Precor TRM 811.v2 Service Manual Download Page 3

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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

Summary of Contents for TRM 811.v2

Page 1: ...Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 1 Service Manual...

Page 2: ...cation 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 Informa...

Page 3: ...eadmill 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 B...

Page 4: ...munications 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 Procedur...

Page 5: ...ution Prohibited by Law Page 5 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...

Page 6: ...ucts 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 do...

Page 7: ...NOTE Use of unapproved lubricants cleaners or solvents may void the treadmill warranty Electrical Requirements When your equipment is delivered you will receive an equipment power cable that meets you...

Page 8: ...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 b...

Page 9: ...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...

Page 10: ...e 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 co...

Page 11: ...es 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 cov...

Page 12: ...n 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...

Page 13: ...idation 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 A...

Page 14: ...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 us...

Page 15: ...5 6 5 1 5 6 5 Club Parameters Changing Machine and or Workout Parameters 6 5 P10 P30 Only Information Display Acquiring Information Hardw are Validat ion Diagnost ic Test s 51765761 Hardware Validatio...

Page 16: ...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 Club Parameter Settings 5651565 T...

Page 17: ...etting 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 p...

Page 18: ...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 main...

Page 19: ...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 functio...

Page 20: ...municate 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...

Page 21: ...ed Reproduction and Distribution Prohibited by Law Page 21 Figure 7 Electrical System On Off Motor Motor Controller Dress Plate Line Filter DB resistor Lift Motor To Console New Electrical System Acti...

Page 22: ...on 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 temperat...

Page 23: ...i 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 occ...

Page 24: ...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 co...

Page 25: ...CLINE 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 lif...

Page 26: ...s 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...

Page 27: ...an 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...

Page 28: ...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 mo...

Page 29: ...chieved 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 Br...

Page 30: ...ettings 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...

Page 31: ...is located on the front of the base and when all conditions are normal it will be a steady blue The Machine Control Light MCL is located on the Machine controller and will be a green when all conditi...

Page 32: ...reset select Next Maintenance Due Reset d Belt Deck replacement ASL reset select Belt Rating REPLACE to reset Yellow Pulsing There are two states for yellow pulsing o An error has recently occurred o...

Page 33: ...Solid Yellow Had error recovered Pulsing Yellow Had error could not recover Motor Controller light The Motor Controller Light MCL will illuminate in one of two states Green MC is working correctly Ye...

Page 34: ...e currents and motor drive voltages and the currents By accessing the Belt Speed test from the diagnostics menus it is possible to see the following Voltage In the voltage from the wall outlet Buss Vo...

Page 35: ...e system powers up and can be at least partially operated o Look for the ASL and MCL note their status o Look in the error log for system information drive system lift system etc as appropriate o Clea...

Page 36: ...ing steps 5 Verify the wall outlets do not share neutral wiring and that each wall outlet is on an individual branch circuit An individual branch circuit will have its own load line neutral line and g...

Page 37: ...he Belt Speed Test in the Diagnostics menu note the voltage while running on the treadmill at 7 0 MPH or higher 4 If any measurement is below 108VAC US or 200VAC International advise the customer to h...

Page 38: ...erify that line voltage is present when the breaker switch is turned on If NO Replace the breaker switch If YES continue with the following steps 3 Measure the AC voltage at the output side of the lin...

Page 39: ...ror location one being the most recent The EVENT LOG P80 stores data from events over the last 30 days The EVENT LOG is only accessible via the Diagnostics mode The error codes are useful in isolating...

Page 40: ...nual can not anticipate every possible cause for a particular error code However it should list the causes encountered in the majority of cases The manual will then list the suggested remedies associa...

Page 41: ...Code Table The following is a list of the error codes currently assigned to the TRM 800 V 2 Table 1 TRM800 V2 Error Code Error Description none Key Depressed at Power Up 10 Line Frequency out of Acce...

Page 42: ...ption 44 Un commanded Lift Motion 45 Lift Moving in Wrong Direction 80 81 82 83 Phase A or B missing Incline Control 85 No DB resistor detected DBR failed Open 86 Old Console Detected on New TM12 Driv...

Page 43: ...Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 43 Table 2 TRM800 V2 Error Codes with Status Lights...

Page 44: ...Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 44 Table 2 continued TRM800 V2 Error Codes with Status Lights...

Page 45: ...des input power error 10 15 16 conditions Console controls stuck key 80 83 or processor memory error 9 11 conditions These are errors that although they are valid to the proper function of the machine...

Page 46: ...ltage power If the low voltage power drops below a preset level the error 12 will be displayed Possible Cause 1 Control Module internal hardware error Possible Remedy 1 Cycle power once if error clear...

Page 47: ...voltage limits either because the DB system wasn t functional or because the bus voltage power exceeded the DB system limit Possible Remedies 1 Check the error log to determine the error frequency an...

Page 48: ...eck need replacement 3 Flipping power switch ON OFF over and over again 4 Motor controller hardware issue Possible Remedies 1 Find out if blackouts brownouts have occurred recently in that area 2 Chec...

Page 49: ...mptoms for these errors are lack of control for incline and speed TRM or resistance and crossramp EFX AMT These errors will occur upon lack of or broken hardware communication The sensors communicate...

Page 50: ...ot generate error codes This troubleshooting procedure is intended for those times If there is an error code for the drive system Error 17 20 25 27 28 35 36 85 88 in the error log go to the appropriat...

Page 51: ...in steps 1 through 3 are not present replace the Motor Controller If the voltage readings in steps 1 through 3 are present continue with step 4 NOTE All resistance measurements must be performed with...

Page 52: ...ure 15 Motor Controller Connector Pin 1 location Table 3 Connector Numbering Connector Pin Pin Description Connector Pin Pin Description INPUT 1 EARTH GROUND COMM 1 DIGITAL GROUND 2 AC LINE 1 LINE 2 8...

Page 53: ...A 8 E STOP 5 MOTOR PHASE B 6 MOTOR PHASE C DBR 1 RESISTOR OUTPUT 2 RESISTOR OUTPUT LIFT 1 COMMON OUTPUT 2 NOT USED MON 1 8VDC 3 SENSE POT VCC 2 BOOT_EN 4 SENSE POT GND 3 TX 5 DECLINE OUTPUT 4 8V GND 6...

Page 54: ...erating modes with the club management If the deck and belt are new this error will go probably go away after a few months of use 1 Unplug all connections from the DB resistor and check switch for 10...

Page 55: ...lfunctions Possible Causes 1 The Control Module has had a hardware failure Possible Remedies 2 If the problem is persistent replace the Control Module 3 4 Error 20 Motor will not start No motor moveme...

Page 56: ...e error log if there are multiple instances of this error replace the module 2 If there is only one Error 25 cycle power to the module once If it does not recover replace the module Error 27 Too Much...

Page 57: ...to ensure that the fan is not clogged with dust Thoroughly clean the fan and ensure that it spins freely 2 The lower PCA is clean and unobstructed but the fan does not spin Ensure that the fan wiring...

Page 58: ...high pulse in excess of 65A the control module will shut down and log an Error 35 Possible Causes 1 Although this error is designed to detect and protect against a high pulse of current the most likel...

Page 59: ...screen b Treadmill at 6 Mph with runner c Treadmill at banner run at 6 Mph on neighbouring tread d If fluctuations of more than 15 are observed between banner case to runner at 6 Mph case OR if fluct...

Page 60: ...that error Note All resistance measurements must be performed with power removed from the treadmill Performing resistance measurements with voltage applied may damage your ohmmeter Operation of lift m...

Page 61: ...om the lift platform 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 If the lift was jammed please refer to Calibrating th...

Page 62: ...e the internal lift fuse to blow If the lift moves un commanded as soon as the power is turned on to the machine and eventually jams the Motor Controller must be replaced The lift switch may also fail...

Page 63: ...t calibration to go out of calibration on its own It would be more likely that something has broken causing the A D value to be wrong 1 Possible Remedies 1 If the incline has drifted down enter diagno...

Page 64: ...number A D value is not 0 or 65535 and does not increment when the lift motor moves replace the lift motor If you have performed all of the procedures above and have been unable to correct the problem...

Page 65: ...e the MC Troubleshooting Communications Errors Errors 30 and 32 Communications Error between Upper and Lower Boards MCL Yellow ASL Yellow Solid Description Errors 30 and 32 indicate the loss of commun...

Page 66: ...Stop state and the upper PCA in the console did not know about it The system uses pin 8 of the data cable to communicate E Stop states between the console and the Motor Controller Possible Causes 1 C...

Page 67: ...ution Prohibited by Law Page 67 Error 86 is defined as a console with TRM10 software being installed onto a TRM800 V 2 Error 87 is defined as a console with TRM800 V 2 software being installed onto a...

Page 68: ...everely worn belt and deck You can attempt to resolve the issue by doing belt deck cleaning maintenance and then resetting the belt Maintenance Reminder function see Introduction to Treadmill Troubles...

Page 69: ...10 or P30 consoles will display USER DETECTED if motion is detected from the running deck or NO USER DETECTED if no motion is detected from the running deck It may take 5 or 6 steps for the USER DETEC...

Page 70: ...rate with a known good chest strap transmitter or test transmitter If the heart rate reading is erratic incorrect or absent continue with step 2 NOTE It may be necessary to lean in closer to the cons...

Page 71: ...BUT NOT LIMITED TO Wi Fi Network Routers Cordless Telephones Cell Phones Electronic Dog Fences Garage Door Remotes Noisy AC feeds Florescent light ballasts 4 Using an ohmmeter verify that upper and l...

Page 72: ...dmill hood Most replacement procedures will require that the hood over the front drive system is removed There are six 3 Phillips screws that secure the hood to the frame The front of the hood is curv...

Page 73: ...the inside of the trim and sharply pull up to unsnap the trim from the rear cover 5 Grasp the landing and pull back sharply about inches to detach the trim from its mounts 6 Install the new landing i...

Page 74: ...3 Remove the 3 Phillips screw securing the corner cover to the frame 4 Pull back on the front of the cover freeing the tab that wraps around the upright 5 Lift the back slightly allowing the side tabs...

Page 75: ...AC outlet 2 Remove the hood 3 Remove the front Corner Cover and the Deck Trim Landing 4 Using your hands pull back the top edge of the side trim to lift if off the plastic anchors 5 Slide the side tr...

Page 76: ...ng and replacing the Line Cord Circuit Breaker or ASL PCB 1 Set the treadmill circuit breaker in the off position and unplug the treadmill s line cord from the AC outlet 2 Remove the hood 3 Remove the...

Page 77: ...holder from the panel by pressing the tabs on the bottom of the panel then lifting the holder Unsnap the PCB from the holder to disconnect the RJ11 connector See Figure 6 Next page 8 Remove and replac...

Page 78: ...screws on the right side until they are free of the frame Do not remove them completely as they will stay attached to the plate mounted to the MC 5 Lift the MC from its location and then disconnect a...

Page 79: ...the drive belt off the pulley on the drive motor 5 Remove the four bolts and plastic isolation spacers that fasten the drive motor to the frame 6 Set the replacement drive motor in its mounting posit...

Page 80: ...tuator jack screw movement up and down Connect the lift motor connector to the MC LIFT input port c Set the treadmill circuit breaker to ON The treadmill will begin to auto calibrate the replacement l...

Page 81: ...ising and securely resting the frame base onto blocks placed under the front corners of the frame 4 Remove the defective lift motor a Remove the green yellow lift motor ground wire from the frame b Re...

Page 82: ...sting turning the lift actuator tube nut c Connect the frame ground wire to the treadmill frame Securely tighten the mounting screw to ensure very good electrical connectivity d Route the lift motor c...

Page 83: ...the old incline platform and remount them on the replacement incline platform 7 Set the replacement incline platform into position and slide the incline mounting pins into place Fasten the incline mo...

Page 84: ...Figure 28 Take Up Roller Adjustment Bolts 4 Lift the roller out of the cassettes 5 Install the new roller ensuring the slotted end of the shaft is on the left side and seated into the tabs of the cas...

Page 85: ...or flywheel Be sure the belt is fully seated in the grooves of both pulleys and correctly aligned 8 Reseat the dust shield and install the four screws removed in step 4 9 Adjust the drive belt tension...

Page 86: ...7101 These must be used to ensure proper tensioning of the belt and proper force on the roller bearings 12 Install the two belt tensioning gauges on both sides of the belt across from each other Set t...

Page 87: ...recor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 87 18 Install all covers check treadmill operation per Checking Treadmill Operation Figure 31 Running Belt Directio...

Page 88: ...ble the running belt deck drive motor rollers and all associated parts Adjustment procedures Adjusting Drive Belt Tension Tensioning the Running BeltError Bookmark not defined Running Belt Tracking Ad...

Page 89: ...r forward or backward and adjust the belt tension 6 Walk the drive belt onto the drive roller pulley by rotating the drive motor flywheel Be sure the belt is fully seated in the grooves of both pulley...

Page 90: ...the running belt so that the seam is positioned underneath the treadmill 6 Attach a running belt tension gauge on each side of the running belt opposite each other avoiding interference from the side...

Page 91: ...ng power tools may overtighten 9 Replace the motor drive belt 10 Start the treadmill and set the speed to 3 mph 5 kph 11 Observe the running belt tracking while verifying that the belt remains centere...

Page 92: ...he treadmill and resting the frame base onto blocks securely placed under the front corners of the frame this procedure removes weight from the lift platform and lift motor actuator tube 4 Disconnect...

Page 93: ...Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 93...

Page 94: ...tive Maintenance Program see Preventative Maintenance Program Maintenance Schedule Preventative maintenance tasks are grouped into Daily Weekly Monthly Quarterly and Semiannual scheduled maintenance t...

Page 95: ...of the following issues are occurring Slipping belts Loose fasteners Unusual noises Worn or frayed power cords Worn damaged missing safety lanyards or clips Visually inspect the running belt conditio...

Page 96: ...following maintenance tasks every month Monthly Task Instruction Verify the Safety clip is attached to the lanyard and functional Pull on the lanyard attached to the Safety clip which trips the Restar...

Page 97: ...front cover Be careful not to bring the nozzle to close to any electronic circuit boards Inspect visible welds frame and wire connections1 Do a visual check of welds and frame Check for loose wire con...

Page 98: ...eful to not put nozzle near PCA electronics Check the console metric and indicator display and numeric keypad functionality Run the Display Keypad diagnostic tests and check the console metric indicat...

Page 99: ...treadmill WARNING If the running belt does not stop turn off the power using the ON OFF switch at the front of the treadmill and unplug the power cord The treadmill must remain out of service until th...

Page 100: ...admill running belt begins to move after pressing Quick Start Ensure you are in the proper position WARNING Press the safety stop key if the towel becomes loose to prevent it from being pulled into th...

Page 101: ...treadmill by pressing the STOP button 6 When the belt has fully stopped moving remove the STOP key tether exit the treadmill and turn the power switch to OFF 7 Grasp both sides of the towel and run it...

Page 102: ...Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 102 System Block Diagram System Block Diagram 120 Volt Models...

Page 103: ...List Identification table are provided as quick reference material and may change without notice For the latest equipment parts information go to either the new Precor Connect website http www precorc...

Page 104: ...Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 104 Exploded View...

Page 105: ...Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 105...

Page 106: ...Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 106...

Page 107: ...Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 107...

Page 108: ...Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 108...

Page 109: ...Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 109...

Page 110: ...Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 110...

Page 111: ...UATOR 120V 16 ASSEMBLY ROLLER DRIVE 19 ASSEMBLY ROLLER TAKE UP 20 BOTTOM COVER SIDE BAR LEFT 21 01 BOTTOM COVER SIDE BAR LEFT 21 02 BOTTOM COVER SIDE BAR RIGHT 22 01 BOTTOM COVER SIDE BAR RIGHT 22 02...

Page 112: ...AP RIGHT 81 PLASTIC END CAP LEFT 82 EXTRUSION SIDE TRIM RH 84 EXTRUSION SIDE TRIM LH 85 SCREW SELF TAPPING 1 4 20 X 0 75 86 PLATE REAR ROLLER ADJUSTMENT INNE 88 PLATE REAR ROLLER ADJUSTMENT INNE 89 SC...

Page 113: ...O HANDRAIL 117 INSIDE COVER SIDEBAR LEFT 118 INSIDE COVER SIDEBAR RIGHT 119 CLIP ASSEMBLY 120 SHIELD COVER BRAKE RESISTOR 121 SCREW TCS 8X1 2 PHIL BLK SHARPERIZ 123 SCREW SELF TAP TRI PAN HD PHIL 8 X...

Page 114: ...01 ASSEMBLY TRAY AND STOP SWITCH PRE 154 02 TRIM RING DASH 156 EXTRUSION REAR ROLLER ADJUSTMENT 158 SPACER REAR ROLLER ADJUSTMENT 159 ASSEMBLY HOOD 160 ISOLATOR PLASTIC MOTOR 181 CONN QK DISC TAB 250...

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Precor TRM 811.v2, Service Manual

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