SIEMENS psx ur L BURDICK T600 Treadmill Service Manual Part No. 086222 iSeuad or 92 SaaS / Siemens Burdick, Inc. 15 Plumb Street Milton, WI 53563 (608) 868-6000 aR eS!Service Manual CONTENTS 1 GENERAL INFORMATION 1.1. Basic System Description. 1.2 Block Diagram i 1.3 Specifications .. Bob 2 SERVICE 2.1 Electrical Service 22 Salety and Service Cautions. 2.3 Test Equipment 2.4 Adjustment Locations... 25 Self Check... 2.6 Configuration .. NNbowe 3 PROBLEM SOLVING 3.1. General Troubleshooting 3.2 Connector Pinouts Blt 12-13 4 REMOVAL AND REPLACEMENT PROCEDURES 4.1 Removal and Replacement 4.1.1 Housing. 4A.2 FUSOS orn 4.1.3 Treadmill Control PCB Assembly... 1.4 Idle Roller Assembly... 1.5. Drive Roller Assembly. 1.6 Walking Belt... 1.7 Drive Belt... 1 1 8 Drive Motor and Flywhec! . 9 Elevation Motor and Brake Assembly 4.1.10 DC Motor Controller. 4.1.11 Clinometer. 4.2 Exploded Views. 4,3 General Wiring, 5 MAINTENANCE 5.1 Preventive Maintenance 5.1.1 Visual Inspection. 5.1.2 Cleaning, 5.1.3 Drive Belt... 1.4 Power Cord. 5 Chassis Leakage 6 Rack Gears. Maintenance... 8 Walking Belt Tension & Tracking .. 9 Speed & Elevation Calibration. 10 Emergency Stop Switch. 4 4 4. 4 4 4 eck...6 THEORY OF OPERATION 6.1 Primary Power Distribution, 6.2 Treadmill Control PCB ... 6.2.1 Power Supply...... 6.2.2 Microprocessor and Logic... 6.2.3 Data Acquisition and 1/0...... 6.2.4 Treadmill Control... 6.25 Serial Communication... : 6.3 Treadmill Control PCB Block Diagram. 7 SCHEMATIC AND COMPONENT DIAGRAM 7.1 Wiring Diagram (1 of 3)... 33 7.2 Treadmill Control PCB Schematic (2 of 3). 33 7.3 Treadmill Control PCB Schematic (Bot), 33 33 7.4 Component Diagram ..Service Manual 1 GENERAL INFORMATION 1.1 BASIC SYSTEM DESCRIPTION The BURDICK T600 Treadmill functions as part of a system which also includes an external treadmill controller. Operator controls and displays are pro- vided by the controller. The main drive and eleva- tion motors are located inside the treadmill housing, The interface circuitry consists of a single printed circuit board assembly, the Treadmill Control PCB, and also is located inside the treadmill housing. The 1.2 BLOCK DIAGRAM 3 1 ' ELEVATION CONTROLLER ' ae SERIAL {| | INTERFACE | 1 oy AUXILIARY | +} CLINOMETER i TREADMILL i CONTROL PCB BURDICK T600 can communicate with current Siemens Burdick products, such as the TA620 controller, E350 electrocardiograph, and §M300/M300d/M700 monitors. ‘A microprocessor on the Treadmill Control PCB handles serial inpuYoutput to/irom the external con- troller. The main drive and elevation motors are con- trolled by triacs, which are actuated by circuitry on the Treadmill Control PCB. Elevation feedback is Provided to the microprocessor by a clinometer. Speed information is provided by a tachometer, which reads the speed directly from the drive motor shalt DC MOTOR CONTROLLER MAIN DRIVE MOTOR TACHOMETER1.3 SPECIFICATIONS Conforms to standard: Power rating: Circuit breaker: Power supply fuses: Elevation circuit fuse: Emergency stop (optional): External YO: auxiliary controller ‘emergency stop Max. allowable voltages at SIP/SOP: controller interface auxiliary interlace Dimensions: size without handrails size with handrails tread area (belt) tread height Weight: Rated load: Speed range: Elevation range: Drive motor: Elevation drive motor: Bearings: BURDICK T600 Treadmill CSA, C22.2No. 125 110-120 VAC, 60 Hz, 12 2-pole rocker switch, 15 A 0.25 A, 250 V, slow blow, (F2) 0.25 A, 250 V, slow blow microfuse for external +15-V supply, (F4) 1.5 A, 250 V, slow blow, (F1) Push-bution activated by patient or operator S-pin D-Sub S-pin D-Sub S-pin internal £12 V (RS232 levels), +15 VOC £12 V (RS232 levels), +15 VOC 90" x 83.5" (76 om x 212 em) 34" x 83,5" (86 cm x 212. cm) 20" x 62" (51 cm x 157 cm) 6" (15 cm) from floor Approx. 345 Ibs (156 kg) 350 Ibs (159 kg) 0.6-10 mph (1.0-16 km/n) +5% 0-25% grade +0.5% indicated 1.75-hp (1.3-kW) brushless de 0.14-hp (105-W) ac gearmotor Permanently lubricated ball typeService Manual 2 SERVICE 2.1 ELECTRICAL SERVICE An electrical service must be provided which is properly grounded to ensure trouble-free operation ‘of the treadmill. A separate 115-VAC electrical ser- vice and circuit breaker is recommended. Symp- toms of an inadequate electrical service include blown fuses and tripped circuit breakers. WARNING — Prolonged operation under improper conditions will result in damage to the treadmill. Damage caused by inadequate electrical ser- vice is not covered by the warranty. NOTE — The treadmill and all peripheral equipment ‘must be properly grounded. The treadmill is equipped with a circuit breaker on the rear side near the power cord input. If the tread- mill draws excessive current due to a component failure, the breaker will rip to remove power from the unit 2.2 SAFETY AND SERVICE CAUTIONS CAUTION — The highest voltage to be encountered within the unit is 190 VDC. This vollage may be present between the de motor controller and ‘motor. Also, 120 VAC is present throughout the treadmill. Always ensure that the unit is unplugged belore attempting to remove the housing or performing any other disassembly. Use of integrated CMOS circuitry on the Tread- mill Control PCB requires that caution be ‘observed when handling the board to prevent damage which can be caused by static elec- tricity. An anti-static work surface is recom- ‘mended! 2.3 TEST EQUIPMENT ‘The BURDICK T600 requires only standard elec- tronic measuring tools and hand tools for mainte- ance. Test equipment should be calibrated per ‘odically and be in good repair. The following equip- ‘ment is recommended: Digital Muttimeter Leakage Current Meter / Safety Analyzer Allen Wrench Set (English) Box End Wrenches (English) ‘Common Screwdrivers Torque Wrench ‘Tape MeasureBURDICK 1600 Treadmill 2.4 ADJUSTMENT LOCATIONS BolSaNNo9 1S31 TWNEBINI $¢ ae 3SNZOUOIN bret i AlddNS ASL + TWHsoN/0SE3 be) Zant NouoT3s Nouoa73s ozo¥s ingiNo Wnd/ZIONIS TWNHON/OS€3 CAT ten fener inaino = YBL3WONND HOLINS iO XOLWOION! 4831 3735 vo an €3cWNF/HOLDENNOD 01S ADNSOBINI Vet] taccccnceaem asna Adds w3MOe 4 bal Fs 4138430 nwo NOUwAgTa v3y Be [=] 35N4_xOLOW 3LyAz1a 24 a aService Manual 2.5 SELF CHECK ‘The BURDICK T600 initiates a self test each time it is powered up. An internal control program verifies proper operation of the RAM, EPROM, and DUART. Circuits. LED D4 provides a visual indication of the test result. f the test fails, the LED flashes. If there is ‘a power failure or the test can not be performed, correctly, the LED does not illuminate. Under normal circumstances, LED D4 is illuminated, indicating that the self check was performed successfully 2.6 CONFIGURATION The BURDICK T600 is configured by switch SW1 and jumpers JMP1-JMP3, The options for SW1 are as follows: tions with the BURDICK TA620 Controller and/or BURDICK M300/M300d/M700 Monitor, When a ‘monitor is attached to the CONTROLLER port, the AUXILIARY port is enabled for output only, making the monitor the sole control device. If wo BURDICK ‘TA620 Controllers are attached, both can control the treadmill; however, the jumper at JMP1 must be in place. I ANALOG TEST MODE is selectod, the treadmill ignores any serial communications and receives. commands via analog test connecter J3 on the Treadmill Control PCB. This is useful for test proce- dures, since the treadmill can be controlled directly by means of a simple switch box connected to J3. {In this mode, three analog inputs to the micropro- cessor are read approximately every 50 ms, emulat- ing the response of a monitor/controller. The active low control signals are defined as follows: DIP SWITCH SETTINGS STANDARD MODE All switchos OFF ANALOG TEST MODE ‘Switch 1 ON ‘Switches 2, 9, & 4 OFF £350 OUT MODE ‘Switch 3 ON ‘Switches 1, 2, & 4 OFF BURN-IN TEST MODE | switch 20N orr_orr_orr_orr | Switches 1,3, & 4 OFF STANDARD MODE is the default setting. In this mode, the treadmill is configured for communica- Function | pina | pina | Pies START o | o sToP o | o wwesreeo | 1 | o vec sPeeD | 0 1 wcevev | 1 0 1 DEC ELEV The E350 OUT MODE allows RS232 communication with a specially configured BURDICK E350 Electio- cardiograph via the AUXILIARY port, Jumpers JMP2 and JMP3 must be set to the E350 position (pins 2 and 3 shorted together) in order to provide the required inverted signals. NOTE: The E350 OUT MODE currently is unused in the United States. The BURN-IN TEST MODE is for factory use only,BURDICK 1600 Treadmill 3 PROBLEM SOLVING 9.1 GENERAL TROUBLESHOOTING TURN ON MAINS POWER, "TREADMILL, AND CONTROLLER. ELEVATION ANO SPEED. aa 1 wrencomecrna castes rean Toe connect Ts conncorens oa EPAMR On REPLACE (avaTonnor acm) POSSIBLE FAULTY CONTROLLER. ‘SWAP WITH KNOWN GOOD. | 0 CONTROLLER Is PROBLEM ‘SOLVED? REPLACE CONTROLLER IS LED D4 ON TREADMILL CONTROL, 'PcB TURNED ON CONTINUOUSLY? REPLACE ‘TREADMILL CONTROL PCO, SLED DEFLASHING? Acpowen source ano [wo FUSE F2 OK? REPLACE. TREADMILL CONTROL Pe®Service Manual 3.1 GENERAL TROUBLESHOOTING (CONTINUED) | ABLE To START WALKING BELT USING CONTROLLER? CONNECTIONS BETWEEN TREAD. | yo MILL CONTROL Pea, MOTOR CON. TROLLER, AND MOTOR OK? REPAIR OR REPLACE EMERGENCY STOP swiTCH INSTALLED? REPLACE EMERGENCY STOP ‘CONNECTOR WITH JUMPER AF JP1, TS PROBLEM SOLVED? ‘NOVAC PRESENT BETWEEN P22 AND JP24? {KH SQUARE WAVE SIGNAL ‘ACROSS ROI RepLace ‘Dc MOTOR CONTROLLER ‘JUMPER PROPERLY INSTALLED ‘ACROSS PING 28 3AT JPY? REPAM OR REPLACE EMERGENCY STOP SwTCH REPLACE ‘TREADMILL CONTROL Pca REPLACE TREADMILL CONTROL Pca.BURDICK T600 Treadmill 3.1 GENERAL TROUBLESHOOTING (CONTINUED) ABLE TO INCREASE BELT ‘SPEED FROM CONTROLLER? ‘TACHOMETER CONNECTIONS "AND WIRING OK? REPLACE OR REPAR oaeaceree ‘TACHOMETER PULSES Present aT U'36° DOES DUTY CYCLE OF 12 SIGNAL ‘ACROSS Ro} WEREASE DURING ‘SPEED INCREASE REQUEST? REPLACE Dc MOTOR CONTROLLER CU) REPLACE ‘TREADMILL CONTROL PCO. ABLE TO BRING TREADMILL TO ‘COMPLETE STOP FROM FULL ‘SPEED WITHIN 10 SECONDS? nina OK To EXTERNAL s OFM ‘BRAKE RESISTOR? REPLACE Bc MOTOR CONTROLLER _—————— REPAIR WIRING OR REPLACE RESISTOR, ABLE TO CHANGE ELEVATION ‘sina CONTROLLER? FUSE FI OK? REPLACE FUSE CONNECTIONS BETWEEN JP6. ELEV. MOTOR, MOTOR DRAKE, RUN CAPACITOR OK? sacar rae AC PRESENT BETWEEN JP8.172 8 JRE DUNG INCIDEG ELEVATION. ‘ATTEMPT? apa [REPLACE MOTOR OR [RUN CAPACITOR REPAIR CONNECTIONS. REPLACE ‘TREADMILL CONTROL PCB a 10Service Manual 3.1 GENERAL TROUBLESHOOTING (CONTINUED) PERFORM ELEVATION CALIBRATION. ‘CHECK CLINOUETER Wines & | ve ceed ENSURE POSITION Is VERTICAL, DISPLAY OK? DOES ELEVATION DISPLAY APPEAR, ‘TOBE CORRECT OVER ENTIRE ‘ow2s% RANGE? DISCONNECT CLINOMETER CABLE. 'AT BOARD. APPLY +i0VDG 10 CCLINOMETER BETWEEN PINS 2 1, {SVDC BETWEEN PINS 3.4 17 REPLACE CLINOMETER vorgsaevirim geron senses (NOT EXCESSIVELY NOISY) LEVATIONSOTOR onane nBURDICK 1600 Treaamill 3.2 CONNECTOR PINOUTS ‘teadmill Control PCB JP1 [TO EMERGENCY STOP swiTCH] 1 GND 2 SIGNAL 3 Hav JP2 [0c MOTOR CONTROLLER] 1-2 ACNEUT 3 START 4 RUNISTOP 5-6 SPDCTRL+ 7-8 HALL JS [INTERNAL Test CONNECTOR] 1 49v 2 GND 3-5 TESTI-TEST3 JP4 {cunoweren} 1 ANALOG GND. 2 +10v 3 CLINOMETER 4 GND JS [acmains) 1 AC NEUTRAL 2 ACHOT JPG [ELEVATION MOTOR / BRAKE] 1 INCELEV 2 DECELEV 3 BRAKE 4 NC 8-6 ACNEUT Ground Emergency stop relay control Supply ‘Ac power return Momentary ac power for motor start Sustaining ac power for motor run Speed resistor output Tachometer input Supply Ground Microprocessor input ports Analog ground Supply Analog clinometer output Ground ‘Ac mains power supply ‘Ac mains power supply ‘Ac power for increase elevation ‘Ac power for decrease elevation ‘Ac power for brake release Unused ‘Ac power return 12Service Manual 3.2 CONNECTOR PINOUTS (conTINUED) - Tceadmill Control PCB (continued) 1 [AUXILIARY - extenwat CONNECTOR] L 1 NC Unused 2 RxD Serial channel 1 input 3 TxD Serial channel 1 output - 4 RIS Serial channel 1 RTS signal 5 GND Digital ground 6 ANALOG SPEED 0- to 10-VDC speod output 7 ANALOG ELEV 0-0 10-VOC elevation output 8 CTS Serial channel 1 CTS signal 9 +15V Jumper selectable unregulated +15 VDC P2 [CONTROLLER - extennat connector] 1 M300 DETECT —M3004/TA620 detection 2 RXD Serial channel 2 input 3 XO Serial channel 2 output 4 NC Unused : 5 GND Digital ground 6 NC Unused 7 ELEV Analog clinometer ouput 7 8 NC Unused 9 +1SVUNREG — Unregulated +15 voc DC Motor Contialler U1 [10 BELT MOTOR & TACHOMETER] 1 we Drive current to motor 2 w3 Drive current to motor 3 wi Drive current to motor 4 HALLOV OV to tachometer 5 HALL+15V +1 Vito tachometer 6 HALA Input from tachometer 7 HALLS Input from tachometer L 8 HAL2 Input from tachometer J2__ [To TrexoMiLL Conrnot PCB) L 1-2 ACNEUT Ac neutral 3 RUNISTOP Control signal 4 START Control signal 5 SPDCNTRL+ — Control signal 6 —SPOCNTRL- Control signal4 REMOVAL AND REPLACEMENT PROCEDURES 4.1 REMOVAL AND REPLACEMENT Refer to the exploded views in Section 4.2 belore performing removal and replacement procedures. WARNING — Always ensure that the treadmill is unplugged prior to pertorming ANY disas- sembly, 4.1.1 Housing Access to the internal components may be gained by following the procedure below: 1. Loosen two (2) nuts on hook bolts which secure the housing to the treadmill frame. 2, Turn hook bolts to allow removal of the housing. Pull housing up and away from the Velero-type attachment. 3. Remove housing. 4. Replace in reverse order, NOTE: When removing or replacing the housing, ensure that no internal parts are damaged. Service can be accomplished with the treadmill at whatever elevation is most convenient. However, a 20% grade is recommended because it provides the best access to the internal components, 4.1.2 Fuses Three fuses are located on the Treadmill Control PCB to provide circuit protection. In addition, a cir- cuit breaker is located on the rear of the treadmill ‘The BURDICK T600 power supply circuitry is pro- tected by fuse F2. The treadmill will not operate it this fuse is blown. Since the effect is the same as a tripped circuit breaker, check the breaker before attempting to change F2. The +15-V extemal con- troller supply is protected by fuse F4, a microfuse which is soldered to the board, The Elevate motor is protected by fuse F1. If op- eration is normal with the exception of the elevation function, check Ft Access to the fuses is gained by removing the ‘Treadmill Control PCB Assembly. Use only replace ‘ment fuses that are the same type and rating as the BURDICK T600 Treadmill originals. If a fuse blows a second time, check the Circuitry for possible shorts. 4.1.3 Treadmill Control PCB Assembly CAUTION — The Treadmill Contro! PCB uses (CMOS integrated circuits and caution must be ‘observed when handling the board to prevent damage which can be caused by static elec- tricity. An anti-static work surtace is recom- mended! 1. Remove the treadmill housing as previously described. 2. Carefully remove all connectors and wires from the Treadmill Control PCB, Remove four (4) mounting screws securing the assembly 10 the treadmill frame. Carefully slide assembly out. Replace in reverse order. Re-calibrate the ele- vation as described in Section 5.1.9. 4.1.4 Idle Roller Assembly 1. Since the idle roller assembly drops out from the bottom, prop up the end of the treadmill 0 allow clearance, 2. Remove the finger guards from each side of idle roller. Each guard is secured by two (2) screws and a pemnut plate. 3. Use an Allen wrench to remove both belt ten- sion adjustment screws and washers located on each side of the idle roller assembly. These screws are threaded into the idle roller shaft Carefully slide the two (2) wooden shalt support blocks towards the center of the treadmill, allowing the idle roller assembly to drop out through the bottom. WARNING — The idle roller assembly is heavy! Handle with caret NOTE: Do not disassemble the idle roller assembly. Replace in reverse order. When re-assembling, ensure that the wooden support block shat holes are offset towards the foot of the treadimil Re-adjust the walking belt tension and tracking as described in Section 5.1.8. 4Service Manual 4.1.5 Drive Roller Assembly 1. Elevate the unit to 20% grade and remove the housing, 2. Remove the idle roller assembly to slacken the walking belt as described in Section 4.1.4. 3. Remove the bottom pan which is secured by six (6) screws and washers. 4, Adjust the tensioning bolt which protrudes: through the motor platform to release pressure on the drive belt. Slip the belt off pulley. 5. Remove three (3) screws securing the bushing socket. 6. Remove the screw, washer, and rubber shock ‘mount at the right side of the drive roller assem- bly. The screw is threaded into the drive roller shaft. 7. Carefully slide the wooden shaft support block towards the center of the treadmill, allowing the drive roller assembly to drop out through the bottom, WARNING — The drive roller assembly is heavy! ‘Handle with care! NOTE: Do not disassemble the drive roller assembly. 8. Replace in reverse order. Ensure that the grooves on the drive belt and pulleys are free of dir and debris. Oil or grease will cause the belt to slip. Remember to install the drive belt before re-installing the drive roller assembly. Re-adjust the drive and walking belts as described in Sections 4.1.7 and 5.1.8, respectively. 4.1.6 Walking Belt 1. Elevate the unit to 20% grade and remove the housing. If handrails are installed on both sides, one side must be removed. 2. Remove the idler roller assembly as described in Section 4.1.4, 3. Remove the drive roller assembly as described, in Section 4.1.5, 4. The walking belt bed is held in place by eight (8) bolts and associated washers, spacers, and futs. To access the bolts, peel off one (1) adhe- sive anti-slip strip from each side of the deck. (These strips should not be reused.) Remove the bolts and deck. 5. Remove the two (2) deck support pieces and walking belt 6. Replace in reverse order. Re-adjust the drive and walking bells as described in Sections 4.1.7 and 5.1.8, respectively. 4.1.7 Drive Belt 1. Remove the drive roller assembly as previously described. 2. Remove old belt and install new one. Adjust the tensioning bolt which protrudes through the motor platform so that the belt does ‘ot slip (do not over-tighten). Test the tension ‘by walking on the treadmill, While adjusting the Grive belt tension, also re-adjust the walking belt tension and tracking as described in Sec- tion 5.1.8, 4.1.8 Drive Motor and Flywheel 1. Raise the treadmill to 10% elevation. 2. Disconnect the treadmill from the AC power line. 3. Remove the housing assembly. Unplug all wire ‘assemblies to motor and remove ground strap. 4. Adjust the tensioning bolt which protrudes through the motor platform to loosen the drive belt and slip off pulley. 5. Remove four (4) bolts and washers securing rive motor to platform. Remove motor and fly- wheel assombly. 6. Replace in reverse order. Re-adjust the drive belt tension as described in Section 4.1.7. WARNING: Ensure flywheel is clear of all wiring and ‘obstructions. Severe personal injury or mechan- ical damage may result if lywheel is cracked or improperly attached to shaft. 4.1.9 Elevation Motor and Brake Assembly 1. Raise the treadmill to 20% elevation, then care- fully lower it onto a sturdy support to relieve the chain pressure . CAUTION — if not properly supported, the treadmill will drop to the floor when the elevation motor is removed. 15BURDICK T600 Treadmill 2. Disconnect the treadmill from the ac power line. 3. Remove the housing assembly. Unplug all wire assemblies to motor and brake assembly. 4, Use an Allen wrench to loosen two (2) set screws on small sprocket attatched to elevation motor. 5. Remove four (4) screws and washers securing elevation motor to mounting panel. Remove motor by carefully pulling it away from the panel and sprocket. 6. Replace in reverse order. NOTE: Do not over-tighten the mounting screws when re-installing. It is recommended that a torque wrench be used to tighten the screws to 50 (+5) inch-pounds. 4.1.10 DC Motor Controller 1. Raise the treadmill to 20% elevation. 2. Disconnect the treadmill from the ac power li 3. Remove the housing assembly. Unplug all wire ‘assemblies to dc motor controller and remove ground strap. (Wires to brake resistor must be temoved at resistor.) 4. Remove four (4) nuts and associated spacers, ‘securing motor controller to mounting bracket. Remove motor controller assembly. 5. Replace in reverse order. 4.1.11 Clinometer 1. Elevate the unit to 20% grade and remove the housing. » Unplug cable assembly at Treadmill Control PCB and remove from cable clip. 3. Remove two (2) screws securing clinometer to ack and pinion box cover plate. Remove cli- nometer. 4, Replace in reverse order. NOTE: Orient the clinometer so that the slot is towards the top. Re-calibrate the elevation as described in Section 5.1.9. 16Service Manual 4.2 EXPLODED VIEWS (1 OF 7) Bo6a24 {EMERGENCY STOP SWiICH (OPTIONAL) 896775, 896777 FRONT RIGHT HANDRAIL HANDRAIL - S 701366 SE 896752 SCREW GRIP a a \__ 705092 HANORAIL KITS re 896865 ~ FRONT HANDRAIL 896865 — LEFT HANDRAIL 845901 896867 — RIGHT HANDRAIL 996776 BUSHING LEFT NOTE: KITS INCLUDE HARD- HANDRAIL 845898 WARE AND’ PRE-INSTALLED BUSHING GRIPS. RH SIDE 845899 BUSHING 845901 BUSHING 705092 —_ WASHER, 701366, ‘SCREW ~ sy" wr 7BURDICK T600 Treadmill 4.2 EXPLODED VIEWS (2 OF 7) gs NNSISW 900608 dls. i BBNBISWS 7 £10608 73ev1 | L | 62688 aa (sdijs s2u9}s0) puo oseere ‘s/8q0) ‘Bulsnoy sepnjouj) S ATEN3SSV ONISAOH 9 q3ev1 & A ONISNOH baad os6ere leie8 18Service Manual 4.2 EXPLODED VIEWS (3 OF 7) 7 roa,BURDICK T600 Treadmill 4.2 EXPLODED VIEWS (4 OF 7) 5 5 oad! Boh HR BH 20BURDICK T600 Treadmill2 EXPLODED VIEWS (7 OF 7)BURDICK T600 Treadmill 4.3 GENERAL WIRING (1 OF 4) aznonns ‘nasv Fieve STREET rows SoM 9: ‘mas Tievo 06 24 SCRE MBIA OL Yo¥ WA | (once 24 ruses ‘aud A A von one an i 4 | cus V WVESVIT ONTSIM 24Service Manual 4.3 GENERAL WIRING (2 OF 4) aa wan MBIA dOL —MOTZE NMOHS SV Sd Sei HONOSHL V AVEOVIC ONTEIM NI-NMOHS SSuIM SINOU z dais 25BURDICK T600 Treadmill 4.3 GENERAL WIRING (3 OF 4) uname ay Nevo ETEEEE BIA OL nosy TOO waURY ORE “8D NB volo canes mows 2 md 2 Wo10N asses noes ome Ne 8 nase) 26Service Manual 4.3 GENERAL WIRING (4 OF 4) MBIA dOL —MOTSE NMOHS SV Sdild S8IM HONOSHL & WVEOvVIO ONISIM NI NMOHS SSSIM ‘ ’ Sino oBls a5 MAINTENANCE 5.1 PREVENTIVE MAINTENANCE ‘The purpose of preventive maintenance is to elimi- ‘ate future problems as much as possible and to keep the equipment in good operating condition. This ensures sate and dependable operation. The following preventive maintenance checks should be carried out al least once a year: * Visual inspection * Cleaning * Drive Belt * Power cord ‘* Enclosure leakage check + Rack gears * Chain maintenance * Speed & elevation calibration * Walking belt tension and tracking adjustments ‘+ Emergency stop function Simple maintenance routines, normally performed Gaily or weekly by the user, are described in the Operating Instructions. In the event of a fault or mal function, refer the repair to an authorized Siemens Burdick Service Representative. 5.1.1 Visual Inspection Check to see if the BURDICK T600 Treadmill has been subjected to extreme mechanical stress, it it has been subjected to liquid spills, if the function ‘seems to be disturbed, if the housing seems to be cracked, or if parts are removed or lost. Inspect the bottom pan vent holes for blockage and dirt accu- ‘mulation. Check the condition of the walking belt. Check all connectors and cords for signs of deterio- ration problems are apparent, unplug the power cable and check the following: + Are mechanical items firmly attached? * Are all internal electrical connections firmly at- tached? * Is there any sign of burning, chafing, or other damage? BURDICK T600 Treadmill 5.1.2 Cleaning The need for cleaning greatly depends on the en- vironment and frequency of use. Disconnect the ac power cord from the mains supply betore attempt- ing any cleaning. Clean the housing and handrails with a damp cloth and mild detergent solution it necessary. Wipe dry with a soft, clean cloth. A brush may be used on the walking belt When the housing is removed, use a vacuum clean- er and soft brush to eliminate any accumulation of dust. CAUTION — Do not use alcohol or solvents to clean the treadmill, Also, do not spill any liquids on the treadmil, since this can result in severe electrical damage. 5.1.3 Drive Belt ‘The drive belt and grooved pulleys must be kept free of ditt and debris. The belt will slip if there is any oil or grease in the grooves. Periodically clean the belt and pulleys with a mild detergent solution. If necessary, the belt tension may be loosened by adjusting the tension bolt on the motor platform. 5.1.4 Power Cord Check the power cord and appliance inlet for any Visible signs of deterioration, loose connections, or burn damage. 5.1.5 Chassis Leakage Check NOTE — Leakage tests should be conducted using 4 Bio-Tek 100M leakage meter or other meter capable of testing to AAMI specifications. Inap- propriate meters can produce erroneous leak- age readings. Leakage tests should be per- formed at a non-conductive work station WARNING — Use caution when conducting this test. The meter must be suitable insulated and capable of withstanding the power line voltage. 1, Turn the BURDICK 1600 Treadmill breaker switch ON. Use the controller to set the walking belt oa speed of approximately 4 miles per hour. 2. Connect a leakage meter between chassis: ground and power line ground. Ensure that leakage current is less than 100 pA. 28Service Manual 3. Open ground tine and ensure leakage current is less than 100 pA. 4. Reverse line polarity and ensure that leakage current is less than 100 A with ground closed. 5. With reversed polarity, open ground line and ensure leakage is less than 100 A. 6. Turn the BURDICK T600 Treadmill breaker switch OFF. Repeat chassis leakage check. 5.1.6 Rack Gears ‘The rack gears should be lubricated with a good quality fibrous whee! bearing grease. This is ac- complished by raising the treadmill to its maximum elevation and applying the grease sparingly. Exces- sive lubrication may stain the floor underneath the unit, 5.1.7 Chain Maintenance The Elevate Drive chain is metal and constructed with a master link. This chain should be examined during scheduled maintenance and lubricated sparingly with a heavy oil applied with a shop towel, Excessive lubrication will attract dirt and may drip through the bottom of the unit, 5.1.8 Walking Belt Tension & Tracking Too much belt tension results in excessive noise and wear. Belt tension should be adjusted prior to adjusting the tracking. The belt tension adjustment screws are located at the ends of the bed support rails and require the use of an Allen wrench. The fin- ger guards should be loosened prior to adjusting the belt tension. 1. Adjust the belt tension so that you can slide your hand under the edge of the walking belt at the center of the walking bed without difficulty. The tension should be equal on both sides of the bed. WARNING — Do not attempt to touch the walk- ing belt while itis in motion. 2. Turn on the treadmill and advance the walking speed to 4 mph. If a tracking adjustment is nec- essary, loosen the belt tension screw on the side corresponding to where the walking belt is moving away. 3. Check the belt for slippage by walking on it. If necessary, tighten both belt tension adjustment screws equally (by about one quarter of a turn). I the drive belt is slipping, also adjust the ten- sioning bolt which protrudes through the motor platform (do not over-tighten). Check the ten- sion again and repeat the adjustments if neces- sary. 4. If tracking is affected by the tension adjustment, remember to loosen the belt tension on the side where the belt is moving away. Tightening, instead of loosening, results in excessive belt tension, 5.1.9 Speed & Elevation Calibration Since the speed is electronically controlled, calibra- tion is normally not required. The minimum speed. adjustment on the de motor controller is factory set. The elevation is calibrated as follows: IMPORTANT NOTE: The treadmill has a built-in slope sensor (clinometer) which is not influ- enced by a sloping floor. However, if the floor is excessively sloped, the treadmill may be driven {0 its mechanical limits before attaining the cor- rect elevation. To avoid this situation, ensure that the treadmiil is on a level surtace (t0.25- inch variance aver a 6-foot area) prior to cali- bration. Also, since some controller displays do not update themselves immediately, be sure to jog the elevation up or down before reading the display. 1. Place the digital level on one of the side rails so that itis parallel to the length of the treadmil Do not put the level on the walking belt itsell. Ensure that the level rests squarely on the rail surface and does not rock or wobble. 2, Use the controller to adjust the treadmil's eleva- tion until the digital level reads 0% (+0.3%). 1 1e controller display reaches zero before the igtal level reads 0%, the treadmill will not go any lower until R33 (elevation offset) is adjust- ed. Use a small screwdriver to turn R33 counter-clockwise one half turn. Again, use the controller to adjust the elevation until the digital level indicates 0%. Ifthe lovel stil does not read 0%, continue to adjust R33 and use the con- troller to lower the treadmill until the digital level indicates 0%. 29It the treadmill hits the mechanical stop before teaching 0% on the digital level, the floor is not level, so adjust the two leveling pads at the foot of the treadmill. Extend the pads by about two tums. Again, use the controller to adjust the ele- vation unti! the digital level indicates 0%. If the level still does not read 0%, continue to adjust the pads two turns at-a-time (maximum dis tance = 2.5" from frame to floor) until the digital level indicates 0%. Check the elevation display on the controller, (Note that some displays do not update until the elevation is increased or decreased.) If the con- troller display does not read 0.0% (0.3%) use a small screwdriver to adjust R33 (elevation off- set) as follows: Connect a multimeter between TP and chassis ground. Turn R33 counter-clockwise until the voltage at TP1 is between +0.005 VDC and ++0.010 VDC. ‘Next, use the controller to adjust the teadmill's elevation until the digital level reads 25% (40.3%). 11 the controller display reaches 25% betore the digital level reads 25% the treadmill will not go any higher unti! R61 (elevation gain) is adjust- €. Use a small screwdriver to turn R61 Ccounter-clockwise one turn. Again, use the con- troller to adjust the elevation until the digital level indicates 25%. If the level still does not fead 25%, continue to adjust R61 and use the Controller to raise the treadmill until the digital level indicates 25%. {the treadmill hits the mechanical stop before reaching 25% on the digital level, adjust the two leveling pads at the foot of the treadmill. Retract BURDICK 7600 Treadmill the pads by about two turns. Again, use the controller to adjust the elevation until the digital level indicates 25%. If the level still does not fead 25%, continue to adjust the pads two turns at-a-time until the digital lovel indicates 25%. 5. Check the elevation display on the controller. (Note that some displays do not update until the elevation is increased or decreased.) If the con- troller display does not read 25.0% (40.3%) use a small screwdriver to adjust R61 (elevation gain) as follows: Connect a multimeter between TP and chassis Ground. Adjust RG1 until the voltage at TP1 is +4.88 VOC (+0.05 VDC). 6. Use the controller to lower the treadmill to 0%, then back up to 25%. Ensure that the controller display agrees with the digital level over the range of elevation settings. If it does not, repeat the calibration procedure. 5.1.10 Emergency Stop Switch If the optional emergency stop switch is installed, its function must be checked periodically. If tis not installed, ensure that a jumper is installed across pins 2 and 3 of connector JP1 on the Treadmill Con- {rol PCB. The treadmill will not run unless either the ‘emergency stop switch or jumper is installed. Test the emergency stop function by running the walking belt at various speeds and pressing the ‘emergency stop button, Each time, ensure that the walking belt slows to a complete stop. CAUTION — To avoid injury, do not pertorm this check when a person is on the treadmill. Stay lear of the walking belt at all mes! 30Service Manual 6 THEORY OF OPERATION 6.1 PRIMARY POWER DISTRIBUTION Power to the primary of transformer T1 is through circuit breaker CB1. Both sides of the line are inter- rupted any time the current draw becomes exces- sive. T1 and the secondary circuits are protected by fuse F2, The walking belt drive motor is powered by a de motor controller. Q4 provides momentary power (lor about 50 ms) to start the controller, Q3 powers the controller during normat operation. ‘An optional external emergency stop switch allows the bell to be stopped quickly. When the normally closed switch is opened, relay K1 opens to disable power to the motor controller. If the stop switch is ot used, pins 2 and 3 of JP1 must be connected with a shorting plug. Power to the elevate motor is supplied through fuse 1. Commands issued from the controlier/monitor to the Treadmill Control PCB determine the direction of elevation by energizing either triac Q1 or Q2, and the motor brake is released by current through triac, Os. 6.2 TREADMILL CONTROL PCB The Treadmill Contiol PCB is located in the BUR- DICK 7600 Treadmill housing. It serves as the com- munication link between the external controller and treadmi 6.2.1 Power Supply Low voltage ac is supplied from the center-tapped transformer secondary on the Treadmill Control PCB. The output ranges between #14 VDC, depending on the treadmill load and line voltage. Diode D1 provides full-bridge rectification of the transformer output. +12 VOC is filtered and regulat- ed through IC1, IC2, and associated components. The +5-V supply is regulated through IC3 and asso- ciated components. 6.2.2 Microprocessor and Logic U1 is a MCBBHC1 1A0 microprocessor/controller which handles logic functions for the Treadmill Con- trol PCB. Program information is stored by US, a 32K x 8-bit EPROM. Temporary data and user- defined protocols are stored by U9, a 2K x B-bit bat- tery backed-up RAM. Addressidata lines ADO-AD7. are latched by U2 under control of the AS signal from U1. Memory and I/O decoding is done by U4- ‘A, U4-B, U4-D, and U16-A. Power-on reset and low voltage detection for the +5-V supply is done by ura The microprocessor, U1, is configured as follows: Port A, bits 0 and 7, monitor tachometer pulses from the belt drive motor and calculate the speed. Bit 6 controls the motor speed by sending a pulse-width Modulated signal to the de motor controller. Port D controls U11, an output driver which acti- vates the triacs. Bits 0 and 1 control the amount ele- vation increase and decrease, respectively. Bit 2 controls the brake release. Bits 3 and 4 are the RUNISTOP and START signals, respectively. Port E, bits 0-3, are for factory testing, Bit § is an analog input to the microprocessor’ internal A/D converter from the clinometer. R22 and D2 provide the necessary 5-V reference. Bit 6 monitors the seri- al connector to determine whether an M300d moni- tor or TA620 controller is attached to the treadmil Bit 7 is polled to determine if the emergency stop button has been activated. 6.2.3 Data Acquisition and VO ‘A clinometer provides analog elevation feedback. U14 and associated components provide the Fequired offset and gain adjustments. R33 allows for variances in individual clinometers, R61 adjusts the gain for 0-5 VDC, corresponding to 0-25% cleva- tion, ‘An optically coupled tachometer provides pulses from the walking belt motor. U13 and associated components transform the pulses to TTL level for input to the microprocessor at port A, bits 0 and 7. ‘The SPEED control signal is sent to the de motor controller via R31, ISO1, and R17. Analog outputs from the treadmill are produced by ‘means of U6, a dual sample-and-hold D/A convert- er. UB and UB provide two 0-10-V0C outputs which are proportional to 0-10-mph speed and 0-25% elevation. These signals are made available at pins 6 and 7 of the AUXILIARY connector as the speed and elevation outputs, respectively. VREF1 provides a 10.00-V precision reference to US and supplies Power for the clinometer. 31BURDICK T600 Treadmill U15-C and associated components determine if the triacs, Q1-Q5, to energize the elevation motor and emergency stop switch is installed. U15-D and brake or de motor controler. associated components determine which type of Controller is installed at external connector P2. 6.2.5 Serial Communication U7, a programmable duart, handles serial commu- nication between the moniter, controller, or other eae contd device. U10 converts the signals to the appropriate Control of the treadmill triacs is determined by the _RS-232 signal levels. Two-wire mode commun ‘microprocessor, U1. Control data is latched for out- tion is available at the external CONTROLLER con- put by U1}. Ifa triacis to be energized, a "1" will be necter, P2, for a monitor or manual controlion Four, written to that corresponding data bit. U1 activales wire mode communication is available at the oxter- the LEDS in the opto-isolating trac drivers TO1=-T05 nal AUXILIARY connector, P1, for a personal com. to enable an output. In turn, this allows the output _ puter or other compatible system. 6.3 TREADMILL CONTROL PCB BLOCK DIAGRAM MONITOR/TA620 i |__|. pemoton DETECTION ! P CONTROLLER SEED MICRO- / opto. } oH cowtrouen =| | mroesston |) | greed | puant | P| tow | | ‘ - vere | TACHOMETER sza2 Drivers | / ri AUXILIARY =-[——>| i 4 hop J ) \, L dl CISA I Ih evevarion CONVERSION. |) / [fp Motor eel i pee i EMERGENCY oon tt RELAY + ACTO & *——j-— CLINOMETER ‘STOP SWITCH DRIVE orrseT |) MOTOR STREET no [+5 voc. en | ac suppty — ——r#12 Voc [-—~+15 voc UNREG. 32Service Manual 7 SCHEMATIC AND COMPONENT DIAGRAM 7.1 WIRING DIAGRAM (1 OF 3) 7.2 TREADMILL CONTROL PCB SCHEMATIC (2 OF 3) 7.3 TREADMILL CONTROL PCB SCHEMATIC (3 OF 3) 7.4 COMPONENT DIAGRAM “33=) Zeegsen w3asy GuvoOg TOYLNOD gagL woi2anno3 ‘vB7au1N03 no.ine 01s vapourSt | WOwLNOD TAINOWSuL “3NT_OTOuNE _SNENSTS ee eerie = T 7 T care TIYWSHIS 89a Faosr—4 _ of LynsHas zeessex wasy ) ) ) )STLVWSHIS God JOBLNOD TAIWOVSHL 331 GuNe SNEWSTS b zeesean wasy 7! = ssivo oasnan”ANBNOJNO3 ‘sure 2 “3310uNS SN3W3IS =