Precor TRM 885.v2, TRM 835.v2, TRM 811.v2 Service Manual

Service Manual

Contents

TRM 800v.2 Series Treadmill ........................................................................................................ 7

Lubricants ...................................................................................................................................... 7

Electrical Requirements ................................................................................................................ 7

US and Canada power requirements ................................................................................ 8

PVS (Personal Viewing Systems) Equipped Units .............................................................. 9

P80/P82 Console Equipped Units ......................................................................................... 9

RF (CATV) Requirements ....................................................................................................... 9

Internet Ethernet Requirements ........................................................................................... 9

Power Input ................................................................................................................................. 10

Nominal 120V systems .......................................................................................................... 10

Nominal 230V systems .......................................................................................................... 10

Procedure .............................................................................................................................. 12

Operation Verification Checklist .................................................................................................. 13

Service Access Codes ................................................................................................................ 14

Accessing the Service Software .................................................................................................. 14

P80 Console ........................................................................................................................... 14

Service Access Codes ................................................................................................................ 15

Hardware Validation Settings (51765761) .................................................................................. 15

Club Parameter Settings (5651565) ............................................................................................ 16

Information Display (65) .............................................................................................................. 17

Consoles ...................................................................................................................................... 19

Basic operation of a console ............................................................................................. 19

Optional TRM800.v2 Base Consoles .................................................................................. 20

Console to Base Communication ................................................................................................ 20

Bleed Resistor ............................................................................................................................. 22

A 1MΩ 1500V bleed resistor between the secondary ground and earth ground is

required for voltage stabilization. ...................................................................................... 22

Dynamic Brake (DB) Resistor ..................................................................................................... 22

Dynamic Brake resistor overload detection (Thermal sensing) ................................... 22

Dynamic Brake resistor detection circuit. ........................................................................ 22

Dynamic Brake thermal switch .......................................................................................... 23

Diagnostics and Indicators .......................................................................................................... 23

Motor Controller Light (MCL) Service Status Indicator .................................................. 23

Active Status Light (ASL) LED .............................................................................................. 23

Drive System Monitoring ............................................................................................................. 24

Input Current Overload Detection .................................................................................... 24

Input current .......................................................................................................................... 24

Input current overload error 36 .......................................................................................... 24

Instantaneous Input Current Overload Detection ......................................................... 24

Input overload error 35 ........................................................................................................ 24

Motor Over Temperature Detection ................................................................................. 24

Motor Current Overload Detection .................................................................................. 24

Lift Drive Motor Operation ........................................................................................................... 25

Lift Motor ................................................................................................................................. 25

Lift accuracy .......................................................................................................................... 25

Lift Motor Operation ............................................................................................................. 25

Lift motor overload protection ........................................................................................... 25

AC Lift System – Motion Control ......................................................................................... 26

AC Lift System – Position Monitoring .................................................................................. 27

Drive / Lift System Control ................................................................................................... 27

Drive Motor Operation ................................................................................................................. 28

AC Drive Motor Controller ................................................................................................... 28

Auto-Stop ............................................................................................................................... 30

Introduction to Treadmill Troubleshooting ................................................................................... 31

TRM 800.v2 Status lights- ...................................................................................................... 31

Active Status Light- ASL ....................................................................................................... 31

Drive Motor and Input Voltage/Current Measurements- ............................................. 34

General Troubleshooting Methodology ....................................................................................... 35

Troubleshooting Tripped Breakers .............................................................................................. 36

If the unit trips the wall breaker: ......................................................................................... 36

If the Treadmill breaker (power switch) is tripped: ......................................................... 37

Troubleshooting No Power to the Console, P10 and P30........................................................... 38

Error Codes ................................................................................................................................. 39

Error Codes ............................................................................................................................. 40

Error Code Table ................................................................................................................... 41

Troubleshooting Input Power & Control Error Codes .................................................................. 45

Error 10 – Line Frequency out of Acceptable Range .................................................... 45

Error 11 - Watchdog (Upepr PCA) Low Voltage ............................................................. 45

Error 12 - Watchdog (Lower PCA) Low Voltage ............................................................. 46

Error 14 – Fan Fail (Lower PCA) ........................................................................................... 46

Error 15 – DC Bus Over Voltage .......................................................................................... 47

Error 16 - A.C. Input Voltage Too Low ............................................................................... 48

Error (none) - Key Depressed at Power Up- No Error Code Generated .................... 48

Error 80, 81, 82, & 83 – P30/P80 Machine Controls Not Working .................................. 49

Troubleshooting the 3 Phase AC Drive Motor System ................................................................ 50

Troubleshooting the Drive Motor ................................................................................................. 50

Procedure: ............................................................................................................................. 50

Error 17 – DB Resistor Thermal Trip Software Detection .................................................. 54

Error 85 – No Dynamic Resistor Detected ........................................................................ 54

Error 19 – PFC Malfunction .................................................................................................. 55

Error 20 – Motor will not start / No motor movement detected .................................. 55

Error 25 – Lower Drive Hardware Error ............................................................................... 56

Error 27 - Too Much Drive Motor Current .......................................................................... 56

Error 28 - Temperature Too High / Drive Electronics ....................................................... 57

Error 88 – Temperature Too High / Motor Temperature Switch .................................... 57

Error 35 - Excessive AC Input Current / Instantaneous................................................... 58

Error 36 - Excessive AC Input Current/ Circuit Breaker Trip Prevention ....................... 58

Troubleshooting the Incline System ............................................................................................ 60

Operation of lift motor for testing: ..................................................................................... 60

Error 40 - No Lift Motion Detected ..................................................................................... 60

Troubleshooting Procedures ............................................................................................... 61

Error 42 - Lift Position Value Out of Range ........................................................................ 62

Error 44 - Un-commanded Lift Motion ............................................................................... 64

Error 45 - Lift Moving in Wrong Direction ........................................................................... 64

Troubleshooting Communications Errors .................................................................................... 65

Errors 30 and 32 - Communications Error between Upper and Lower Boards ......... 65

Error 37 - E-Stop Upper State vs. Lower State Mismatch ............................................... 66

Error 86, 87 – Console / Motor Controller Mismatch – P10/P30 Only ........................... 66

Belt Rating Details ....................................................................................................................... 68

Procedure .............................................................................................................................. 68

Troubleshooting the Auto Stop Feature ...................................................................................... 69

Troubleshooting Heart Rate Issues ............................................................................................. 69

Hand Held Heart Rate Does Not Work ............................................................................. 69

Wireless Heart Rate Does Not Work ................................................................................... 70

Possible sources of interference signals include, BUT NOT LIMITED TO: ...................... 71

Removing the treadmill hood. ...................................................................................................... 72

Removing and replacing the Deck Trim Landing Strips. ............................................................. 73

Removing and replacing the front Corner Cover ......................................................................... 74

Removing and Replacing the Side Trim ...................................................................................... 75

Removing and replacing the Line Cord, Circuit Breaker or ASL PCB. ....................................... 76

Replacing the Motor Control (MC) Module .................................................................................. 78

Replacing the Drive Motor ........................................................................................................... 79

Replacing the Lift motor .............................................................................................................. 80

Replacing the Incline Platform ..................................................................................................... 82

Replacing the Take-Up Roller ..................................................................................................... 83

Drive Belt and Roller Replacement ............................................................................................. 84

Running Belt and/or Deck Replacement ..................................................................................... 85

Drive Belt Tension Adjustment .................................................................................................... 88

Running Belt Tension and Tracking Adjustment ......................................................................... 90

Tensioning the Running Belt ................................................................................................ 90

Running Belt Tracking Adjustment ..................................................................................... 91

Calibrating the Lift Motor ............................................................................................................. 92

About ........................................................................................................................................... 94

Maintenance Schedule ................................................................................................................ 94

Daily ............................................................................................................................................. 94

Quarterly .................................................................................................................................. 98

Running Belt and Deck Cleaning Procedure ............................................................................... 99

System Block Diagram - 120 Volt Models ................................................................................. 102

FInding Part Numbers ........................................................................................................ 103

Exploded View ........................................................................................................................... 104

Parts List .................................................................................................................................... 111

About This Document

Warning:

This service manual is for use by Precor trained service providers only. If you are not a Precor Trained Servicer, you should not attempt to service any Precor products. Call your dealer for service.

This document contains information required to perform the majority of troubleshooting and replacement procedures required to repair and maintain this product.

This document contains general product information, software diagnostic procedures (when available), preventative maintenance procedures, inspection and adjustment procedures, troubleshooting procedures, replacement procedures and electrical block and wiring diagrams.

Part No: 20039-180 rev A05 .

General Information

NOTE

Use of unapproved lubricants, cleaners, or solvents may void the treadmill warranty

IMPORTANT

note

An individual branch circuit provides a hot conductor and neutral conductor to a receptacle. The conductors must not be looped, "daisy-chained", or connected to any other conductors or receptacles. The circuit must be grounded according to NEC guidelines or local region electric codes..

TRM 800v.2 Series Treadmill

This manual covers service information for the TRM 800 Series Treadmill.

Lubricants

 Do not apply any lubricants to the deck and belt. Do not use Wax Blast, silicon sprays, or other

applied lubricants. The use of these lubricants will quickly degrade the low-friction surface of the deck.

 Do not use petroleum based lubricants on mechanical components such as the lift, as this may

result in degradation of nylon gearing mechanisms. Use only synthetic lubricants such as "Super Lube with Teflon" or "Mobile One Synthetic" grease (RED).

Electrical Requirements

When your equipment is delivered you will receive an equipment power cable that meets your local electrical code requirements. Precor treadmills must be connected to a 20 amp, individual branch circuit that can be shared only with one PVS (Personal Viewing System) screen. If you need additional help with the power connections contact your Precor authorized dealer.

Note: NEC (National Electric Code) guidelines or local region electric codes must be followed.

US and Canada power requirements

Power

Equipment voltage

Outlet/Plug type

US & Canada

120VAC, 50/60 Hz

NEMA 5-20R/5-20P

US & Canada

240VAC, 50/60 Hz

NEMA 6-20R/6-20P

The treadmill base is outfitted with a removable line cord plugged into a power entry socket. This is designed to accommodate either 120V or 240V NEMA compatible line cords, as well as line cords for other countries. The diagram below shows a NEMA 20A plug for both 120V and 240V configurations in the United States.

PVS (Personal Viewing Systems) Equipped Units

For equipment fitted with a PVS screen, a separate power connection is required. Using a 20 amp branch circuit, up to 10 screens can be connected. No other devices except PVS may be connected to this circuit.

P80/P82 Console Equipped Units

For self-powered equipment fitted with a P80 console, a separate power connection is required. Using a 20 amp branch circuit, up to ten P80 consoles can be connected. No other devices except P80 consoles may be connected to this circuit.

RF (CATV) Requirements

Where P80 or PVS screens are used there is a minimum RF power requirement to properly supply CATV to the screens. We require +5dB to +10dB RF power with a minimum of +40dB C/N Channel to Noise ratio) at each screen for analog video and -5dB to 0dB for digital video signal. If a wall RF outlet is to be used to power several screens in a row of equipment there is a minimum RF power requirement at the outlet of +35dB (at +40dB C/N) for analog video (+25dB for Digital video). RF signal strength of +35dB can power 17 to 19 screens in a single row when properly tapped out.

Internet Ethernet Requirements

It is recommend a dedicated CAT6 Ethernet feed to each equipment location. Communication Requirements:

 512Kb/s up  5-10Mb/s down  Switch Ports: 80, 123, 443

The P80 console uses a security token for communication to Precor servers. The security token is a hash string that is sent with every API call from the FE’s to the Amazon Cloud.

It originates after the equipment is registered at the location. The P80 issues a ‘Call’ which returns the registration token and the fitness equipment URL. Every event after that uses the URL and the token to validate/authenticate communication with the Amazon servers and Preva Business Systems (PBS).

All communication with our servers is currently done via outgoing (originating from the console) HTTPS sessions. The P80 utilizes NTP to set its clock and for synchronization. At no time is Precor connecting to your network to "push" any data. The P80 initiates all data requests.

Power Input

Nominal 120V systems

Operating voltage range: 85 – 145 VAC Frequency: 47 – 65 Hz

Nominal 230V systems

Rated operating voltage range: 180 – 264 VAC Precor internal required operating voltage range: 180 – 275 VAC with reduced performance

allowed. Frequency: 47 – 65 Hz

120 Vac Systems

120 VAC distribution systems utilize a single pole circuit breaker (hot lead) and a neutral lead connected to a common neutral (ground) bar. The A.C. safety ground (green wire) is connected to a separate ground bar in the distribution system.

If it is determined that any of the above electrical conditions are in question, please consult with a qualified electrician to make appropriate circuit changes.

Safety Guidelines

Safety guidelines you should know and follow include:

 Read the owner’s manual and follow all operating instructions.  Operate the equipment on a solid, level surface.  Visually check the equipment before beginning service or maintenance operations. If it is not

completely assembled or is damaged in anyway, do not attempt to operate the equipment.

 When operating the treadmill:

o Do not wear loose clothing. o Do not wear shoes with heels or leather soles. o Check the soles of your shoes and remove any embedded stones. o Tie long hair back.

 Do not rock the unit.  Do not stand or climb on the handlebars, display enclosure or cover.  Do not set anything on the handlebars, display enclosure, or cover. Never place liquids on any

part of the treadmill while performing service.

 To prevent electrical shock, keep all electrical components away from water and other liquids.  Do not use accessory attachments that are not recommended by the manufacturer-such

attachments might cause injuries.

 Removing the hood exposes high voltage components and potentially dangerous machinery.

Exercise extreme caution when you perform maintenance procedures with the hood removed.

Operation Verification

This section provides a method of checking the treadmill basic operation. Check the treadmill operation at the end of a maintenance procedure or any time it is necessary to ensure that the treadmill is operating properly. For a complete guide to all operating parameters, refer to the Operators Manual.

Procedure

Plug the power cord into the wall outlet and then switch the circuit breaker to the "ON" position. Press and hold the reset key or the stop button for at least 6 seconds, if errors are present the error

log will be displayed. Make note of all the errors in the error log and odometer reading for which the error occurred. The odometer in the error log can help you determine age and relevance of the error.

 Enter the Hardware Validation test by entering Diagnostic mode as follows:

o Press either the STOP, PAUSE or RESET buttons and then enter 5,1,7,6,5,7,6,1

 Select and run the Display Test, the Keypad Test, and the Heart Rate Test. Verify the following

results.

o LEDs light o Keys all function o Heart rate is acquired and displayed

 Enter the Machine Tests (submenu) and run the Belt Speed test and the Incline test, verify

following results:

o Running belt moves and is controlled from 0.5mph to 12.0mph in 0.1 increments. o Lift goes up and down and the A/D value is approximately 6800+/-500 at 0% incline)

 Press the reset key to exit diagnostics.  Operate the treadmill in the Manual program. Adjust the speed of the running belt to 2–3mph.

Operate the treadmill for at least 5 minutes while walking on the unit.

 Concentrate on the feel of the running belt, the sound of the drive motor and rollers. Be on the alert

for unusual noises, smells or vibrations.

 Observe the LED’s on the electronic console. Make sure that each LED lights as the information

corresponding to that LED is displayed on the electronic console.

 Press the INCLINE he electronic console. Confirm that the running deck inclines

 Press the INCLINE

to a level position and the incline display decrements to 0% as the INCLINE (Depending on the software configuration of the console, the lowest level of incline might be -3%)

 While the unit is running and the running belt is in motion, press the STOP button and verify the

running belt stops.

 While the unit is running and the running belt is in motion, pull the ESTOP cord and verify the

running belt stops.

 Press and hold the reset key for at least 6 seconds and look at the error log again. This time look for

any NEW errors displayed resulting from the verification test indicating that the unit

Operation Verification Checklist

 Check, record, and then clear any errors in the error log.  Verify that all LEDs function properly during the Hardware Validation Tests.  Verify that all keys on the keypad function properly during the Hardware Validation Tests.  Verify that the heart rate functions normally and displays a valid heart rate.  Verify the running belt drive system functions properly throughout the minimum to

maximum range of control. All drive system components (deck, belts, rollers, IFT) are free of excessive noise, vibrations, or smells

 Verify the Incline A/D value is approximately 6000+/-500 at 0% incline; the incline operates

within the complete range of the lift when the  or  keys are pressed and is free of excessive noise or vibrations.

 The STOP button stops the running belt from moving.  Pulling the ESTOP cord stops the running belt from moving.  Check for new errors that may have been recorded in the error log during operation

verification of the treadmill.

Service Access Codes

Included topics:

 Service Access Codes  Club Parameter - Settings (5651565)  Information Display (65)

NOTE

The keypad X configuration sequence should be not faster than 1 second between each key stroke. Any speed faster than 1 second may result in an unsuccessful access to the sign-in screen.

Service Access Codes

The service access codes are utilized on the following consoles:

 P10  P30  P80

The service codes access three functional modes, Hardware Validation, Club Parameters, and an Information Display.

 Hardware Validation is a set of functional diagnostic tests that are useful in troubleshooting

problems as well as verifying proper operation.

 Club Parameters are sometimes referred to as Club Settings or Workout Parameters and

are used to manage usage of the machine.

 Information Display is used to access information such as the odometer, software versions

and error logs.

Accessing the Service Software

Accessing the service code functional modes is accomplished in the same way on the P10 and P30 consoles. The differences in the P80 will be discussed below.

To enter Service Software, press either the STOP or the PAUSE or RESET key followed by a numeric code for the area of service software you wish to access.

The standard access codes use sequential key presses, not simultaneously holding down multiple keys. The allowable delay between key presses is short. If too much time is taken between key presses or the wrong key is pressed, the access procedure will be aborted. If the access is aborted, it will be necessary to start over from the beginning.

P80 Console

 Use the System Settings to test your equipment and set parameters that benefit your users and

your facility.

The Welcome screen will be the first screen you see when you approach the P80 console. Press the Pause key and continue holding it down while you single press in sequential order an X configuration on the Volume and Channel key pad (Channel Up, Volume Down, Volume Up, Channel Down). Release the Pause key when done pressing the arrows.

Access Code

Heading Name

Function

5,1,7,6,5,7,6,1

Hardware Validation

Running Diagnostic Tests

5,6,5,1,5,6,5

Club Parameters

Changing Machine and /or Workout Parameters

6,5

(P10 & P30 Only)

Information Display

Acquiring Information

Enter Hardware Validation settings mode.

Press STOP/PAUSE/RESET key, 5, 1, 7, 6, 5, 7, 6, 1

DISPLAY TEST

Steps through a check of all LEDs on console

KEYBOARD TEST

Checks all key actions on console

PVS 10 KEY TEST

Checks all 10 keys

HEART RATE

Simulates heart rate activity

Figure 2: P80 Sign In Access

The sign-in screen will be displayed. Type in the technician access ,5,1,7,6,5,7,6,1, and then touch OK. The Settings menu will be displayed.

Service Access Codes

Hardware Validation - Diagnost ic Tests (51765761)

Hardware Validation Settings (51765761)

The Hardware Validation settings access code is 51765761.

Figure 3: Hardware Validation

ACTIVE STATUS LIGHT

Shows current status of light- Hold QuickStart to reset

AS LIGHT BRIGHTNESS

Varies ASL LED brightness from Low, Med, High

MC LIGHT STATE

Shows current state of MC LED-Hold QuickStart to reset

MACHINE TEST

Allows manual operation of machine functions – all tests work independently of workout limits.

BELT SPEED

Tests belt speed in 0.1 increments Displays Input Voltage, Current to the treadmill, and output voltage, current to the drive motor.

AUTO STOP

Checks Auto Stop function by averaging footplants Displays if the user is detected or not detected. Footplant averaging delay renews with each speed change.

INCLINE

Tests incline/decline Displays A/D number, Glitches, communication time between LPCA and UPCA.

STOP KEY (P10/P30)

Checks Stop Key function Requires Stop Button press, then Lanyard E-Stop pull and button reset. Will exit the tests to the Welcome screen.

Enter Club Parameter settings mode (P10& P30)

Press STOP/PAUSE/RESET key, 5, 6 , 5 , 1 , 5 , 6 , 5

SAFETY CODE

Either enabled or disabled. When enabled, the setting requires a password (1234) to be entered in order to start the unit. Factory default is disabled.

SELECT LANGUAGE

Sets the default language for all workouts on this machine. Language for single use workouts can still be set by the user from the workout options.

SELECT UNITS

Sets units of measure (US standard or Metric). Factory default is US standard.

SET MAX WORKOUT TIME

Sets the maximum allowable workout time for each user. Factory default is 60 minutes.

SET MAX PAUSE TIME

Sets the maximum time that the workout can be paused during a workout. Factory default is 120 seconds.

Club Parameter Settings (5651565)

The Club Parameter settings access code is 5651565.

Figure 4: Hardware Validation

SET COOL DOWN TIME

Sets the amount of time that a cool down period will occur at the end of every workout. Factory default is 5 minutes. Settable in 1 minute increments.

SET METRICS DEFAULT

Sets a metric that may be of specific importance to the specific facility or fitness trainer. The selected metric will scroll across the screen at regular intervals during the workout. Factory default is "NONE".

SET SPEED LIMIT

Sets the maximum speed the user can set the unit to. Factory default is 12 MPH.

SET INCLINE LIMIT

Sets the maximum value the user can set the unit to. Factory default is 15%.

HIDDEN PROGRAMS

Either enabled or disabled, the setting allows the unit to access specialized fitness tests designed for police, fire fighters and the military. Factory default is disabled.

REMOTE SPEED CONTROL

Not currently used or supported in software.

AUTOSTOP CONFIGURE

Sets the Auto Stop setting to On or Off. Factory default is “ON”

SET CUSTOM PROGRAM 1

Intended for a custom program to be programmed if the tread is used in a residential setting.

SET CUSTOM PROGRAM 2

Intended for a custom program to be programmed if the tread is used in a residential setting.

ITEM

DESCRIPTION

ODOMETER

Displays the total number of accumulated miles on the unit. This value is stored in the upper PCA in the console so if the PCA is replaced the accumulated miles would start again from "0".

HOUR METER

Displays the total number of hours that the unit took to accumulate unit miles. This value is stored in the upper PCA in the console so if that PCA is replaced the hours of use would start again from "0".

BELT RATING

Displays a belt rating from 10 (best) to 0 (worst). Resettable to 10 by holding QuickStart.

U-BOOT SW

Displays the current version of boot-up software for the upper PCA (console).

U-BASE SW

Displays the current version of software loaded in the upper PCA (console). This is the unit specific console software.

LOWER SW

Displays the current version of software loaded in the Machine Controller.

Information Display (65)

Information Display Access: press STOP/PAUSE/REST > 6,5

METRICS BOARD SW

Displays the current version of software loaded in the metrics board.

SER. NUMBER

The base serial number can be set here using the WinCSAFE computer software. The factory default is NONE.

USAGE LOG

Displays the type of workout programs the users are accessing most frequently.

ERROR LOG

Displays a running log of the last 30 errors encountered on the unit.

TREADMILL MAINTENANCE

Used to monitor and reset the 1000 mile belt cleaning maintenance reminder. Mileage counter starts at 1000 miles and decreases to 0 miles which triggers a blue pulsing ASL light indicating it’s time for belt cleaning maintenance. The maintenance counter and ASL light is reset as follows: P10/P30 console

1. Select Treadmill Maintenance.

2. Press and hold QUICKSTART until 1000 Miles is displayed. The ASL light is also

reset.

3. Exit the menu by pressing BACK or PAUSE/RESET.

P80/P82 consoles:

1. Access the service diagnostics (5,1,7,6,5,7,6,1).

2. Select Maintenance page.

3. Select Next Maintenance Due page > Reset.

On P82/P80 consoles, the belt cleaning reminder ASL function can be switched ON or OFF, select Maintenance Reminder > ON/OFF.

Theory of Operation

Included topics:

 Consoles  Console To Base Communication  Treadmill Base Operation

Consoles

Basic operation of a console

The purpose of this section is to describe the operation and maintenance of the treadmill base, however it would be difficult to explain the base operation without referring to the console controls. This section will explain basic functions that apply to all models of consoles. For specific details about a particular model of console (P10, P30, P80), refer to the applicable console manual.

The Controls

All consoles provide user input (keypad functions), user display (LED display / user feedback), automated control (heart rate program, interval program) and service software routines (tests, settings, and information).

The keypad functions can vary between different console models, however the basic functions that all consoles have are QuickStart, Incline (up or down) and Speed (up or down).

The Display

The display features can vary between different console models, however the information conveyed by those displays are very similar.

Service software routines are handled exactly the same for all console models. Entering into Hardware Validation tests, Club Parameter settings, or Information Display is also the same and is called Standardized Service Access Codes.

The service software and standard access codes are described in detail in Standardized Service

Access Codes of this manual.

Optional TRM800.v2 Base Consoles

Figure 6: Commercial Treadmill Consoles

P10

P30

P80

Console to Base Communication

The processor in the console provides user input, user display and automated control to the system. The processor in the lower electronics module performs the actual machine function.

The two processors communicate via a serial data stream. When the user requests a machine function to take place via the keypad, the console processor communicates the request to the processor in the lower electronics module.

Once the lower processor receives the request the lower control module performs the machine task associated with the request. The console processor continues to monitor keypad entry and provide display feedback. The lower processor also provides status back to the console processor (via the serial data stream) to report if everything occurred properly, or if an error code needs to be written to the error log.

Figure 7: Electrical System

Off

Motor

Motor Controller

Dress Plate

Line

Filter

DB resistor

Lift Motor

To Console

New Electrical System

Active

Status Light

Bleed Resistor

A 1MΩ 1500V bleed resistor between the secondary ground and earth ground is required for voltage stabilization.

Dynamic Brake (DB) Resistor

The dynamic brake resistor is turned on to dissipate power generated from the main motor. This can occur when the user runs at a high incline. The brake resistor must add the needed load to the system to prevent the treadmill from accelerating from the target speed. The dynamic brake resistor will go active when slowing to a stop if the system inertia causes the motor to generate power.

Dynamic Brake resistor overload detection (Thermal sensing)

The lower software has built in thermal sensing. This thermal sensing indicates when the brake resistor is too hot to use.

A power time algorithm will be used to estimate the temperature of the brake resistor. The intent is to shut down the treadmill based on this algorithm before the thermal switch opens.

When the maximum brake resistor operation time (temperature) has been reached:

Error 17 is sent to the display.

Dynamic Brake resistor detection circuit.

The DB resistor is tested on power up only. If it is not working an error 85 is thrown but the treadmill will operate normal except if the DB resistor is needed. When the DB resistor has failed, the buss voltage will increase until Over Voltage condition causing an error 15 event and the treadmill will stop.

A broken thermal switch to Motor Controller wire connection will cause the same symptoms.

Dynamic Brake thermal switch

As long as the thermal switch is open the console will show the “use another treadmill” message. The treadmill cannot be used when the DB resistor is overheated causing the thermal switch to open. When the DB resistor cools enough to allow the thermal switch to close the treadmill will return to normal operation. A broken wire will exhibit the same symptoms as an open thermal switch.

The DB resistor is only self-tested on power up. If it is not working correctly an error 85 is triggered but the treadmill will continue to operate normally except if the DB resistor is required. In this case the buss voltage can increase to an over voltage condition causing and an error 15 to trigger and the treadmill to stop.

The thermal switch contacts are easily spread and damaged by inserting meters probes while testing. This can cause intermittent connector electrical contact. If this occurs the DB resistor assembly will need to be replaced.

Diagnostics and Indicators

Motor Controller Light (MCL) Service Status Indicator

The MCL is a tri-colored LED showing service status, used to indicate an error condition within the MC. Currently only two colors are used – Green indicates no problems with the MC, Yellow indicates that an error has occurred, and diagnosis should be performed.

The console is in charge of setting the LED state; the MC will not change the LED state unless it is requested by the display.

The MC will remember the status even after a power cycle. It can only be reset via the console through the diagnostics menus.

The LED status is used to check the drive’s status when it is returned to the factory. Status and error tracking data is stored in non-volatile memory. This provides information on recent

operation and error in the drive. This is like ‘black box’ type of recorder for the drive.

Active Status Light (ASL) LED

The ASL is visible on the front of the treadmill and will indicate the status of the treadmill. There are currently four states for the ASL – Blue solid, Blue Flashing, Yellow Solid, and Yellow Flashing. These are described in detail in the Troubleshooting section.

The ASL is microprocessor controlled, and located on a PCB mounted to the front of the treadmill. The ASL will show blue at bootup. Communication between this board and the MC is via a four pin cable with RJ11 type connectors.

The console will determine, through the MC, what color will be displayed.

Drive System Monitoring

Parameters in the drive system must be monitored to ensure proper operation and to respond to overload conditions. This includes the input current, input voltage, motor current and temperature.

Input Current Overload Detection

The drive system will monitor the line input current. The drive should detect the overload before the circuit breaker.

Input current

Input current is reported in true RMS Input current is averaged over 2500mSec rolling period.

Input current overload error 36

The error code is reported to the display when this overload is detected. The error is reported per the communications protocol.

Instantaneous Input Current Overload Detection

The drive system will monitor the input current for fast input current incursions. The drive will detect the overload before the circuit breaker. A hardware delay will define the error response time.

Input overload error 35

The error code is reported to the display when this overload is detected. The error is reported per the communications protocol.

Motor Over Temperature Detection

The motor temperature is monitored with a thermal switch in the motor winding and a time current shutdown algorithm. The thermal switch is an indicator the motor is getting hot and is used to start the current time counter algorithm. Thermal switch is normally closed.

An open thermal switch will report error 28. The thermal switch must be closed before the motor will start.

Motor Current Overload Detection

A motor current and time algorithm will determine the time to shutdown of the motor. This algorithm will be adjusted to the drive’s performance to maximize the time the motor can safely be operated with high current.

Motor current overload error 27

The error code is reported to the display when this overload is detected. The error is reported per the communications protocol

Lift Drive Motor Operation

Lift Motor

The lift motor changes the grade of the treadmill. The drive switches AC line voltage to control a dual-coil, single-phase AC induction motor. The lift motor incorporates a potentiometer to show the lift’s grade position.

Lift accuracy

The accuracy of the lift is a function of the lift motor’s gearing, linearity of the potentiometer, tolerance of the potentiometer, and tolerance of the voltage on the potentiometer combined with the tolerance of the voltage reference of the A to D converter. Circuit design tolerances are minimized by the design using the same voltage to the potentiometer and the A to D voltage reference.

Lift Motor Operation

The lift potentiometer must be in range, -3% to 15% grade before the lift motor will move. The lift motor will not move if out of range, except when in the INCLINE diagnostic test. After turning on the lift motor a change in potentiometer must be detected within 2 seconds. All lift errors disable the lift motor from operating. A power cycle will allow the lift motor to operate again. When the main motor is running, if the lift motor is moved from the target position the lift motor will

be moved back to the target position. The lift motor is moved back to target if it has drifted further than 0.5% grade from the target

position. If the lift motor was moving down and immediately back driven out of range the lift should move

back to the target position. This is an exception to the out of range operation. When moving the lift motor down, when the lift motor is turned off, the up direction is run for a short

burst in order to stop the motor. This is to prevent the condition above from happening. Lift motor diagnostics Open loop diagnostics commands will allow the lift motor to move regardless of potentiometer

range or error state. The display will use those commands when in the diagnostics service mode.

Lift motor overload protection

The lift motor has a protection circuit. The protection circuit opens when the lift motor stalls. A 2A fuse is used and it is capable of being replaced by treadmill servicers.

AC Lift System – Motion Control

The motor used in the lift system is a "Permanent Split Capacitance" type, single phase AC motor. What this means is that the motor incorporates the use of a capacitor to provide the torque required to lift the weight of the user as well as the weight of the unit. Power to the lift motor is provided directly from the AC coming into the unit.

In order to turn the motor in 2 directions, the AC motor has 2 separate windings, one for up and one for down. AC1 has a continuous connection to the center / common connection of the motor.

The system has a 2A fuse to protect the components from over-current failure. When a control signal is applied to the "UP" input, AC1control line is active and turns on the up

triac. This directs the AC2 connection to the up winding of the motor, causing the motor to spin in the up direction.

When a control signal is applied to the "DOWN" input, AC2 control line is active, turns on the down triac. This directs the AC2 connection to the down winding of the motor, causing the motor to spin in the down direction.

Since the lift motor runs directly on the AC line voltage coming into the unit, it is important to note that the lift motor is a different part number for a 120v unit than for a 240v unit.

Figure 8: AC Lift System - Motion Control

AC Lift System – Position Monitoring

IMPORTANT

note

It is important to note that the lower control module is a different part number for a 120V unit than for a 240V unit.

The unit also requires an absolute measurement of lift position. This is achieved through the use of a potentiometer. The potentiometer is turned by gearing in the lift motor, which changes the wiper resistance.

With +3.3V DC applied across the potentiometer, the center wiper connection will be a variable voltage (between 0 and +3.3V DC), dependent on the position of the lift. This variable voltage is applied to the input of a 16-bit A/D converter which converts the analog voltage into a 16-bit binary numeric representation that the processor can understand.

As the voltage returned by the potentiometer changes between 0 and 3.3V DC, the corresponding A/D values change between 0 and 65507. In this way, the processor can keep track of where the lift is positioned.

It is important to note that since the potentiometer is mechanically connected to the gearing of the motor, it would be unlikely for a lift motor to go out of calibration without having some damage that needs to be repaired, see Troubleshooting the Incline System if this occurs.

Drive / Lift System Control

The Drive/ Lift System consists of an AC drive motor controller, an AC lift motor controller and a +8.5V DC power supply to power the console.

The electronic circuits in the console operate on +5V DC, however the lower control module sends +8.5V DC due to the optional external equipment such as Fitlinxx, that may be connected to the CSAFE (Communication Standard for All Fitness Equipment) port. Sending a higher voltage (+8.5V) and regulating the voltage down to +5V DC, ensures that we can supply enough power to both the console and the optional external equipment.

Drive Motor Operation

AC Drive Motor Controller

Treadmills use an AC drive system to control a three phase AC drive motor. In an AC motor, speed is controlled by frequency independent of voltage or current and torque is controlled by the voltage/current applied to the 3 windings. The windings (stator) and rotor core of the motor are designed to spin at a specific speed at the design frequency. This is by design of the motor itself. By changing the frequency of the drive current, we can change the speed. The lower control module generates the correct frequency to drive the motor at the desired speed. Since the speed of an AC motor is controlled by frequency, there is no need for a speed sensor.

Figure 9: AC Drive Motor Controller

The frequency is then sent to the motor over 3 lines; with each of those lines being phase shifted 120 degrees from each other. This type of AC motor is referred to as a 3 phase AC motor and is used to allow enough torque to be applied over a continuous duty run time. The amplitude (voltage/current) of all three sine waves is the same at any given time and allows the torque to be applied smoothly throughout the rotation of the motor. Increasing the amplitude increases the torque and decreasing the amplitude decreases the torque.

The Motor Controller (MC) is responsible for sending the proper frequency to control speed and the proper amplitude (same on all 3 lines) to control torque. The motor must then be balanced both mechanically and electrically in order to translate the frequency and amplitude into fluid motion. Mechanical balance is achieved by balancing the weight of the flywheel, and electrical balance is achieved by all 3 windings being equal (same number of ohms).

Other features of this AC drive motor controller include "Dynamic Braking" and "Power Factor Correction". Dynamic Braking addresses an issue where an over-speed condition could occur. If a heavy user runs at a high incline, the weight of the user has the potential to push the running belt to go faster than the motor control was trying to maintain. The dynamic brake circuit senses the load variations and applies a braking force within the motor. The system utilizes an external power resistor to determine the point at which the braking force is applied, and to absorb the extra power being created by the motor. Power Factor Correction is a feature that attempts to reduce power consumption. The system monitors that this power factor is held within certain parameters. If it falls outside those parameters (i.e., the system is suing more current than expected), the system will flag an ERROR 27. Error codes are addressed in detail in the troubleshooting section of this manual.

Figure 10: AC Motor Phase Chart

Auto-Stop

The Auto Stop feature monitors the current used to drive the walk/run belt. The current bursts necessary to overcome foot plants and the resultant increase in friction indicates a user is present. The lack of current bursts indicates that a user is not present. If the running belt is moving and the Auto Stop does not detect motion from the belt drive, the Auto Stop feature will stop the motion of the running belt.

The auto-stop feature is controlled electronically via the Motor Controllers software. When a program is entered, Quick Start is pressed or the treadmill has been resumed after being paused, the treadmill starts at 1 mph. The user will then have 60 seconds to enter any remaining workout settings before motion detection begins. Once motion detection has commenced and if no or very little motion is detected, the Auto Stop feature interprets that the treadmill is no longer in use. The Auto Stop feature will continue to monitor the treadmill for motion for 30 seconds; if a user is still not detected a 10 second count down will be displayed on the console. After the 10 second count down has elapsed and a user has not been detected, the Auto Stop feature will stop the motion of the running belt and go into pause mode. If a user is detected within the 10 second count down cycles the shutdown feature will be aborted.

The Auto Stop feature can be enabled or disabled within the service software menus. See "Setting Club Parameters" in the corresponding P10, P30 or the P80 console service manual.

Note: If enabled, adjustment and tracking procedures should be performed while in the Hardware Validation – Belt Speed Test. This is because the Auto-Stop feature is not active during the Belt Speed Test.

+ 84 hidden pages

Precor TRM 885.v2, TRM 835.v2, TRM 811.v2 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual