Johnson T3XM Service Manual

T3XM Console Service Manual Approval Review Editor Kyle Schweitzer Jerry Zhu

1.1 Console Overview..................................................................................................................................1 1.2 Serial Location/Model Type Apply List.................................................................................................. 2 CHAPTER 2: CONSOLE INSTRUCTION.........................................................................................................3 2.1 T3XM Console Description....................................................................................................................3 CHAPTER 3: CONSOLE SPECIAL MODE 3.1 Special Mode Browse............................................................................................................................5 3.2 Manage Mode........................................................................................................................................6 3.3 Engineer Mode.......................................................................................................................................7 3.4 Service Mode.........................................................................................................................................8 3.5 Test Mode..............................................................................................................................................8 CHAPTER 4: TROUBLESHOOTING 4.1 Electrical Diagram..................................................................................................................................9 4.2 Ports Description................................................................................................................................. 10 4.3 Error Code List.....................................................................................................................................11 4.3.1.Speed Errors.......................................................................................................................... 11 4.3.2.MCB Errors.............................................................................................................................11 4.3.3. UCB Error..................................................................................................................................13 4.3.4. Communication Errors............................................................................................................. 14 4.4 Console Does Not Light Up.................................................................................................................15 SYMPTOM:..........................................................................................................................................15 SOLUTION:..........................................................................................................................................15 4.5 Speed Do Not Display......................................................................................................................... 15 4.6 Keypad/Heart Rate.............................................................................................................................. 16 SYMPTOM:..........................................................................................................................................16 SOLUTION:..........................................................................................................................................16 4.7 Safe Key Issue.....................................................................................................................................16 SYMPTOM:..........................................................................................................................................16 SOLUTION:..........................................................................................................................................16 4.8 WIFI Issue............................................................................................................................................17 CHAPTER 5: MAIN COMPONENT INSTALLATION 5.1 Wi-Fi Module Install............................................................................................................................. 18 5.1.1.Wi-Fi module Install.................................................................................................................. 18 5.1.2. Wi-Fi configuration file prepare and uploading.......................................................................18 5.1.3.Wi-Fi setup................................................................................................................................ 19

CHAPTER 2: CONSOLE INSTRUCTION 2.1 T3XM Console Description The Matrix machine is inspected before it is packaged. It is shipped in two pieces: the base and the console. Carefully unpack the unit and dispose of the box material. Note: There is a thin protective sheet of clear plastic on the overlay of the console that should be removed before use. A) WORKOUT KEYS: Simple program view and selection buttons. Press Fitness Test button to cycle through available tests. B) GO: One Touch Start. C) ENTER: To confirm each program setting. D) BACK: Go to previous program setting. E) NUMBER KEYPAD: Allows for easy number inputs. F) UP/DOWN INCLINE: Adjust incline and make program selections. G) UP/DOWN SPEED: Adjust speed and make program selections. H) UP/DOWN TIME: Adjust workout time. I) TOGGLE DISPLAY: Cycles between 3 rows of workout information displayed in LED window. The console will automatically cycle between the workout information if the Toggle Display button is pushed and held down for 3 seconds. J) EMERGENCY STOP / IMMOBILIZATION: To stop all functions and immobilize the unit. The emergency stop on this treadmill must be returned to its original position in order to allow normal operation of the unit. K) STOP: Ends workout and shows workout summary data. L) PAUSE: Pauses workout. Pause duration can be set in manager or engineering mode. M) COOL DOWN: Puts treadmill into Cool Down mode. Cool Down time is dependent on the length of the workout.

N) BELT DIRECTION: Press to change belt direction from forward to reverse. O) USB PORT: Used for software updates only.

CHAPTER 3: CONSOLE SPECIAL MODE 3.1 Special Mode Browse Mode Name Method Programmer List Special Mode Manage mode “√” + “1001” + “√” Refer to below picture Engineer mode “√” + “2001” + “√” Service mode “√” + “3001” + “√” Test mode “√” + “5001” + “√” Notes: Press “+/-“to scroll menu. Press “√” to refer more details about programs. Press “←” to return.

3.2 Manage Mode Category Name Default Range Workout Maximum Time 60 4-99 Default Time 20 4-max Default level 1 1-10 Pause Time 5:00 00:30/1:00/2:00/3:00/4:00/5:00 User Age 30 10-100 Weight 150lb/68kg 50lb/23kg-400lb/182kg Default height 72/183(inch/cm, 1inch=2.54cm) 36/91-96/244 Gender male Male/female Date &Time Date 30 10-100 Time 150lb/68kg 50lb/23kg-400lb/182kg Time Zone 21 1-78 Speed Unit Standard Standard/Metric Software Version -- UCB/LCB/Language/Wi-Fi/boot loader Update -- UCB/LCB/Language Auto Update Disable/Enable/Time/Check update General Accumulate Distance 0 0-999999 Accumulate Time 0 0-999999 Language Default Language English 12 language Erase EEPROM -- Notes: Erase language data in EEPROM Machine Type -- Select the right one Serial Number --Console --Frame Input the right serial number Console/Frame Out of Order off On/off Beeper on On/off Headphone Jack -- Notification --enable --30000 --Enable/Disable --1000~1000000 USB Port --Protection Enable Enable/Disable Keypad -- Stuck Check -- Notification -- Enable -- Enable -- Enable/Disable -- Enable/Disable

Category Name Default Range Internet Disable/Enable -- Disable/Enable MAC ID Shows the actual MAC address -- IP Shows the actual IP address -- AP Mode OFF ON/OFF Export setting to USB -- Export Wi-Fi setting to USB Import setting from USB -- Import Wi-Fi setting to USB Signal strength Disconnected/25%/50%/75%/100% Reset -- Reset internet ERP -- OFF OFF~30 3.3 Engineer Mode Category Name Default Range Error Codes -- Enable Enable/Disable DAPI Server Production Dev/QA/Staging/Production SSL ON ON/OFF

3.4 Service Mode Category Name Default Range Accumulate Distance 0~999999 Mile/Km Time 0~999999 Hours Log Error --Display --Reset None Error0~Error10/None Headphone Jack Sensor --Insert Counts --Reset -- --0~999999 --Clear log in times Configuration Export to USB -- -- Import from USB -- -- Factory Default Reset Notes: Factory default reset Asset Management Disable/Enable Disable Disable/Enable 3.5 Test Mode Category Test Procedure Display Press “√” to test display, press”←” to back, press”+/-“ to scroll menu Keypad Press “√” to test the keypad, press”←” to back, press”+/-“ to scroll menu CSAFE 1. Press ”√”+”5 0 0 1”+”√” in turn to enter test mode. 2. Press “+/-” to select CSAFE. 3. Press “√” to start testing, display will show “CSAFE OK or FAIL” Wi-Fi 1. Press ”√”+”5 0 0 1”+”√” in turn to enter test mode. 2. Press “+/-” to select Wi-Fi. 3. Press “√” to test the Wi-Fi hardware. Headphone Jack Test Headphone Jack hardware. ErP Auto/5/10/30/60(seconds) ErP testing only works in Test Mode, it will not save and not work when the console out of Test Mode. Auto means the machine will enter ErP mode after press”√”.

4.1 Electrical Diagram T3XM Electrical Diagram

MCB introduction T3XM UCB PORTS DESCRIPTION UCB Front side CN1 USB CN8 Heart Rate CN2 Interface digital CN9 Quick Key/Earphone/HRT CN3 TV power CN10 TV Keypad CN4 JTAG1 CN11 Main Key CN5 UCB STATUS CN12 C-SAFE/TV CN6 Overlay LED CN13 TV CN7 SAFEKEY CN14 C-SAFE/PCTV

4.3.1. Speed Errors Error Code Description Class Level 0040 Roller RPM sensor - no speed response of roller. B 0041 After setting speed on the console, speed cannot reach the target in 60 seconds. (Speed too low) B 0042 After setting speed on console, speed cannot reach the target in 60 seconds. (Speed too high) B 0043 RPM reading from RS232 mismatches with the RPM measured from the speed/RPM line – only used for AC motors B 0044 Actual speed is higher than commanded speed by limit and is ac celebrating B 0045 Automation speed up and speed down mode fail B 00A0 Fail to rectify speeds C 00A1 No response of motor speed sensor (keep time for LCB default) C 4.3.2.MCB Errors Error Code Description Class Level 0201 LCB battery low voltage (Battery voltage <11.2V) A 0240 Low AC power input voltage B 0241 Low DC bus voltage of motor driver B 0242 LCB over temperature B 0243 Soft start circuit of DC bus fail B 0244 ECB sensor fail B 0245 ECB calibration fail B 0246 ECB over current B 0247 LCB fail B 0248 Battery disconnection or fail B 0249 LCB Fan fail B 024A Change to 02C2. B 024B On step sensor error B 024C Temperature sensor abnormal. B 024D Touch the control zone over 60 seconds B 024E Touch frame IR sensor over 60 seconds B 029F An error that a generic class "B" error with the MCB B 02A0 Encoder disconnection or fail C 02A1 Over AC power input voltage C

C 02A3 Over voltage limited in DC bus C 02A4 U phase current sensor and circuit fail C 02A5 V phase current sensor and circuit fail C 02A6 W phase current sensor and circuit fail C 02A7 Over Irms of phase current of motor C 02A8 Inverter circuit of motor driver fail (MOSFET, IGBT ) C 02AA Main motor has over limited current C 02AB LCB type setting fault C 02AC Main motor out of control (speed too high ) C 02AD LCB over temperature C 02B2 Safe key action response C 02B3 Machine type error C 02B4 Resistance type error C 02B5 Inverter sensor the normal rated current over 150%, can hold 60 seconds. C 02B6 Speed up has over current. (Software discover) C 02B7 Speed down has over current. (Software discover) C 02B8 Running status has over current. (Software discover) C 02B9 The inner memory IC data write error C 02BA The inner memory IC data read error C 02BB Inverter inner line of communication error C 02BC Ground connection or fuse error C 02BD Inverter hardware interrupt error C 02BE DC brake error C 02BF DC brake has over current C 02C0 DC brake into manual mode C 02C1 Velocity error is too large. C 02C2 LCB E-Stop sensor error C 02C3 LCB IR sensor error C

Error code Description Class Level 0301 Memory block fail (Flash, EEPROM ) A 0302 UCB low battery voltage A 0303 UCB low supply voltage A 0304 Earphone board needs to replace A 0305 USB Hardware OT or OC A 0306 Keypad press keep 60 seconds A 0307 Not enough free space on the console to apply the update A 0308 Software package install failed A 0309 Software package MD5 check failed A 030A Failed to download software package A 0340 Keypad in extraordinary operation (Press keypad 5 seconds. while power ON) B 0341 Fan has over current B 0343 UCB has over supply voltage B 0344 Timeout for receiving packet (Not recommended for re-use, make use of 04B0 code) B 0345 Correct packet but LCB without the function B 0347 VA load program fail. B 0348 Motor not to run. B 03A5 Failed to load program (The programs existed in the file system, this error could mean the file system is corrupt) C 03A6 Failed to run program (The program read from the file system is invalid or has an invalid format, therefore it cannot be executed) C 03A7 Change to 0347 C 03A8 Control settings on the machine does not match the shape and under control. (ex. Bike console connect TM MCB) C 03A9 Change to 0348

Error code Description Class Level 0440 通訊接收逾時 (起始 byte 至結束 byte 之間逾時) Timeout for receiving communication packet B 0441 通訊命令格式正常, 但無法執行該命令 Correct format of communication command but LCB could not execute the command B 0442 The received command code from the console is correct and is supported, but it has less or more data arguments B 0443 MCB read or write wrong. B 04A0 LCB 無通訊回應 LCB has no communication response. LCB 逾 3 秒未收到 UCB 任何正確數位通訊命令封包 LCB has no communication command packet from UCB in 3 seconds EUP 喚醒機制下 : (EUP Wake up mode) EUP 喚醒(400ms 觸發訊號+0x7A 指令)至收到第 2 道(非 0x7A)指令前停止 Timeout 的計數動作, 直到第 2 道指令收到確 認後才開始進行 Timeout 3 秒的計數動作。 When EUP Wake up (400ms trigger signal and 0x7A command) and before next command come in, LCB needs to stop the Timeout count, Until next command has been received, then LCB will restart the Timeout 3 seconds count. C 04B0 UCB 無通訊回應 UCB has no communication response 逾 5 秒未收到 LCB 任何正確數位通訊命令封包(含 command) Which has no communication command packet from LCB in 5 seconds C

SYMPTOM: When the power switch is ON, the console does not turn on. Which means the console is damaged or the console cable is not connected properly. The poor connection to the terminals on the lower control board. The lower control board is damaged. The generator is damaged. SOLUTION: The outlet the machine is plugged into is functional. Double check that the breaker has not tripped. The correct power cord is being used. Only use the power cord included or provided by Customer Tech Support. The power cord is not pinched or damaged and is properly plugged into the outlet and the machine. Check to see if the connection of adapter is well. Remove the console and check to see if the console wire has good connected with the console. Remove the console mast and check to see if the console upper cable and console lower is connected well. Remove the side cover and check to see if the wires are connected well. If the voltage through the console cable is 12VDC, the console is defective, replace it. 4.5 Speed Do Not Display SYMPTOM: The speed value does not display on console SOLUTION: Unplug power cord, remove the console and check that all connections to the console are secure and not damaged or pinched. Remove the side cover and check to see if the sensor wire is connected well. Check to see if one corner of the sensor is aligned with the magnet and the distance less than 5mm.

SYMPTOM: The Keypad has no reaction /The Keypad function does not match screen display. The screen cannot display heart rate pulse SOLUTION: 1. The console cable is connected improperly. Remove the console mast and check to see if the console upper cable and console lower cable are connected well. 2. The poor connection to the terminals on the lower control board and the upper control board. Remove the side cover and plug in /plug out terminals to see if the terminals are connected well. 3. Check if Keypad and heart rate metal are connected by multimeter. 4.7 Safe Key Issue SYMPTOM: The Safe Key has been triggered but the machine does not STOP. SOLUTION: 1. The poor connection to the terminals on the console control board. Check if the safe key connection wire has broken by multimeter. If the connection wire has broken. The multimeter will read ∞ ohms. Replace the safe key connection wire. 2. Wrong safe key connection wire be used Check if used correctly safe key connection wire. 3. Console board is damaged Replace new console board and test again. 4. MCB board is damaged Replace new MCB board and test again.

1. Use mobile phone or portable device search router SSID and login (Fig. 1) 2. Use the SPEEDTEST App. to measure upload and download speed. It is normally up to 64kB or higher, depends on local ISP (internet service provider) but 0kB means fail to connection. (Fig. 2) 3. Browse www.google.com or any other website.(Fig. 3) If connection fail at step 1. It needs to login another router SSID and try again. If connection fail at step 2 & 3. It is ISP problem. Please contact local ISP (internet service provider). Fig. 1 Fig. 2 Fig. 3

CHAPTER 5: MAIN COMPONENT INSTALLATION 5.1 . Wi-Fi Module Install 5.1.1.Wi-Fi module Install 1) Prepare Wi-Fi Module ： Wi-Fi module; HF-A11-0;(Fig. 1) 2) To loose 2 pcs of screws already in Wi-Fi Module socket (Fig. 2) 3) Take the Wi-Fi Module and Push Wi-Fi module into socket carefully (Fig. 3) 4) Fix the Wi-Fi Module with 2 pcs of screws (Fig. 3) 5) Install the UCB into consoles 5.1.2. Wi-Fi configuration file prepare and uploading 1. Prepare the Wi-Fi configuration file, and the filename is: “Wi-Fi_set.cfg” 2. Store the file to USB stick. 3. Insert USB stick in console USB port 4. Press “√” + “1001” + “√” enter Manage Mode and choose Internet/Import setting from USB 5. Upload the file to console. HAPTER 5: MAIN COMPONENT INSTALLATION Fig. 3 Fig. 1 Fig. 2

5.1.3. Wi-Fi setup 1) Power on 2) Press “enter” key 3 seconds and display “CSAFE OK”. (Fig. 1) 3) Press“( - ) ” key back to previous menu. (Fig. 2) 4) Press speed up “ + “ key and choice Wi-Fi” function (Fig. 3) 5) Press “enter“ for auto search Wi-Fi (Fig. 4) 6) When you see “Wi-Fi OK”, Wi-Fi setup completed. 7) Press “-“ back to previous user menu. (Fig. 5) Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5