Saturday, January 07, 2017

Precor Fitness Equipment – Error code troubleshooting – Treadmill error codes – Elliptical error codes

ERROR 15 - DC Bus Over Voltage
Applies to
Issue Symptoms
The AC input voltage is monitored. If the AC input momentarily reaches the upper limit, error 15 is logged.
The upper acceptable input voltage limit is 132 VAC on 120 VAC systems and 264 VAC on 240 VAC systems. This issue is most often caused by a faulty DB resistor, in conjunction with a user pushing hard on the hand grips while the MC is driving the belt.
Troubleshooting steps
1. Check DB resistor connection
a. Clear the error log.
b. Turn off unit.
c. Verify all DB resistor connections are connected and are seated properly.
2. Check DB resistance
a. Check DB resistance. It should be 100ohms. If greater than 150ohms, replace DB resistor.
b. Check resistance between either terminals of the switch connector (smaller black) to either terminal of the resistor element connector (larger white/natural). The resistance should be greater than 1Meg of resistance. If less than 1Meg, replace DB resistor.
3. Verify input AC voltage is within the acceptable range.
4. If none of the above, replace the motor controller.
AC Input Voltage Too Low
Applies to
All AC powered cardio equipment
Issue Symptoms
The condition that causes error 16 has to persist for 15 seconds before it is logged. The most common cause of this problem is external power fluctuations due to brownouts, blackouts or other poor power conditions. This can also be caused by wiring that is too small of a gauge to handle the current, or if the neutrals are shared between multiple outlets. Less likely but possible is a worn deck and belt causing high current.
Troubleshooting steps
1 Find out if blackouts/brownouts have occurred recently in that area
2 Check if treadmill was running off of a backup generator or backup power source
3 Ask that an electrician verify wiring
4 Monitor minimum rms line voltage with:
5 Treadmill at banner
6 Treadmill at 6MPH with runner
7 Treadmill at banner, run at 6MPH on a neighboring tread
DB Resistor Thermal Trip
Applies to
TRM 800.v2
Issue Symptoms
This error monitors generated current being sent to the Dynamic Brake (DB) resistor. When the drive motor is energized, and external forces cause it to turn faster than it is being driven, current is created. This current is sent through the MC to the DB resistor. When the MC perceives that enough current is being delivered to the DB resistor to make it hot, this error is displayed and the treadmill comes to a stop. The most likely causes for this are a runner at incline with a new deck and belt, a large runner at incline, or a user pushing against the handgrips while forcing the belt with their feet.
Troubleshooting steps
1 If deck and belt are new, this failure mode will likely go away after a few months of use.
2 Allow DB resistor to cool down- reset MC status- monitor for repeat error.
DB Resistor Thermal Switch Open
Applies to
TRM 800 v2 (2014)
Issue Symptoms
As with Error 17, current generated by the drive motor is sent to the DB resistor. If sufficient current is sent to the DB resistor such that it becomes excessively warm, an internal thermal switch will open, which will stop the treadmill and display Error 18. This error will be displayed if the DB resistor thermal switch connector is not plugged in, or if the DB resistor has reached its thermal upper limit.
Troubleshooting steps
1 Check to see if the DB resistor thermal switch is properly seated into the connector (it can be wedged into the connector opening without being properly seated)
2 Check DB resistor temperature. If it is stuck on it may be hot. If stuck ON and it is not hot, replace both drive and DB resistor.
3 Unplug all connections from the DB resistor and check resistance of the DB thermal switch (smaller black connector). If 10Ohm or greater, replace the DB resistor.
PFC Malfunction
Applies to
TRM 800 v2 (2014)
Issue Symptoms
The treadmill uses Power Factor Correction (PFC) to maximize the input power for greatest efficiency. This allows for fluctuations in the input voltage without affecting the performance of the treadmill. When the MC detects that the PFC circuitry is not able to correctly compensate for fluctuating input voltage, the treadmill will stop and Error 19 will be displayed.
Troubleshooting steps
1 Check for an error 16. If the Error 16 is present, troubleshoot that first. The PFC will not be able to compensate for input voltage that is below the lowest threshold. As such, an Error 19 will be displayed along with an Error 16.
2 Absent an accompanying Error 16, replace the MC.
Motor Will Not Start / No Motor Movement Detected
Applies to
All AC drive motor treadmills
Issue Symptoms
The treadmill is monitoring the motor movement, through current monitoring. If the lower PCA does not detect that the motor is moving an error 20 will be displayed. This can be caused by a disconnected drive motor, or a very heavy user standing on the belt while starting.
Troubleshooting steps
1 Verify motor connector is connected to drive
2 Check machine for stalling during operation 1MPH through 6MPH
3 Check error log for motor current during fault - If it is very low, check the connector and contacts, if it is over 7amps, it is likely a true stall condition
4 Check belt rating and current draw of treadmill - replace belt and deck if necessary.
Too Many Maximum Consecutive Power Requests
Applies to
Consumer Treadmills, Commercial treadmills pre 2006
Issue Symptoms
This error monitors the treadmill's power bit reading when the treadmill was operating at speeds above 1 mph. Power bits indicate the relative time that the motor controller drive circuit is turned on. Therefore power bits is an indication of the amount of power the load is demanding from the motor controller. Error 21 indicates that at a speed of greater than 1 mile per hour an excessive amount of power is being demanded from the motor controller.
The main cause of this error being displayed while the treadmill is being used is a badly worn running belt/deck.
This error can also be caused by badly worn motor brushes, or brushes that are not making contact with the commutator. Least likely but possible is a shorted drive motor.
Troubleshooting steps
1 A clamp-on AC ammeter must be used to determine the amount of A.C input current being drawn by the treadmill under no load and loaded conditions. Remember, many running beds are double sided and the bed can be flipped over rather than being replaced. If the current is excessively high at slow speed replace the belt and deck surface with new.
2 Turn off the treadmill, and disconnect power from the wall receptacle. Remove and inspect the motor brushes for arcing and pitting. If present replace both drive motor brushes. Also check that the brush can move smoothly in the grooves, and that the spring is able to press the brushes against the commutator.
Adjust or replace the brushes as necessary.
3 Test the drive motor resistance, it should not be near 0Ohm. If 0Ohm, a known good drive motor must be substituted for the existing drive motor.
ERROR 22, 23, 26
Motor Pulses Incorrect
Applies to
Consumer Treadmills, Commercial Treadmills prior to 2006
Issue Symptoms
Dust on the speed sensor, an inoperative sensor, and a failed lower PCA will cause these errors to be displayed.
# Error 22 indicates that the drive motor has been instructed to start, by either manual or program control, and the monitoring system has not received any response from the speed sensing system indicating that the drive motor has started.
# Error 23 indicates that the speed sensor signal was lost while the treadmill was in operation.
# Error 26 monitors the speed sensor signal and verifies the speed sensor signal is appropriate for the requested speed. If the speed sensor signal is incorrect or erratic an Error 26 will be displayed.
Troubleshooting steps
1 Carefully, vacuum out the drive motor compartment with a static safe vacuum cleaner.
2 Test the speed sensor at the board for a 0-5Vdc transition when the sensor is activated by the appropriate device or actuator. The 400 Series treadmills utilize an optical (infrared) through speed sensor. The through sensor beam is broken by a chopper wheel attached to the motor. Dust can accumulate in the sensor. The 200 Series treadmills use a reed switch attached to the frame, actuated by a magnet installed in the drive roller pulley. Check to make sure the magnet is still installed in the pulley.
3 Turn off the treadmill, and disconnect power from the wall receptacle. Remove and inspect the motor brushes for arcing and pitting. If present replace both drive motor brushes. Also check that the brush can move smoothly in the grooves, and that the spring is able to press the brushes against the commutator.
Adjust or replace the brushes as necessary.
4 Substitute a known good lower PCA to determine if the lower PCA is bad.