SCREW GR8 1/4-20 X .88
STUD FULL THREAD GR
SCREW HX G8 5/16X1.5
SCR HEX HD 5/16-18 X 2.00
SCREW GR 8 3/8-16 X 3/4LONG
SCREW GR8 1/2-13X 3
SCREW SKT 82FLH 1/4-20X1.25BLK
SCREW PH 4-40X 1 1/4L
SCREW HEX HD 3/8-16X3.50L BLK
SCREW SELF TAPPING 8-32X.32
WASHER FLAT STL 5/16
WASHER SPLIT BLACK .375 I.D.
WASHER FLAT STL 1/2
WASHER LK SR STL 1/4
WASHER LK SR STL5/16
WASHER LK SR STL 1/2
WASHER FLAT HDN 3/8
WASHER FLAT SS #4
TREAD RUBBER W/HOLE
SCREW PH GREY W/WSHR 8-32X.38L
NUT HEX ESNA 10-24
ADHESIVE,BLACK MAX
RACK STL 10P 14.5DEG W/O NOTCH
NUT JAM 3/4-10 UNC
WASHER BELLEVILLE .56X.19X.028
DAMPENER SOUND 3.00LG TRDML
WHEEL 3.25OD
GREASE LUBRIPLATE
BOARD WALKING W/WAX
HARN ELEV POT TO PCB P7
HARN ELEV LIMIT SW TO PCB P8
WIRE 14GA GN/Y 8IN LONG
ASSY ELEC BOX W/O EMI/RFI
WSHR FL STL.321IDX1.06ODX.105
CEMENT LOCTITE 242
SCREW SEMS PH 6-32X1/2
SCREW GRB 1/4-20 X .62
Series 2000 Treadmill
409110-004
Part Number
408929-001
408931-001
410465-001
408891-002
410625-001
45002-114
411746-001
45002-224
45002-549
45002-312
45002-548
45019-120
4502-440
45027-362
45070-612
45076-012
45090-001
45076-015
45076-111
45076-112
45076-115
45076-213
4520-004
408888-001
45021-806
4521-310
4851-058
408897-002
4546-003
4550-031
58520-003
4704-001
4850-017
56944-009
700337-001
700338-002
80306-075
900418-101
45053-002
4851-003
45000-608
45002-110
Qty
1
1
1
1
1
3
3
6
2
2
2
12
2
2
8
6
2
2
19
10
2
2
4
2
13
4
0.01
1
2
4
4
2
0.01
1
1
1
1
1
6
0.01
2
8
Revision D
Parts Lists and Drawings for Configuration without CE: Treadmill Assembly 900367-001T
Item
86
87
88
89
90
91
93
94
95
96
97
98
99
100
101
102
103
104
105
106
112
113
Revision D
Description
1/4-20X5/8 SKTCAP SCREW W/NYL
SCREW SEMS PH 1/4-20 .625L
HARN EBOX TO CNTRLR RBN 16 PIN
NUT 5/16-18 FLANGED LOCKING
SCREW HEX 5/16-18 FLANGED LK
GREASE SYNTHETIC WITH TEFLON
BUMPER PLASTIC 1.00 OD
SCREW SEMS PH PHIL 4-40 X.312L
SPLICE CE 22-14
SPLICE CE 16-10
TERMINAL INS RING#10
CABLE CLAMP 7.43LG X .187W
CODE T2000 V001E
DAMPENER SOUND 5.00 X 7.00
SCREW SET CPP 8-32X1/4
WASHER LOCK SPLIT #10
SHIELD PINCH POINT 2000
WASHER FLAT SS #10
SCREW PH WOOD #10 X .62L
ADHESIVE LOCKTITE 262
LABEL UL CLASSIFIED
LABEL UL CLASSIFIED CANADA
Series 2000 Treadmill
409110-004
Part Number
45023-212
45000-710
700337-002
410686-001
410686-002
410748-001
410746-001
45000-405
4533-201
4533-202
4531-410
4535-102
410114-003
58520-004
4518-808
4520-910
57071-007
4520-010
408714-003
4851-069
408230-009
408230-010
Qty
4
4
1
13
14
0.06
2
2
1
3
1
7
0
1
2
4
2
4
4
0.10
1
1
5A-9
Parts Lists and Drawings for Configuration without CE: Treadmill Assembly 900367-001T
1 of 4
1
109
Tension to 1/2%
77
54
8 PL
900433-001 Ref
103 2 PL
104
4 PL
102
4 PL
105 4 PL
900433-001 Ref
Tension belt 45 LBS. - 55 LBS.
28
61 3 PL
16
47
3 PL
8
90 6 PL
13
90 8 PL
52 2 PL
59
12
2 PL
900433-001 Ref
408907-002 Ref 14
20
18 Ref
64 2 PL
9
67 2 PL
86 4 PL
72 2 PL
Flush or below
inside surface
36
56 2 PL
20
76
30 2 PL
10 PL
408907-001 Ref
3 2 PL
5A-10
Series 2000 Treadmill
409110-004
Revision D
Parts Lists and Drawings for Configuration without CE: Treadmill Assembly 900367-001T
2 of 4
89 2 PL
69 4 PL
4117929-003 Ref
See note
34 below
73 4 PL
23
27 8 PL
31 2 PL
81 -001
66 -002
410465-005 Ref
51 2 PL
94
2 PL
58 2 PL
50
54 4 PL
68 9 PL
89 4 PL
6 PL 62
82
38
100
4
44
106
See view B
98 7 PL
93 2 PL
74 4 PL
Assy to outside 57 7 PL
corners
87 4 PL
15
As REQD 83
26 12 PL
83
89 3 PL
48
40
1 PL 45
As REQD 83
101
37
17
41
84 2 PL
See View A
19
78
See Wire Chart
39
24
22
6 E4
89 4 PL
25 Ref
61 8 PL
85 8 PL
35
2 PL
21
29 2 PL
43 or 111
42
18 E3
11 2 PL
35 2 PL
61 8 PL
57
53 2 PL
2 8 PL
58 4 PL
63 2 PL
80 -001
108 -002
62 4 PL
60 2 PL
7 2 PL
51 4 PL
32 2 PL
70 As Req'd
91 2 PL As Req'd
Note:
1. Mark Label Item No. 34:
1. ST. Line: T2000 Treadmill
2. ND. Line: Serial Number T.B.D.
2. Locate Label per 900418-101/102.
75 2 PL
71
Revision D
10
Series 2000 Treadmill
409110-004
43 + 4 FT. -LBS
2 PL
5A-11
Parts Lists and Drawings for Configuration without CE: Treadmill Assembly 900367-001T
3 of 4
55 2 PL
65 4 PL
33 2 PL
25
79
W1
To J8
View A
Lead ITEM
Ident. NO.
W5
W1
W2
W3
W4
W6-1
W6-2
W6-3
W6-4
W6-5
W7-1
W7-2
W7-3
W8
W9
W10
78
79
80
88
6
44
44
44
6
44
44
44
44
4
107
108
From
To
Circuit
ITEM
Circuit
ITEM
Point
NO.
Point
NO.
–––
78
J7
81, 66
S2, S3
33
J8
81, 66
E2
81
E3
18
J5
81
J10
5
MOTOR
6
J12
81, 66
CNTRL-1
96
MOTOR-1
6
CNTRL-2
96
MOTOR-2
6
CNTRL-3
96
MOTOR-3
6
CNTRL-BLU 95 CNTRL-BLU
6
CNTRL-GND 97
E4
6
BLK-L1
44 L1-MTR 20A 81, 66
BLK-L2
44 L2-MTR 20A 81, 66
ORG-GND
44
GND
81, 66
MOTOR
4
J6
81, 66
J5
66
J10
44
E2
66
E3
18
View B
100
5A-12
Series 2000 Treadmill
409110-004
Revision D
Series 2000 Treadmill
409110-004
E3
IT. 18
CASTING
E1
S1
P2
-4
I/0 SWITCH
408759-001
Y-WHT
X-BLK
W10 (900367-002)
E2
IT. 66, 81
ELECT. BOX
W2 (900367-001)
POWER INLET
408935-001
G-GRN/Y
408935-002 (900367-002)
-2
LINE
-1
W1 700338-002
LOWER LIMIT
(CLOSEST TO IT. 25 PLATE)
J5
J8
800334-003
PCB AC
POWER
MOTOR 20A
J12
W1 700338-002
LINE-2
LINE-1
W6 GREENFIELD CABLE
SUPPLIED W/CNTROL. BOX
BLK-3
WHT-1
NC
N0
GRN-2
N0
408918-001
LIMIT SWITCH
S3
S2
W3 700337-002 W9 700337-003
(900367-001)
(900367-002)
NC
RED-4
BRN
BLU
408933-002
(900367-002 ONLY)
W7 SUPPLIED W/CONTR. BOX
-2
LOAD
-1
900367-002 ONLY
AC LINE
FILTER
409348-001
W8 PART OF MTR. IT. 4
IT. 4
ELEV.
MOTOR
(900367-002 ONLY)
BRN
408935-001 (900367-001)
P1
-3
BLK
BLK
ORN
408934-001
(900367-001 ONLY)
IT. 44.5
CONTROL BOX
Revision D
BLU
408933-002
-1
-3
MOTOR CAP
410570-001
700338-001
800320-001
PCB
CONTROL
W4
SUPPLIED W/MOTOR
J9
IT. 6
DRIVE MOTOR
E4
J6
J7
700337-001
W5
5 TURN POT.
Parts Lists and Drawings for Configuration without CE: Treadmill Assembly 900367-001T
4 of 4
5A-13
Parts Lists and Drawings for Configuration without CE: Electronics Box Assembly 900418-101B
Electronics Box Assembly
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
19
20
21
24
25
26
27
28
29
31
32
5A-14
900418-101B
Description
PLUG MC EQUIPOTENTIAL
SWITCH CKT BRKR 240V 20A
PANEL SVC ACCESS TMILL-2000
PANEL RFI/EMI SHIELD 9-PIN D
KIT ELECTRONICS BOX
HARN PWR INPUT OUTLET-FILTER
NUT ESNA 4-40
LABEL SET 2000T ELECTRNCS BOX
CAP MOTOR 10UF 10% 250VAC
GROMMET SNAP-IN 1.31 ID
SCREW SEMS PH 4-40 X 1/4
SCREW SEMS PH 6-32X1/2
SCREW SEMS PH 8-32 X .50L
SCREW PH 6-32X 2 1/2L
SCREW TT PH 6-32X1/4
WASHER FLAT SS #6
WASHER LOCK EXTT #6
NUT HEX KEPS 6-32
TERMINAL FASTON .250M 45 BLADE
WASHER LOCK INTT #6
PCB 2000 TRDML CONTROLLER
PCB T2000 PWR EMI RS232
CLAMP CORD MEDIUM
HARN SWITCH TO PCB/FLTR W/RING
HARN ELEV CAP PCB P6 PIN 1/3
TAPE FOAM URETHANE 1/4X1/2W
SCREW SELF TAPPING 8-32X.32
CABLE CLAMP 7.43LG X .187W
Series 2000 Treadmill
409110-004
Part Number
400040-001
408759-001
408927-001
408928-101
408932-106
408935-001
4521-304
417929-001
410570-001
410666-001
45000-404
45000-608
45000-808
4502-680
45040-604
4520-006
4520-306
4521-706
4534-901
4520-206
800320-001
800334-003
4528-006
408933-002
700338-001
4819-016
45070-612
4535-102
Qty
1
1
1
1
1
1
3
1
1
1
7
4
3
4
6
4
2
2
1
4
1
1
3
1
1
1.33
1
1
Revision D
Parts Lists and Drawings for Configuration without CE: Electronics Box Assembly 900418-101B
10
5 Ref
408932-105
Location of
UID Label
(Ref)
9
Serial Number Label
Ref 404525-001
locate with Bar Code
to outer edge
7 2 PL
25
8 Ref
417929-002
7
4
1
2
31
32
16 4 PL
1
19
12
E1
4 PL
1
15
3
17
17
21
6 PL
14
4 PL
29
4 PL
20
E2
24
19
11 3 PL
6
13 3 PL
"UL" Labels
Ref. 408230-009
408230-010
5
Ref 408932-002
11
4 PL
Revision D
6
6
6
From
Circuit
Point
X-BLK
Y-WHT
G-GR/Y
Item
No
6
6
6
To
Circuit
Point
S1-P2 BLK
S1-P1 WHT
E1 GR/Y
Item
No
2
2
5
27
27
28
28
Line-L2 BRN
Line-L1 BLU
CAP
CAP
25
25
9
9
S1-4 BRN
S1-3 BLU
J6-1
J6-3
2
2
25
25
Lead
Ident
Item
No
W1-1
W1-2
W1-3
W3-1
W3-2
W4-1
W4-2
Series 2000 Treadmill
409110-004
5A-15
Parts Lists and Drawings for Configuration without CE: Stop Switch Assembly 88380-006B
Stop Switch Assembly
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
5A-16
88380-006B
Description
SWITCH SPST NC
ACTUATOR EMER PB
CLAMP EMERGENCY STOP T-2000
SCREW FH 6-32X.38 R
NUT HEX KEPS 4-40
CLAMP CORD MEDIUM
NUT SPRING TYPE T-U 6-32
STUD CPTV PMP 4-40 X 5/16
STRAIN RELIEF 1/2D 5N-4
SCREW BLK PH 6-32 X 3/8
SCREW BLK PH 10-32 X 5/8
NUT HEX ES 10-32
CABLE, 3 COND P/P 10FT
BRACKET EMER SW
COVER REAR EMERGENCY SWITCH
BRACKET SWITCH
LABEL BLANK 2 X 3/4
EMRGNCY STP SWTCH INSTL INS
LABEL CLEAR OVERLAMINATE
Series 2000 Treadmill
409110-004
Part Number
1668-001
1668-101
402183-003
45009-606
4521-704
4528-006
4529-016
4557-003
4582-112
4641-606
4641-910
4644-310
5512-002
56984-001
56985-002
56998-001
404525-001
404061-001
413608-001
Qty
1
1
2
2
1
6
6
1
1
4
1
1
1
1
1
1
1
1
1
Revision D
Parts Lists and Drawings for Configuration without CE: Stop Switch Assembly 88380-006B
2
S1
17 See Note 2
14
19 Apply over Item 17.
9
13 Ref. 10.00 FT
Notes:
P2
7 4 PL
1. Place Items 3, 6, 11, and 12 in a
plastic bag.
2
2. Item #17 to read:
I st Line: (Part number)
2 nd Line: (Lot code)
1
7 2 PL
8
16
E1
5
15
Clear (Sleeve)
4 2 PL
E1
S1
NC
C
Black (Tip)
P2
White (Ring)
SCHEMATIC
10
4 PL
3 2 PL
12
11
Revision D
Series 2000 Treadmill
409110-004
5A-17
Parts Lists and Drawings for Configuration without CE: Stop Switch Assembly 88380-006B
5A-18
Series 2000 Treadmill
409110-004
Revision D
5B
Parts Lists and Drawings for
Configuration with CE
Ordering Parts
......................................................................... 3
Field Replaceable Units for Product Code Y5 w/CE ................................ 4
Revision D
Rev R
Upper-Level Assembly ............................................. 5
900444-00XG
50/60 Hz Full Handle Assembly .................................. 6
900433-001G
Full Handrail Kit..................................................... 6
900367-002T
Treadmill Assembly w/CE ......................................... 7
900418-102B
Electronics Box Assembly w/CE ................................ 14
88380-006B
Stop Switch Assembly ........................................... 16
Series 2000 Treadmill
409110-004
5B-1
5B-2
Series 2000 Treadmill
409110-004
Revision D
Parts Lists and Drawings for Configuration with CE: Ordering Parts
Ordering Parts
Introduction
This chapter contains the current parts lists, drawings, some
schematics, and any kits for the standard treadmill configurations
available at the time of the manual release date. The upper-level parts
list appears first, followed by the assembly parts. The upper-level parts
list specifies all the items that ship with the equipment such as upgrade
kits, software disks, power cords, and manuals.
These parts lists and drawings supply enough detail for you to order
parts for the assemblies considered field serviceable. See chapter 6 for
component-level drawings and part numbers. To order parts, contact
Service Parts at the address or telephone number on the page, “How to
Reach Us...,” provided at the beginning of the manual.
Revision D
Series 2000 Treadmill
409110-004
5B-3
Parts Lists and Drawings for Configuration with CE: Field Replaceable Units for Product Code Y5 w/CE
Field Replaceable Units for Product Code Y5 w/CE
The following items may not be assigned separate manufacturing part
numbers because they are normally part of a larger assembly. Since they
are considered field replaceable units (FRUs), they have specific service
part numbers so they can be ordered and replaced by service
technicians.
NOTE
Verify part numbers before ordering service
parts. See the tech memo series for this
product for changes or additions to this list.
Table 5B-1. Field Replaceable Units
Item
5B-4
Part Number
WALKING BELT
3602-009
WALKING BOARD
56944-009
DRIVE BELT
408913-001
DRIVE MOTOR 3.0 H.P.
408893-002
DRIVE MOTOR CONTROLLER
408891-002
ELEVATION MOTOR
408890-001
POWER PCB
800334-002
CONTROL PCB
800320-001
CE LABEL
408230-008
EMI E-BOX GROUND WIRE HARNESS W10
411810-003
E-BOX TO CONTROLLER W/CHOKE HARNESS W9
700337-003
SOUND DAMPENER MATERIAL
58520-003
POWER INPUT HARNESS
408935-002
HARNESS SWITCH TO EMI FILTER
408934-001
HARNESS SWITCH TO PCB
408933-002
AC LINE FILTER
409348-001
Series 2000 Treadmill
409110-004
Revision D
Parts Lists and Drawings for Configuration with CE: Upper-Level Assembly Rev R
Upper-Level Assembly
Revision D
Rev R
Item
1
2
3
4
5
7
8
9
10
11
12
23
Description
2000 TRDML W/FULL HNDL DOM
2000 TRDML W/FULL HNDL INTL
2000 TRDML W/EMI FULL HNDL DOM
2000 TRDML W/EMI FULL HNDL INT
CABLE TRDML/CASE INTCON
MTC-1 REHAB/STRESS MPH T2000
MTC-1 REHAB/STRESS KPH T2000
MTC-1 EXER MPH T2000
MTC-1 EXER KPH T2000
MTC-I FIELD SERVICE CE
T2000 FIELD SERVICE
CAB 8P MINI DIN 20FT
Part Number
900444-001
900444-002
900444-003
900444-004
80690-001
9563-501
9563-502
9563-503
9563-504
407143-003
409110-004
400073-001
1
1
1
1
1
1
1
1
1
1
1
1
25
26
27
28
39
40
41
42
43
REWORK 2000 TRDML, W/FULL HNDL
REWORK 2000 TRDML W/FULL HNDL
REWORK T2000 EMI FULL HNDL DOM
REWORK 2000 TRDML W/EMI FH INT
REWORK MTC-1 REHAP/STRESS MPH
RWK MTC-1 REHAB/STRESS KPH
REWORK MTC-1 EXER MPH T2000
RWK MTC-1 EXER KPH T2000
CABLE TREADMILL TO STRESS SYS
900444-001R
900444-002R
900444-003R
900444-004R
9563-501R
9563-502R
9563-503R
9563-504R
700609-001
1
1
1
1
1
1
1
1
1
Series 2000 Treadmill
409110-004
Qty
5B-5
Parts Lists and Drawings for Configuration with CE: 50/60 Hz Full Handle Assembly 900444-00XG
50/60 Hz Full Handle Assembly
Item
1
2
3
4
5
6
7
8
900444-00XG
Description
2000 TRDML W/FULL HNDL DOM
2000 TRDML W/FULL HNDL INTL
2000 TRDML W/EMI FULL HNDL DOM
2000 TRDML W/EMI FULL HNDL INT
2000 TRDML FULL HNDL GERMAN
2000 TRDML W/EMI FULL HNDL GRM
2000 TRDML FULL HNDL SWED
2000 TRDML W/EMI FULL HNDL SWE
Full Handrail Kit
900444-001
900444-002
900444-003
900444-004
900444-005
900444-006
900444-007
900444-008
Qty
0
0
0
0
1
1
1
1
900433-001G
Item
1
2
3
4
10
11
13
19
5B-6
Part Number
Description
SOCKET ALLEN 3/16 HEX
HANDLE-T
SCREW SKT 1/4-20 X 3/4
SCREW SKT 1/4-20 X 1.63
BOX MAILER 11.75L 11.00W 2.88H
KIT TEE HANDLE LH-RH
NUT ESNA 1/4-20
KIT HANDRAIL FULL-PACKAGING
Series 2000 Treadmill
409110-004
Part Number
400056-001
400093-001
407236-001
407236-002
9924-101
408912-003
4521-311
412562-001
Qty
1
1
2
2
2
2
4
1
Revision D
Parts Lists and Drawings for Configuration with CE: Treadmill Assembly w/CE 900367-002T
Treadmill Assembly w/CE
Item
2
3
4
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Revision D
900367-002T
Description
SCREW SKT 1/4-20 X 1.00L
EXTRUSION SIDE RAIL T2000
MOTOR ELEVATION 185-265V .13HP
MOTOR 3HP 4000 RPM DC-QUIET
CLAMP HANDRAIL TERM TO BASE
ROLLER ASSEMBLY FRONT
ROLLER ASSEMBLY REAR
RACK STL 10P 14.5 DEG PRESS
GEAR PINION 11T 10P
BRACKET HEAD TO FRAME
SUPPORT FRAME TO CASTING
WELD FRAME TREADMILL T2000
SPROCKET 25T 5MM P .62 BORE
SPROCKET 90T 5MM P
FLYWHEEL 8.00DIA X 1.00W
BASE HEAD CASTING
TOWER FABRICATION
KIT END CAP LH-RH
ELEVATION BLOCK RH
ELEVATION BLOCK LH
SHROUD TMILL-2000
ENDPLATE ELEVATION BLOCK
ENDPLATE SW MTG ELEVATION BL
SPACER DELRIN TWR MNT
SPACER DELRIN EBOX MNT
BELT DRIVE 5MM P 20MM W
BSHG 1.0 OD X .625 ID X .50 W
FOOT FRAME
FOOT HEAD
PIN DOWEL .2502D X 1.000L
SW LEVER SPST NO 3A 250VAC
LABEL BLANK 2 X 3/4
KEY WOODRUFF 3/16 X 5/8
SCR TRILOBE PH FLTHD #10X.50
TUBE TYGON 3/16ID X 5/16OD
REAR PANEL TREADMILL 2000
SHAFT ELEVATION
COUPLING ISOLATION ELE MTR
PANEL POT ISO FROM TOWER
Series 2000 Treadmill
409110-004
Part Number
407236-003
413690-001
408890-001
408893-002
408894-001
408895-001
408896-001
408897-001
408898-001
408899-001
408900-001
413689-001
408902-001
408903-001
408904-001
408905-001
408906-002
408907-003
408908-001
408908-002
408909-001
408910-001
408910-002
408911-001
408911-002
408913-001
408914-001
408915-001
408915-002
408916-001
408918-001
404525-001
408920-001
408921-001
408922-001
408924-001
408925-001
408926-101
408929-001
Qty
8
2
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
12
8
1
2
2
2
2
2
1
2
10
0.06
1
1
1
1
5B-7
Parts Lists and Drawings for Configuration with CE: Treadmill Assembly w/CE 900367-002T
Item
42
43
44
45
47
48
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
82
83
84
85
86
87
5B-8
Description
BRKT DRIVE MTR MOUNTING
LABEL 2000T SHROUD
CONTROL BOX DRIVE MOTOR CE MRK
KEY 3/16 X 3/16 X 7/16
SCREW GR8 1/4-20 X .88
STUD FULL THREAD GR
SCREW HX G8 5/16X1.5
SCR HEX HD 5/16-18 X 2.00
SCREW GR 8 3/8-16 X 3/4LONG
SCREW GR8 1/2-13X 3
SCREW SKT 82FLH 1/4-20X1.25BLK
SCREW PH 4-40X 1 1/4L
SCREW HEX HD 3/8-16X3.50L BLK
SCREW SELF TAPPING 8-32X.32
WASHER FLAT STL 5/16
WASHER SPLIT BLACK .375 I.D.
WASHER FLAT STL 1/2
WASHER LK SR STL 1/4
WASHER LK SR STL5/16
WASHER LK SR STL 1/2
WASHER FLAT HDN 3/8
WASHER FLAT SS #4
ASSY ELECTRONICS BOX EMI/RFI
TREAD RUBBER W/HOLE
SCREW PH GREY W/WSHR 8-32X.38L
NUT HEX ESNA 10-24
ADHESIVE,BLACK MAX
RACK STL 10P 14.5DEG W/O NOTCH
NUT JAM 3/4-10 UNC
WASHER BELLEVILLE .56X.19X.028
DAMPENER SOUND 3.00LG TRDML
WHEEL 3.25OD
GREASE LUBRIPLATE
BOARD WALKING W/WAX
HARN ELEV POT TO PCB P7
HARN ELEV LIMIT SW TO PCB P8
WSHR FL STL.321IDX1.06ODX.105
CEMENT LOCTITE 242
SCREW SEMS PH 6-32X1/2
SCREW GRB 1/4-20 X .62
1/4-20X5/8 SKTCAP SCREW W/NYL
SCREW SEMS PH 1/4-20 .625L
Series 2000 Treadmill
409110-004
Part Number
408931-001
410465-001
408891-002
410625-001
45002-114
411746-001
45002-224
45002-549
45002-312
45002-548
45019-120
4502-440
45027-362
45070-612
45076-012
45090-001
45076-015
45076-111
45076-112
45076-115
45076-213
4520-004
900418-102
408888-001
45021-806
4521-310
4851-058
408897-002
4546-003
4550-031
58520-003
4704-001
4850-017
56944-009
700337-001
700338-002
45053-002
4851-003
45000-608
45002-110
45023-212
45000-710
Qty
1
1
1
1
3
3
6
2
2
2
12
2
2
8
6
2
2
19
10
2
2
4
1
2
13
4
0.01
1
2
4
4
2
0
1
1
1
6
0
2
8
4
4
Revision D
Parts Lists and Drawings for Configuration with CE: Treadmill Assembly w/CE 900367-002T
Item
89
90
91
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
112
113
Revision D
Description
NUT 5/16-18 FLANGED LOCKING
SCREW HEX 5/16-18 FLANGED LK
GREASE SYNTHETIC WITH TEFLON
BUMPER PLASTIC 1.00 OD
SCREW SEMS PH PHIL 4-40 X.312L
SPLICE CE 22-14
SPLICE CE 16-10
TERMINAL INS RING#10
CABLE CLAMP 7.43LG X .187W
CODE T2000 V001E
DAMPENER SOUND 5.00 X 7.00
SCREW SET CPP 8-32X1/4
WASHER LOCK SPLIT #10
SHIELD PINCH POINT 2000
WASHER FLAT SS #10
SCREW PH WOOD #10 X .62L
ADHESIVE LOCKTITE 262
HARN EBOX TO CNTLR W/CHOKE
ASSY T2000 EMI E-BOX GRND
BELT WALKING T2000 EMI
LABEL CE MARK
LABEL UL CLASSIFIED
LABEL UL CLASSIFIED CANADA
Series 2000 Treadmill
409110-004
Part Number
410686-001
410686-002
410748-001
410746-001
45000-405
4533-201
4533-202
4531-410
4535-102
410114-003
58520-004
4518-808
4520-910
57071-007
4520-010
408714-003
4851-069
700337-003
411810-003
3602-009
408230-008
408230-009
408230-010
Qty
13
14
0.06
2
2
1
3
1
7
0
1
2
4
2
4
4
0.10
1
1
1
1
1
1
5B-9
Parts Lists and Drawings for Configuration with CE: Treadmill Assembly w/CE 900367-002T
1 of 4
1
109
Tension to 1/2%
77
54
8 PL
900433-001 Ref
103 2 PL
104
4 PL
102
4 PL
105 4 PL
900433-001 Ref
Tension belt 45 LBS. - 55 LBS.
28
61 3 PL
16
47
3 PL
8
90 6 PL
13
90 8 PL
52 2 PL
59
12
2 PL
900433-001 Ref
408907-002 Ref 14
20
18 Ref
64 2 PL
9
67 2 PL
86 4 PL
72 2 PL
Flush or below
inside surface
36
56 2 PL
20
76
30 2 PL
10 PL
408907-001 Ref
3 2 PL
5B-10
Series 2000 Treadmill
409110-004
Revision D
Parts Lists and Drawings for Configuration with CE: Treadmill Assembly w/CE 900367-002T
2 of 4
89 2 PL
69 4 PL
4117929-003 Ref
See note
34 below
73 4 PL
23
27 8 PL
31 2 PL
81 -001
66 -002
410465-005 Ref
51 2 PL
94
2 PL
58 2 PL
50
54 4 PL
68 9 PL
89 4 PL
6 PL 62
82
38
100
4
44
106
See view B
98 7 PL
93 2 PL
74 4 PL
Assy to outside 57 7 PL
corners
87 4 PL
15
As REQD 83
26 12 PL
83
89 3 PL
48
40
1 PL 45
As REQD 83
101
37
17
41
84 2 PL
See View A
19
78
See Wire Chart
39
24
22
6 E4
89 4 PL
25 Ref
61 8 PL
85 8 PL
35
2 PL
21
29 2 PL
43 or 111
42
18 E3
11 2 PL
35 2 PL
61 8 PL
57
53 2 PL
2 8 PL
58 4 PL
63 2 PL
80 -001
108 -002
62 4 PL
60 2 PL
7 2 PL
51 4 PL
32 2 PL
70 As Req'd
91 2 PL As Req'd
Note:
1. Mark Label Item No. 34:
1. ST. Line: T2000 Treadmill
2. ND. Line: Serial Number T.B.D.
2. Locate Label per 900418-101/102.
75 2 PL
71
Revision D
10
Series 2000 Treadmill
409110-004
43 + 4 FT. -LBS
2 PL
5B-11
Parts Lists and Drawings for Configuration with CE: Treadmill Assembly w/CE 900367-002T
3 of 4
55 2 PL
65 4 PL
33 2 PL
25
79
W1
To J8
View A
Lead ITEM
Ident. NO.
W5
W1
W2
W3
W4
W6-1
W6-2
W6-3
W6-4
W6-5
W7-1
W7-2
W7-3
W8
W9
W10
78
79
80
88
6
44
44
44
6
44
44
44
44
4
107
108
From
To
Circuit
ITEM
Circuit
ITEM
Point
NO.
Point
NO.
–––
78
J7
81, 66
S2, S3
33
J8
81, 66
E2
81
E3
18
J5
81
J10
5
MOTOR
6
J12
81, 66
CNTRL-1
96
MOTOR-1
6
CNTRL-2
96
MOTOR-2
6
CNTRL-3
96
MOTOR-3
6
CNTRL-BLU 95 CNTRL-BLU
6
CNTRL-GND 97
E4
6
BLK-L1
44 L1-MTR 20A 81, 66
BLK-L2
44 L2-MTR 20A 81, 66
ORG-GND
44
GND
81, 66
MOTOR
4
J6
81, 66
J5
66
J10
44
E2
66
E3
18
View B
100
5B-12
Series 2000 Treadmill
409110-004
Revision D
Series 2000 Treadmill
409110-004
E3
IT. 18
CASTING
E1
S1
P2
-4
I/0 SWITCH
408759-001
Y-WHT
X-BLK
W10 (900367-002)
E2
IT. 66, 81
ELECT. BOX
W2 (900367-001)
POWER INLET
408935-001
G-GRN/Y
408935-002 (900367-002)
-2
LINE
-1
W1 700338-002
LOWER LIMIT
(CLOSEST TO IT. 25 PLATE)
J5
J8
800334-003
PCB AC
POWER
MOTOR 20A
J12
W1 700338-002
LINE-2
LINE-1
W6 GREENFIELD CABLE
SUPPLIED W/CNTROL. BOX
BLK-3
WHT-1
NC
N0
GRN-2
N0
408918-001
LIMIT SWITCH
S3
S2
W3 700337-002 W9 700337-003
(900367-001)
(900367-002)
NC
RED-4
BRN
BLU
408933-002
(900367-002 ONLY)
W7 SUPPLIED W/CONTR. BOX
-2
LOAD
-1
900367-002 ONLY
AC LINE
FILTER
409348-001
W8 PART OF MTR. IT. 4
IT. 4
ELEV.
MOTOR
(900367-002 ONLY)
BRN
408935-001 (900367-001)
P1
-3
BLK
BLK
ORN
408934-001
(900367-001 ONLY)
IT. 44.5
CONTROL BOX
Revision D
BLU
408933-002
-1
-3
MOTOR CAP
410570-001
700338-001
800320-001
PCB
CONTROL
W4
SUPPLIED W/MOTOR
J9
IT. 6
DRIVE MOTOR
E4
J6
J7
700337-001
W5
5 TURN POT.
Parts Lists and Drawings for Configuration with CE: Treadmill Assembly w/CE 900367-002T
4 of 4
5B-13
Parts Lists and Drawings for Configuration with CE: Electronics Box Assembly w/CE 900418-102B
Electronics Box Assembly w/CE
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
30
31
32
5B-14
900418-102B
Description
PLUG MC EQUIPOTENTIAL
SWITCH CKT BRKR 240V 20A
PANEL SVC ACCESS TMILL-2000
PANEL RFI/EMI SHIELD 9-PIN D
KIT ELECTRONICS BOX
HARN PWR INPUT W/CHOKE TO FLTR
AC LINE FILTER 250V 20A
LABEL SET 2000T ELECTRNCS BOX
CAP MOTOR 10UF 10% 250VAC
GROMMET SNAP-IN 1.31 ID
SCREW SEMS PH 4-40 X 1/4
SCREW SEMS PH 6-32X1/2
SCREW SEMS PH 8-32 X .50L
SCREW PH 6-32X 2 1/2L
SCREW TT PH 6-32X1/4
WASHER FLAT SS #6
WASHER LOCK EXTT #6
NUT ESNA 4-40
NUT HEX KEPS 6-32
TERMINAL FASTON .250M 45 BLADE
RIVET BLIND 5/32 0-.250
WASHER LOCK INTT #6
CLAMP CORD MEDIUM
PCB 2000 TRDML CONTROLLER
PCB T2000 PWR EMI RS232
HARN SWITCH TO EMI FILTER
HARN SWITCH TO PCB/FLTR W/RING
HARN ELEV CAP PCB P6 PIN 1/3
TAPE FOAM URETHANE 1/4X1/2W
SCREW SELF TAPPING 8-32X.32
CABLE CLAMP 7.43LG X .187W
Series 2000 Treadmill
409110-004
Part Number
400040-001
408759-001
408927-001
408928-101
408932-106
408935-002
409348-001
417929-001
410570-001
410666-001
45000-404
45000-608
45000-808
4502-680
45040-604
4520-006
4520-306
4521-304
4521-706
4534-901
4590-154
4520-206
4528-006
800320-001
800334-003
408934-001
408933-002
700338-001
4819-016
45070-612
4535-102
Qty
1
1
1
1
1
1
1
1
1
1
7
4
3
4
6
4
2
3
2
1
2
4
3
1
1
1
1
1
1.33
1
1
Revision D
Parts Lists and Drawings for Configuration with CE: Electronics Box Assembly w/CE 900418-102B
10
5 Ref
408932-105
Location of
UID Label
(Ref)
9
Serial Number Label
Ref 404525-001
locate with Bar Code
to outer edge
18 2 PL
25
8 Ref
417929-002
18
4
1
4
16 4 PL
2
31
32
19
12
4 PL
AD
LO
15
22
6 PL
14
3
17
30
A
E er
M1
E1
17
ovo
Filt
er
x
4 PL
E
LIN
4 PL
-1
24
E2
-2
7
19
20
11 3 PL
6
13 3 PL
21 2 PL
"UL" Labels
"CE" Label location.
(Ref. 408230-009) (Ref. 408230-008)
408230-010
5
Ref 408932-002
10
4 PL
Revision D
Lead
Ident
Item
No
W1-1
W1-2
W1-3
W2-1
W2-2
W3-1
W3-2
W4-1
W4-2
6
6
6
26
26
27
27
28
28
From
Circuit
Point
X-BLK
Y-WHT
G-GR/Y
Line-L2
Line-L1
Line-L1 BLU
Line-L2 BRN
CAP
CAP
Series 2000 Treadmill
409110-004
Item
No
6
6
6
7
7
25
25
9
9
To
Circuit
Point
S1-P2 BLK
S1-P1 WHT
E1 GR/Y
S1-3 BLU
S1-4 BRN
Load - 1
Load - 2
J6-1
J6-3
Item
No
2
2
5
2
2
7
7
25
25
5B-15
Parts Lists and Drawings for Configuration with CE: Stop Switch Assembly 88380-006B
Stop Switch Assembly
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
5B-16
88380-006B
Description
SWITCH SPST NC
ACTUATOR EMER PB
CLAMP EMERGENCY STOP T-2000
SCREW FH 6-32X.38 R
NUT HEX KEPS 4-40
CLAMP CORD MEDIUM
NUT SPRING TYPE T-U 6-32
STUD CPTV PMP 4-40 X 5/16
STRAIN RELIEF 1/2D 5N-4
SCREW BLK PH 6-32 X 3/8
SCREW BLK PH 10-32 X 5/8
NUT HEX ES 10-32
CABLE, 3 COND P/P 10FT
BRACKET EMER SW
COVER REAR EMERGENCY SWITCH
BRACKET SWITCH
LABEL BLANK 2 X 3/4
EMRGNCY STP SWTCH INSTL INS
LABEL CLEAR OVERLAMINATE
Series 2000 Treadmill
409110-004
Part Number
1668-001
1668-101
402183-003
45009-606
4521-704
4528-006
4529-016
4557-003
4582-112
4641-606
4641-910
4644-310
5512-002
56984-001
56985-002
56998-001
404525-001
404061-001
413608-001
Qty
1
1
2
2
1
6
6
1
1
4
1
1
1
1
1
1
1
1
1
Revision D
Parts Lists and Drawings for Configuration with CE: Stop Switch Assembly 88380-006B
2
S1
17 See Note 2
14
19 Apply over Item 17.
9
13 Ref. 10.00 FT
Notes:
P2
7 4 PL
1. Place Items 3, 6, 11, and 12 in a
plastic bag.
2
2. Item #17 to read:
I st Line: (Part number)
2 nd Line: (Lot code)
1
7 2 PL
8
16
E1
5
15
Clear (Sleeve)
4 2 PL
E1
S1
NC
C
Black (Tip)
P2
White (Ring)
SCHEMATIC
10
4 PL
3 2 PL
12
11
Revision D
Series 2000 Treadmill
409110-004
5B-17
Parts Lists and Drawings for Configuration with CE: Stop Switch Assembly 88380-006B
5B-18
Series 2000 Treadmill
409110-004
Revision D
6
PCB Assemblies
800320-001H
Control PCB .......................................................... 3
SD800320-001G Control PCB Schematic ............................................ 6
800334-003A
Power PCB ......................................................... 12
SD800334-003A Power PCB Schematic ........................................... 16
Revision D
Series 2000 Treadmill
409110-004
6-1
6-2
Series 2000 Treadmill
409110-004
Revision D
PCB Assemblies: Control PCB 800320-001H
Control PCB
800320-001H
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
21
22
23
24
25
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Revision D
Description
RES SM CER 100 5% 1/8W
RES SM CER 10K 5% 1/8W
RES SM CHIP 68K 5% 1/8W
RES SM CER 100K 1% 1/8W
RES SM CER 4.99K 1% 1/8W
RES SM CER 1K 1% 1/8W
RES SM CER 10.0K 1% 1/8W
RES SM CHIP 47.5K 1% 1/8W
RES SM CHIP 15K 1% 1/8W
RES SM CHIP 499 1% 1/8W
RES SM CER 39.2K 1% 1/8W
RES SM CER 32.4K 1% 1/8W
CAP SM TANT 47UF 20% 10V
CAP SM CER COG .01UF 5% 50V
CAP SM CER COG 220PF 5% 100V
CAP SM CER COG 470PF 5% 100V
CAP SM CER X7R .33UF 20% 50V
CAP SM CER X7R .1UF 50V
CRYSTAL SM 12.000MHZ MA506
DIODE SM SERIES PR D7000
DIODE SM REF LM385 1.2V SO-8
TRANSISTOR SM PNP T3906
IC SM RS232 5RCV/3DRV LT1133
IC SM HC 74HC14
IC FLAT PACK VOLT CONV 7660CSA
IC SM OP AMP LM358
IC MICROCOMPUTER CMOS PD78310
IC SM PWR MONITOR DS1232S
IC SM CMOS RAM 62256FLP
IC SM EPROM X28C64 32PLCC
IC SM HC 74HC573
CAP SM TANT 1.0UF 10% 35V
DIODE ZENER SM 16.8V
IC SM CMOS 4053
IC SM AMPL L2726 SOL20
CAP SM TANT 10UF 10% 35V
DIODE ZENER SM 5V1
CONN HDR SM B/ENTRY 50P .1X.1
PAL T2000 78310 DECODE V2.0
Series 2000 Treadmill
409110-004
Part Number
1081-101
1081-103
1081-491
1082-100
1082-101
1082-103
1082-104
1082-757
1082-857
1082-867
1082-881
1082-324
405585-001
1181-103
1181-221
1181-471
1186-334
1187-104
413773-001
2013-201
2015-386
2511-101
3023-133
3038-014
3142-002
3144-358
3155-004
3168-001
3202-256
400626-002
401971-001
403907-001
403937-001
404002-001
404495-001
406884-013
406918-001
409056-001
410113-002
Qty
22
14
1
8
2
6
1
10
2
1
1
1
4
1
1
22
14
3
1
4
1
1
1
1
1
2
1
1
1
1
1
3
4
1
1
7
0
1
1
6-3
PCB Assemblies: Control PCB 800320-001H
Item
42
43
44
45
46
47
48
6-4
Description
IC SM TEMP SENSOR LM35DM
CKT BD 2000 TRDMILL CONTROL
SCHEM 2000 TREADMILL CONTROL
RES SM CHIP 300 5% 1/8W
CAP SM CER COG 22PF 5% 100V
BEAD SM 1206 600@100 200MA
CAP SM CER Z5U .47UF 20% 50V
Series 2000 Treadmill
409110-004
Part Number
410121-001
800321-001
SD800320-001
1081-497
1181-220
408746-001
407860-001
Qty
1
1
0
1
2
2
1
Revision D
PCB Assemblies: Control PCB 800320-001H
Install Capacitor C59
diagonally across
Pins 1 & 3 of CR6
CR6 not installed
Revision D
Series 2000 Treadmill
409110-004
6-5
PCB Assemblies: Control PCB Schematic SD800320-001G
Control PCB Schematic
SD800320-001G
1 of 3
6-6
Series 2000 Treadmill
409110-004
Revision D
PCB Assemblies: Control PCB Schematic SD800320-001G
Revision D
Series 2000 Treadmill
409110-004
6-7
PCB Assemblies: Control PCB Schematic SD800320-001G
2 of 3
6-8
Series 2000 Treadmill
409110-004
Revision D
PCB Assemblies: Control PCB Schematic SD800320-001G
Revision D
Series 2000 Treadmill
409110-004
6-9
PCB Assemblies: Control PCB Schematic SD800320-001G
3 of 3
6-10
Series 2000 Treadmill
409110-004
Revision D
PCB Assemblies: Control PCB Schematic SD800320-001G
Revision D
Series 2000 Treadmill
409110-004
6-11
PCB Assemblies: Power PCB 800334-003A
Power PCB
800334-003A
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
6-12
Description
10M 0,33W<250PPM VR25
RES COMP 10 5% 1/2W
RES MINI MF 47.5 1% 1/4W
RES MINI MF 100 1% 1/4W
RES MINI MF 499 1% 1/4W
RES MINI MF 750 1% 1/4W
RES MINI MF 2.49K 1% 1/4W
RES MINI MF 3.01K 1% 1/4W
RES MINI MF 3.92K 1% 1/4W
RES MINI MF 10.0K 1% 1/4W
RES MINI MF 10.5K OHMS 1% 1/4W
RES MINI MF 20.0K 1% 1/4W
RES MINI MF 100K 1% 1/4W
RES MINI MF 750K 1% 1/4W
RES MINI MF 1M 1% 1/4W
VARISTOR 250VAC V250LA20A
CAP CER RAM .33UF 50V +80/-20%
CAP TANT 1.0UF 10% 35V
CAP TANT 10UF 10% 35V
CAP TANT 22UF 10% 35V
CAP AL R 1000UF 20% 50V
CAP AL R 330UF 20% 25V
CAP CER COG 470PF 10% 50V
CAP CER COG 4700PF 10% 50V
CAP CER X7R .01UF 10% 50V
CAP CER X7R .1UF 10% 50V
CAP CER COG .001UF AX 5% 50V
CAP CER Z5U .1UF +80/–20% 50V
XFMR PWR ISO UL2601 7V 185-265
IND CHOKE 47UH 4.0A
SPEAKER 8 OHM .2W
HLDR FUSE 3AG HORIZ PC MT
JACK 1/4 PH 3 COND R ANGLE PCB
POST .025SQ .320H
CONN PC PIN HEADER MR 4M
CONN PC PIN HEADER MR 12M
CONN 90 RIB EJCTR - 16P
HEADER MTA-156 W/LOCKS VERT 3P
HDR MTA .100CTR W/LOCKS 8P
CONN MINI CIR DIN PC MT 8P
Series 2000 Treadmill
409110-004
Part Number
100/21012/106
1002-100
1023-065
1023-096
1023-162
1023-179
1023-229
1023-237
1023-248
1023-287
1023-289
1023-316
1023-383
1023-467
1023-479
1075-250
1110-334
1224-105
1224-106
1224-226
1253-102
1259-331
1281-471
1281-472
1282-103
1282-104
1283-102
1287-104
1401-221
1441-014
1663-004
1740-101
1769-101
1778-604
1785-504
1785-512
1824-016
1850-103
1868-208
1876-402
Qty
6
2
2
2
3
9
2
2
2
14
1
2
4
1
2
1
7
2
2
1
1
2
2
1
2
4
7
5
1
2
1
2
1
2
1
1
1
1
1
1
Revision D
PCB Assemblies: Power PCB 800334-003A
Item
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
Revision D
Description
FUSE 3AG 1/2A SB
PROTECTOR CURRENT PTC 500 mA
DIODE ZENER 500mW 5.1V 1N751A
DIODE ZENER 500MW 5.6V 1N752A
DIODE ZENER 18V 500MW 1N967B
DIODE 500W TVS505
DIODE LL FDH300
DIODE SCHOTTKY 3A 40V 1N5822
DIODE REC 1A 400V 1N4004
TRANSISTOR NTWK DARL NPN 2003A
TRANSISTOR PNP MPS-A56
HEATSINK EXTRUDED W/PINS
IC CMOS 4538
IC HCMOS 74HC05
IC HCMOS 74HC14
IC AMPL DIP LM358
IC SW REG LT1074CT
IC OPTOCOUPLER CNW136
INSULATOR SILICONE TO-220
CAP AL RAD 10000UF +/-20% 50V
FILTER EMI 50VDC
RELAY 5A 1NO/1NC 5V PCB
CAP CER DHR12 470PF 20% 7.5KV
THERMISTOR NTC 10 OHM 5 AMP
CAP MPE .047UF 20% 250VAC
INDUCTOR TOROID 300UH 20A RMS
FUSE CLIP 13/32 DIA FUSE PCB
CONN RCPT D RA 94V 9P W/RIVETS
SPACER XFMR POWER BOARD
HEADER 50P 0.500 STANDOFF
CAP MPE 0.068UF 20% 250VAC
FUSE 13/32 KTK-15 FAST
CHOKE COMMON MODE LINE 9A
IC DIP 485/232 XCVR LTC1334CNW
SCREW SEMS PH 6-32 X 1/4
SCREW PH 4-40 X 3/8
TERMINAL PWR LUG 10P
NUT HEX KEPS 4-40
TIE WRAP 8.00LG X .187W
SPACER M/F 4-40 X 0.50
CKT BD T2000 PWR EMI RS232
SCH T2000 TMIL PWREMI RS232
SCREW SEMS PH 6-32X1/4
Series 2000 Treadmill
409110-004
Part Number
1910-012
1913-050
2000-751
2000-752
2000-967
2002-505
2003-001
2050-822
2401-100
2599-001
2652-002
2812-120
3001-538
3019-005
3019-014
3102-358
3129-074
3151-036
3961-002
400079-001
402151-001
404549-002
405282-001
406067-002
406247-001
408116-001
408282-001
408845-001
408923-001
410162-001
410406-001
411682-001
415494-001
417042-001
45000-604
4502-412
45139-001
4521-704
4535-002
4656-408
800335-003
SD800334-003
45000-604
Qty
2
3
14
2
8
3
6
6
1
1
2
2
1
1
1
1
2
3
2
2
1
4
1
1
2
2
4
2
1
1
4
2
1
1
5
2
5
6
2
4
1
0
5
6-13
PCB Assemblies: Power PCB 800334-003A
Component (Top) Side View
6-14
Series 2000 Treadmill
409110-004
Revision D
PCB Assemblies: Power PCB 800334-003A
Revision D
Series 2000 Treadmill
409110-004
6-15
PCB Assemblies: Power PCB Schematic SD800334-003A
Power PCB Schematic
SD800334-003A
1 of 3
6-16
Series 2000 Treadmill
409110-004
Revision D
PCB Assemblies: Power PCB Schematic SD800334-003A
Revision D
Series 2000 Treadmill
409110-004
6-17
PCB Assemblies: Power PCB Schematic SD800334-003A
2 of 3
6-18
Series 2000 Treadmill
409110-004
Revision D
PCB Assemblies: Power PCB Schematic SD800334-003A
Revision D
Series 2000 Treadmill
409110-004
6-19
PCB Assemblies: Power PCB Schematic SD800334-003A
3 of 3
6-20
Series 2000 Treadmill
409110-004
Revision D
PCB Assemblies: Power PCB Schematic SD800334-003A
Revision D
Series 2000 Treadmill
409110-004
6-21
PCB Assemblies: Power PCB Schematic SD800334-003A
6-22
Series 2000 Treadmill
409110-004
Revision D
A
Appendix A:
Abbreviations
Standard Abbreviations ................................................................. 3
Revision D
Series 2000 Treadmill
409110-004
A-1
A-2
Series 2000 Treadmill
409110-004
Revision D
Standard Abbreviations
A
A
A-ang
A-arh
A-coa
A-hyp
A1 - A4
AAMI
ABP
ac, AC
ACLS
A/D
Adj
AG
Ah
AHA
Al
AllRam
AllSec
AllTrk
ALT
Alt-Off
am, AM
AM-1
AM-1M
AM-2
AM-3
AM-4
amp
Ampl
AMU
ANA
ANLG
AnsrTone
A/O
ASCII
ASSY
Attn
AUG
AUST
AUSTRALN
Auto
AutoRhym
AUX
aVF
avg
aVL
Revision D
ampere
antianginal
antiarrhythmic
anticoagulants
antihypertensive
auxiliary leadwires
American Association of Medical
Instrumentation
ambulatory blood pressure
alternating current
Advanced Cardiac Life Support
analog-to-digital
adjustable
automotive glass
ampere hours
American Heart Association
aluminum
all RAM
all sector
all track
alternate
alternate offset
acquisition module, ante meridiem
acquisition module-1
acquisition module-1 modified
acquisition module-2
acquisition module-3
acquisition module-4
ampere
amplifier
ambulatory monitoring unit
analog
analog
answer tone
Analog Output
American Standard Code for Information
Interchange
assembly
attention
August
Australian
Australian
automatic
automatic rhythm
auxiliary
augmented left leg lead
average
augmented left arm lead
aVR
AWG
augmented right arm lead
American Wire Gage
B
Bd
BDGH
BetaB
BKSP
BLK
BLU
Blvd
BP
BPM
BRIT
BRN
BSI
Btu
board, baud
binding head
beta blockers
backspace
black
blue
boulevard
blood pressure
beats per minute
Britain
brown
British Standards Institute
British thermal unit
C
CalcBlk
CAPOC
CASE
Catoprl
Cauc
Cer
CFM
CGR
Ch, CH
C/L
CLK
Clonid
cm
cm2
Cmd
CMMR
CMOS
c/o
COM1
COM2
ComLink
Comp
Confrmd
Cont, CONT
Coumadn
CPR
CPU
CR
Series 2000 Treadmill
409110-004
calcium blockers
Computer Assisted Practice of
Cardiology
Computer Aided System for Exercise
Catopril
Caucasian
ceramic
cubic feet/minute
computer graphic record
channel
center line
clock signal
Clonidine
centimeter
square centimeters
command number
common mode rejection ratio
complementary metal-oxide
semiconductor
in care of
communications port 1
communications port 2
communications link
composition
confirmed
Continental, continued
Coumadin
cardiopulmonary resuscitation
central processing unit
diode
A-3
CRC
CRD
crt, CRT
CSA
CTRL
cyclic redundancy check
cord
cathode ray tube
Canadian Standards Association
control
EPLD
EPROM
ESD
etc, etc.
EURO
EXP
D
D/A
DA
dac, DAC
DAN
Dat/Tim
dBm
dc, DC
DD
DDD
DEC
Del
DEMO
DES
DevId
Diag
Digital
Digitox
Digox
Digoxin
DIP
Dirctry
Diurt
DOB
DOS
DP
DPST
DRAM
DR/DT
DSKTP
Dysopyr
digital to analog
damping relay
digital-to-analog converter
Danish
date/time
decibel (referenced to 1 milliwatt into
600 ohms)
direct current
double density, day
Digital Diagnostic Diskette
Digital Equipment Corporation,
December
delete
demonstration
designation
device identification
diagnostic
Digitalis
Digitoxin
digoxin
Digoxin-Lanoxin
dual in-line package
directory
diuretics
date of birth
disk operating system
diametral pitch
double-pole, single-throw
dynamic RAM
digital recording/digital transmission
desktop
Dysopyramide
E
E
ecg, Ecg, ECG
ECO
EDIC
EEPROM
e.g.
EGA
EMF
EMI
ENG
EOF
EPIC
A-4
enable, vector electrode site, vector lead
electrocardiogram
Engineering Change Order
Electrocardiograph Digital Information
Center
electrically erasable programmable ROM
for example
enhanced graphics adapter
electromotive force
electromagnetic interference
English
end of file
Electronic Patient Information Chart
electrically programmable logic device
eraseable, programmable, read-only
memory
electrostatic discharge
et cetera
Europe, European
Expanded
F
F
F1-F5
Fax
FCC
FE
FILH
FLH
FLRAM
FR
FrntEnd
FSK
ft
Furosem
fuse, Farad, female
function keys 1 through 5
facsimile
Federal Communications Commission
front end
fillister head
flat head
flash RAM
French
front end
frequency shift keying
foot, feet
Furosemide
G
g
GB
GERM
GND
GRN
GRY
gram, acceleration due to gravity
Great Britain
German, Germany
ground, digital ground (dc common)
green
gray
H
H
HDLC
Hex, HEX
HH
HiRes
Hr
Hydral
Hz
high, vector electrode site, vector lead
high-level data link control
hexagon, hexadecimal
hour
high-resolution
hour
Hydralazine
Hertz (cycles per second)
I
I
I, II, III
IC
ID
i.e.
IEC
in
IN
inc, inc., INC
Info
Ins
Series 2000 Treadmill
409110-004
on, input, vector electrode site
limb leads
integrated circuit
identification
that is
International Electrotechnical Commission
inch
input
incorporated
information
insert
Revision D
I/O
I/P
ISA
Isosorb
IT
input/output
input
industry standard architecture
Isosorbide
Italian, Italy
Misc
mm
MM
MMM
mm/mV
mm/s
MMS
Modem
MOS
MPE
ms
MS-DOS
MTBF
mtg
MTR
MUSE
J
JAN
JIS
January
Japan Industrial Standards
K
k, K
Kb, KB
kg, Kg
kHz, KHz
kV, KV
Kyb
kilo, 1000, 1024
kilobyte
kilogram
kilohertz
kilovolt
keyboard
mux
mV
mVR
L
L
L1
L2
LA
lb
LCD
Lcl Line
Ld Grps
LED
LH
Lidoca
LL
Loc
LocPc
LogRetry
Ltd
line
level one
level two
left arm
pound
liquid crystal display
local line
lead groups
light-emitting diode
left hand
Lidocaine
left leg
location
Local MAC PC
log retry
limited
N
N
n/a
NA
NC
Nitrate
NLQ
NMI
NMOS
No
NO
norm
nS
NSR
mA
MAC
mains voltage
max
Measure
Med
MEM
MF
MHz
min
Revision D
neutral
not available
not applicable
no connection
nitrates
near letter quality
non-maskable interrupt
N-channel metal-oxide semiconductor
number
normally open
normal
nanoseconds
Normal Sinus Rhythm
O
M
m
M
miscellaneous
millimeter
minute
month
millimeter per millivolt
millimeter per second
Marquette Medical Systems
modulator/demodulator
metal oxide semiconductor
metallized polycarbonate expitaxial
milliseconds
Microsoft Disk Operating System
mean time between failures
mounting
MOTOR
Marquette Universal System for
Electrocardiography
multiplexer
millivolt
minus (inverted) aVR
meter
megabyte, metric, vector electrode site,
vector lead, male
milliamperes
Microcomputer Augmented Cardiograph
voltage of a supply mains between 2 line
conductors of a polyphase system or
voltage between the line conductor and
the neutral of a single-phase system
maximum
measurements
medications
memory
metal film
megahertz
minutes, minimum
O
OE
OEM
OH
OneSec
ORG
Orig
OUT
oz
off, original
other errors
original equipment manufacturer
off-hook relay
one sector
orange
original
output
ounce
P
P
p-p
PA
Params
Passwds
Series 2000 Treadmill
409110-004
P wave (section of the ECG waveform)
peak-to-peak
P wave amplitude
parameters
passwords
A-5
PatData
PatInfo
PATN
PC
PCB
pF
Pgm
PgmId
Phenoth
Phenytn
PID
PLCC
PM
pm, PM
PM-2
PM-3
pn, PN
PNH
PPA
PR
Pro-Off
Procain
PROM
Propran
PSK
PSU
Psych
PUP
PVC
PWM
PWR
PWR CRD
patient data
patient information
patient
printed circuit, personal computer
printed circuit board
picofarad
program
program identification
Phenothiazide
Phenytoin
patient identification digit
plastic leadless chip carrier
power module
post meridiem, preventive maintenance
Power Module-2
Power Module-3
part number
pan head
P wave amplitude
ECG signal interval
progressive offset
Procainamide
programmable read-only memory
Propranolol
phase shift keying
power supply unit
psychotropic
pull-up signal
polyvinyl chloride
pulse-width modulation
power
power cord
Q
Q
QA
QAD
QAM
QC
QD
QRS
QT
QTC
QTY
Quinid
transistor
quality assurance, Q wave amplitude
Quality Assurance Deviation
quadrature amplitude modulation (phase
and amplitude modulation)
quality control
Q wave duration
QRS complex (portion of ECG waveform),
interval of ventricular depolarization
QRS interval
QRS interval
quantity
Quinidine
R
R
RA
RAM
RC
A-6
resistor, red, reset
right angle, right arm or R wave
amplitude
random access memory
resistor capacitor
RD
Ref
REN
Reserp
REV
RevdBy
RevXmit
rf
RFI
RGB
RI
RL
RMR
ROM
RPA
RPD
rpt, Rpt
RTC
RTI
RTN
RVS
R/W
R wave duration
reference, refresh
Ringer Equivalence Number
Reserpine
revision
reviewed by
reverse transmission
radio frequency
radio frequency interference
red, green, blue
ring indicate
right leg
Rhythm and Morphology Report
read only memory
R wave amplitude
R wave duration
report
real time clock
relative to patient input
return
reverse
read/write
S
12SL
s, S
SA
SB
SCL
SD
SE
sec
sec.s
SEER
SING
SP
SPA
SPDT
SRAM
ST-T
12 simultaneous leads
second, select, switch
s wave amplitude
slow-blow
safe current limits
schematic diagram, S wave duration
serial input/output errors
second
seconds
Solid-state Electronic ECG Recorder
Singapore
Spanish
S wave amplitude
single-pole, double-throw
static RAM
ST-T wave (section of the ECG
waveform)
standrd, Standrd standard
STD
standard
STE
ST segment displacement at the end
STJ
ST segment displacement at the J point
STM
ST segment displacement at the midpoint between STJ and STE
stmts, Stmts
statements
supply mains
permanently installed power source
SVT
power cord type; 300 V
sw, SW
switch, software
SW
Swedish, Sweden
Series 2000 Treadmill
409110-004
Revision D
T
T Tone
TA
Tant
TDML
TE
Tech
Thiazid
TM
Tot
TP
TPA
TRAM
Tricyli
TTL
TVS
X
touch tone
T wave amplitude
tantalum
treadmill
timeout errors
technical
Thiazide
trademark
total
test point
T’ wave amplitude
Transport Remote Acquisition Monitor
Tricylic antidepressant
transistor-transistor logic, TTL levels
transient voltage suppressor
U
UE
uF
UL
Unconf
UUT
undefined errors
microfarad
Underwriters’ Laboratory, Inc
unconfirmed
unit-under-test
V
v, V
V1-V6
V123
V3R
V456
V4R
V ac
V dc
VA
Var
VDE
Vent.
VF
VGA
VIA
VIO
Volt
VRAM
vs
volt, volts
precordial leads
V1, V2, V3
precordial lead
V4, V5, V6
precordial lead
volts, alternating current
voltage, direct current
volt-amperes
variable
Verband Deutscher Elektrotechniker
(German regulatory agency)
ventricular
ventricular fibrillation
video graphics array
versatile interface adapter
violet
voltage
video RAM
versus
x
XCV
X,Y,Z
by (as in “8-1/2 x 11”)
transceiver
orthogonal leads
Y
Y
yr
yrs
YY
year, yellow
year
years
year
Symbols
↑
µ
µF
µs, µsec
68K
&
#
°C
°F
Ω
%

>
<
±
*
12SL
SHIFTed or alternate function
micro
microfarad
microsecond
68000
and
number
degrees Celsius
degrees Fahrenheit
Ohm, ohm
percent
registered
greater than
less than
plus or minus
An asterisk after a signal name indicates
the signal is active at its relatively lower
potential, or “active-low.” Signals
without the asterisk suffix are active at
their relatively higher potential, or
“active-high.”
12 simultaneous leads
W
w/
W
Warfar
WHT
WI
Revision D
with
watt
Warfarin
white
Wisconsin
Series 2000 Treadmill
409110-004
A-7
A-8
Series 2000 Treadmill
409110-004
Revision D
B
Appendix B: Technical
Description
Technical Specifications ............................................................... 3
Revision D
Series 2000 Treadmill
409110-004
B-1
B-2
Series 2000 Treadmill
409110-004
Revision D
Appendix B: Technical Description: Technical Specifications
Technical Specifications
Table B-1. Performance Specifications
Item
Specification
Maximum Rated Load
182 kg (450 lbs)
Drive Motor
3.0 HP, brushless, DC motor
Elevation Motor
0.13 HP
Belt Speed Range
0.0 to 22.5 km/h (0 to 13.5 mph) at 220V, @ 50/60 Hz continuously variable, zero
mph start-up
Belt Speed Tolerance
±0.16km/h (±0.1mph)
Belt Speed Acceleration/Deceleration
Approximately 0.8 km/sec (0.5 mph/sec)
Elevation Range
0.0 to 25.0% grade, continuously variable
Elevation Range Increase/Decrease
1.14%/sec. @ 60 Hz
Manual Treadmill Controller (Optional)
Functions: On, Off, Up, Down, Fast, Slow, Automatic Protocol Selection, Elapsed
Time, Distance Traveled
Automatic Protocols: 15 exercise and 15 rehabilitation (includes Bruce, Naughton,
Balke II, Ellestad, Low Performance)
Maximum Leakage Current
100 µA, chassis to ground
Interface
Either RS-232 port or RS-422 serial port, 9600 baud
Mode of Operation
Continuous
Degree of protection against ingress
of water
Ordinary
Table B-2. Physical Specifications
Item
Specification
Weight
181.4 kg (400 lb)
Walking Area
45.7 cm x 152.4 cm (18 in x 60 in)
Floor Space Required
73.7 cm x 195.6 cm (29 in x 77 in)
Walking Surface Height
14.0 cm (5.5 in)
Handrail Height Above Walking
Surface
Front: 101.6 cm (40 in)
Side: Maximum 88.9 cm (35 in) descending at 5° angle to 81.3 cm (32 in)
Table B-3. Power/Environmental Specifications
Item
Specification
Power Requirements
200 to 265 VAC, 60 Hz, single phase, 20 A, NEMA 6-20 R wall socket (dedicated
circuit recommended)
Power Consumption
1540 watts, 16 A
Revision D
Series 2000 Treadmill
409110-004
B-3
Appendix B: Technical Description: Technical Specifications
Table B-4. Safety
Item
Description
Certification
UL classified
CSA certified
Type of Protection Against Electrical
Shock
Class 1
Degree of Protection Against Ingress
of Liquids
Ordinary
Handling of Disposable Supplies and
Other Consumables
■
■
■
Use only parts and accessories manufactured or recommended by Marquette.
Follow manufacturer’s instructions for use for disposable/consumable product.
Follow local environmental guidelines concerning the disposal of hazardous materials
(e.g. lead acid batteries).
Patient Mode of Operation
Continuous
Patient Leakage Current
Not applicable
Degree of Protection Against
Electrical Shock
Not applicable
Maintenance Frequency
■
■
■
Repair Guidelines
Test the stop switch assembly monthly.
Recommended user daily visual inspection and cleaning.
Recommended six-month routine maintenance checks and test procedures performed
by qualified technical personnel.
Calibration instructions, equipment descriptions, and all other service information to
repair those parts of the equipment designated as field repairable by qualified
technical personnel is available in the service manual.
Upon request, Marquette will provide circuit diagrams and component parts lists for
printed circuit boards deemed repairable by qualified technical personnel.
Table B-5. Environmental
Item
Description
Operating Conditions
Ambient temperature
10°C to 40°C (50°F to 104°F)
Relative humidity
20% to 90%
Atmosphere pressure
525 mmHg to 795 mmHg (20.7 to 31.3 in Hg)
Storage Conditions
B-4
Temperature range
–40°C to 70°C (–40°F to 160°F)
Relative humidity
15% to 95%
Atmosphere pressure
500 hPa to 1060 hPa (375 mmHg to 795 mmHg)
Series 2000 Treadmill
409110-004
Revision D