Friday, January 13, 2017

Precor Fitness equipment – Error code and troubleshooting

Error 35, 36
Excessive AC Input Current
Applies to
TRM 800.v2
Issue Symptoms
Error 35: This error monitors the instantaneous input current to the treadmill. If the input current should spike above 65 amps, an Error 35 will be displayed. The most likely cause of this error will be a catastrophic failure internally to the MC.
Error 36: This error monitors the average input current to the treadmill. If the MC detects current in excess of 20 amps for a sustained period an error 36 is displayed and the treadmill shuts down. The most likely cause of this is a worn deck and belt. It is possible that this error could be caused by a combination of a worn deck/belt and the DB Resistor being stuck ON. Low line voltage can cause error 36; however this usually causes an error 16, so check for that error in the log. If the error 36 occurs when the treadmill is fairly new, and the facility has not had other treadmills plugged in previously, it is possible that the wiring to the outlet is not of sufficient gauge to handle the current required.
Troubleshooting steps Error 35
If error 35 is persistent, replace the MC.
Troubleshooting steps Error 36
1. Check the belt rating (120VAC only) and current draw of the treadmill, replace the belt and deck as necessary
2. Monitor the minimum line voltage as follows:
a. With the TRM at the Welcome banner
b. With a runner at 6MPH
c. With the TRM at the Welcome banner, and a runner at 6MPH on an adjoining tread
3. If fluctuations of greater than 15% are observed between the banner case (a.) and the runner @6MPH case (b.), or if fluctuations of 5V or more are seen when running on the adjoining TRM, request an evaluation of the distribution wiring.
Error 37
E-STOP Upper PCA/Lower PCA Mismatch
Applies to
TRM800.v2, TRM2XX
Issue Symptoms
The error 37 may occur after an E-STOP event. If the E-STOP event is not successfully cleared in the lower PCA and the upper display believes the E-STOP has been cleared, a error 37 will occur. Possible causes include pulling and resetting the E-STOP twice within the 10 second time-out period, pulling the E-STOP, turning off the treadmill, turning the treadmill back on, and then starting a course, or pulling the E-STOP, turning off the treadmill, reset the E-STOP, turning the treadmill back on, and then starting a course. Also possible is a break in the E-STOP line, or a loose cable connection.
Troubleshooting steps:
1. Verify the connectors are seated properly.
2. Verify Dielectric grease has been applied to both connectors.
3. Run the treadmill and move the communications cable attempting to duplicate the error. If it reproduces, change out the cable.
4. If this error is persistent and none of the above corrects the problem, install a new console.
5.If the console does not correct the problem, change the MC.
Recommended Additional Action:
Add Dielectric grease, to both connectors, recommended for all products regardless of age.
Error 40
No Lift Motion Detected
Applies to
All Treadmills and EFX, AMT12
Issue Symptoms
Error indicates that the incline (lift) system on either a treadmill, EFX or AMT12 has been instructed to start moving and no lift motion has been detected by the lift position monitoring system. Most likely causes are a blown lift fuse on the lower PCA or the lift motor is physically jammed and unable to move. On the EFX and the AMT12 a fully dead battery can also cause this error. While unlikely but possible, a faulty lift motor capacitor or winding will prevent movement.
Troubleshooting steps:
1. Remove power from the unit and remove the lift fuse from the lower PCA. Measure the fuse with an ohmmeter, if the reading is higher than very near zero, replace the fuse.
2. Disconnect the lift motor from the lift platform (treadmill, AMT12) or ramp (EFX). If the lift tube or lift nut is jammed against the motor housing, rotate the lift nut or lift tube away from the motor housing. Calibrate and install the lift motor per the appropriate service manual procedure.
3. With a voltmeter reading AC volts, measure between the black wire of the lift motor connector and the hot lead of the line filter. You should read line voltage. Enter Diagnostics, Machine Test, Incline Test, and operate the lift in the up direction. You should read approximately 200VAC (120V Units) or 300V (240V Units). If this value is significantly low the capacitor is failing, requiring lift motor replacement.
4. If a lift motor winding is bad the lift will not operate in one or both directions depending on the exact fault in the motor. The lift motor winding may be checked with an ohmmeter. A.C lift motors will have a split winding (3 wires). D.C lift motors will have a single winding (2 wires). On A.C motors both windings must be checked. Depending on the lift motor being tested, normal winding readings could vary anywhere between 1 and 60 ohms. Refer to the appropriate service manual for the motor being tested.
Error 42
Lift Position Out Of Range
Applies to
All Treadmills and EFX, AMT12
Issue Symptoms
The software on the lower PCA is expecting that the A/D value from the lift potentiometer is within a certain range, low to high. If the A/D value goes outside this range, an Error 42 will be displayed. The most likely cause of this error is the motor moving further than it should, or jamming against the housing. A loose connector or a damaged potentiometer inside the motor assembly will also cause this error.
Troubleshooting steps:
1. If the lift motor has drifted too low, disconnect the motor from the lift assembly and adjust the jack screw until the motor is in range. Perform the appropriate lift motor calibration procedure. If the motor continues to drift low, replace the motor.
2. Inspect the lift motor connector, verifying the pins are secure in the connector. Attach the connector to the lower PCA and ensure that it is locked into the header.
3. Enter Diagnostics, Machine Test, Incline or Crossramp test. Run the lift all the way extended and back to minimum. The A/D number should climb and decrease smoothly during the test. If not, replace the lift motor.
4. While in the Incline or Crossramp test scroll to see Glitches, and run the lift to both extremes. Glitches are anomalies recorded by the lower board during lift movement, indicating a possible or existing problem with the internal potentiometer or the gearing that turns it. Very few if any glitches should be recorded. If greater than 50 glitches are recorded during a full movement to either extreme, replacement of the lift motor is necessary.
Error 44
Un-commanded Lift Motion
Applies to
All machines with a lift actuator
Issue Symptoms
The lift control system has detected that the lift is in motion without a lift command having been issued. This can happen in one of two ways: either the lift drive circuit has failed in a turned on condition or the lift position sensor (lift position potentiometer or revolution sensor) is sending an erroneous signal to the lift control circuit. This is most often caused by a poor or intermittent connection of the lift motor potentiometer, or the potentiometer itself is defective. Less likely but possible is a defective lower PCA.
Troubleshooting steps:
1. Verify all wiring and connections associated with the lift motor assembly. Repair or replace wiring or connections as appropriate.
2. Operate the lift in the diagnostics while monitoring the lift position A/D number being displayed. If the reading is erratic and makes large changes in readings the lift position potentiometer is probably bad.
Replace the lift motor assembly.
3. If there is actual lift motion without a manual or program control lift command having been issued, replace the lower PCA.
Error 45
Lift Moving In The Wrong Direction
Applies to
All machines with a lift actuator
Issue Symptoms
The lift control system has detected that the lift is moving in the opposite direction of the issued lift command. This error would typically happen when the lift was already in motion (typically downward) when a lift command in the opposite direction (lift up) was issued. Some motors exhibited a very long turnaround time and the lift motor would still be moving in the original direction (downward) while the control system was attempting to move the lift in the opposite direction. Less likely but also possible would be a defective motor controller.
Troubleshooting steps:
1. Check that the MC is properly controlling the lift motor. Measure between the line filter hot output and the red wire of the lift motor connector while pressing the up button in Diagnostics. You should see line voltage when the motor is not being driven, and 0Vac when it is being driven. Repeat the test with the black wire of the connector and the downward drive. If the MC is not switching properly, replace the MC.
2. If the error 45 condition is persistent and the voltages from the controller are correct, replace the lift motor.
Error 46
Low Battery Voltage
Applies to
All self-powered units
Issue Symptoms
The operating system has a battery monitoring system. If the battery voltage falls below 11 Vdc when stride height movement is initiated (AMT12) or the battery voltage falls below 10 Vdc after the ramp movement has been initiated (EFX), ramp movement will be stopped and the message ERROR 46 will be displayed. Stride Height motion will not be enabled until such time as the battery voltage exceeds the above limits. The battery voltage must be raised to correct this condition either by battery charging or battery replacement. This is strictly a battery problem and not an incline system or incline motor problem. Possible causes include an open 10A slow blow fuse (AMT12 only) on the battery terminal, faulty or poor connection on the battery or lower PCA, or a depleted battery.
Note: While an occurrence of the error is possible, this error is rarely reported on self-powered bikes and climbers.
Troubleshooting steps:
1. (AMT12) Remove the lift fuse from the in-line fuse holder on the positive battery cable. Measure the fuse with an ohmmeter, the fuse should read approximately 1 ohm or less. If the ohmmeter reading is significantly high, replace the fuse.
2. Check battery cable connector for shorts or poor connections.
3 Enter the diagnostic program per procedure, P80 Settings or Accessing the P30 Diagnostic Software. Using the diagnostic program allows you to test the incline system without continuously pedaling the unit if you have an external power supply. Otherwise, you will need to continue to pedal the unit. Connect a DC volt meter to the J3 connector on the lower PCA as follows: voltmeter common lead to terminal 3 (black wire) and voltmeter "hot" lead to terminal 2 (red wire). Using the STRIDE HEIGHT. The voltmeter should read +12 Vdc approximately when the incline is instructed to move upward and -12 Vdc approximately when the incline is instructed to move downward. If the either voltage measurement is significantly low, replace the battery.