Procedure 5.2 - Troubleshooting the Lift System
Contents
1. There are four typical failure modes for the hand held chest strap heart rate system They are 1 hand held is normal no chest strap reading 2 no hand held reading chest strap normal 3 no hand held or chest strap reading 4 constant or intermittent readings when neither hand held or chest strap are in use Diagram 5 3 Hand held chest strap heart rate PCA _ 3 owe Geom Oo o D TERETI ag Lower Right 20 Sie Right i LEEN Upper Left i Lower Left Internal Chest A Strap Setting gt bets ees PERE SDE e Normal hand held reading No chest strap reading 1 Set the on off switch in the ion position and access the diagnostic program Procedure 2 1 or 2 2 Advance to the heart rate display portion of the diagnostic program Verify that a chest strap signal is not being accepted with either a Polar heart rate test transmitter or a known good chest strap transmitter If this reading is good skip to step 3 2 Using a Polar heart rate test receiver verify the operation of the chest strap transmitter furnished with the unit If the Polar heart rate test receiver does not receive a signal replace the chest strap transmitter 5 C960 Series Commercial Treadmill Set the on off switch in the ioffi position and remove the display housing Verify the internal chest strap setting is set as shown in Diagram 5 3 Verify that a ferrite bead is installed on the heart rate PCA to upper PCA ca2. 1 of J1 and the black wire term 3 of J1 The measurement should be approximately 1KW With an ohmmeter measure the resistance between the red wire term 1 of J1 and the white wire term 2 of J1 and measure the resistance between the white wire term 2 of J1 and the black wire term 3 of J1 The sum of the last two measurements should total approximately 1 KW If either of the two 1 KW measurements are open i or significantly low or high replace the lift motor assembly If you have performed all of the above procedures and have been unable to correct the problem call Precor Customer Support C960 Series Commercial Treadmill Procedure 5 4 Troubleshooting the Speed Sensor Note The speed sensor is a hall effect sensor that emits a pulse when a flywheel lobe passes it The speed control circuit processes the pulse train emitted by the speed sensor The speed sensor signal is a real time representation of the operating speed of the treadmill The speed control circuit compares the real time speed speed sensor output with the speed that it expects the treadmill to be operating at and acts accordingly to control treadmill speed or initiate an error code sequence if necessary Typically if a problem exists with the speed sensor the drive motor will operate perhaps only briefly before a speed related error occurs errors 20 26 Note Some speed sensor have red black and white wires and some have red black and green wires The
3. Support Typically when the lift is able to physically move but causes a lift error the problem is in the lift position identification system rotation sensor and zero sense switch Connect a DC voltmeter between the white wire term 2 of J3 and the red wire term 4 of J3 on the lower PCA Set the treadmill circuit breaker in the ion position and slowly rotate the hub at the bottom of the lift motor by hand The DC voltmeter should read approximately 0 Vdc when the magnet in the hub is not near the hall effect sensor and approximately 5 VDC when the magnet is near the hall effect sensor If the voltage switches between 0 and 5 Vdc as the magnet passes the hall effect sensor continue with step 11 10 C960 Series Commercial Treadmill Measure the voltage between the red wire term 4 of J3 and the black wire term 1 of J3 The voltage should read a constant 5 Vdc If the voltage is 0 or significantly lower than 5 Vdc disconnect the rotation sensor connector from the lower PCA Measure the voltage between the red wire term 4 of J3 and the black wire term 1 of J3 on the lower PCA If the voltage is still 0 Vdc or significantly low replace the lower PCA If the voltage is now correct replace the hall effect sensor Note If possible set the lift in a position that does not operate the zero sense switch The zero sense switch may be operated by hand to perform the tests in step 11 11 12 At this point the hall effect sens
4. following procedures will assume red black and white wires If the speed sensor on the unit under test has red black and green wires perform your test procedures using the green wire instead of the white wire The white and green wires serve the same function 1 Set the treadmill circuit breaker in the ion position Using a DC voltmeter measure the voltage between terminal 1 of J5 red wire and terminal 3 of J5 white wire on the lower PCA Slowly rotate the drive motor flywheel The voltage should read approximately 5 Vdc as a flywheel lobe passes the speed sensor and approximately 0 Vdc when a flywheel lobe is not in front of the speed sensor 2 Ifthe voltage in step 1 is correct go to step 5 If the voltage in step 1 is 0 Vdc or significantly low when a flywheel lobe passes the speed sensor continue with step 3 3 Measure the voltage between terminal 1 of J5 red wire and terminal 4 of J5 black wire on the lower PCA The voltage should read approximately 5 Vdc 4 Ifthe voltage is missing or significantly low disconnect the speed sensor plug from the lower PCA Measure the voltage between pins 1 amp 4 of the J5 plug on the lower PCA If the voltage is approximately 5 Vdc replace the speed sensor If the voltage is missing or significantly low replace the lower PCA 5 At this point the speed sensor output is good but speed error occur There are three potential causes for this condition They are ribbon cable upper PCA or l
5. motor winding should read approximately 32W 120 Vac units or 115W 240 Vac units Therefore if the measurement is significantly lower than 32W or 115W disconnect both red leads from the lift capacitor Measure the resistance between the black leads on the lift capacitor and red lead to the lower PCA If it measures significantly low replace the lower logic lift PCA Measure the resistance between the black leads on the lift capacitor and red lead to the lift motor If it measures significantly low replace the lift motor Measure the resistance between the black leads on the lift capacitor and other terminal of the lift capacitor If it measures significantly low replace the lift capacitor At this point the lift fuse is good but there is no AC voltage on the lift capacitor when the lift is actuated There are three potential causes for this condition They are lower logic lift PCA ribbon cable or upper PCA There are no good means of troubleshooting these components other than substituting known good components Replace only one component at a time If the component that you replaced does not correct the problem replace the original component Try substituting the lower PCA first the ribbon cable second and the upper PCA third If you have performed all of the above procedures and have been unable to correct the problem call Precor Customer Support Using an ohmmeter measure the resistance across the lift capacitor terminals The lower
6. C960 Series Commercial Treadmill Section Five Troubleshooting Procedures Note This section contains troubleshooting procedures specific to the C96X family of treadmills Please refer to the troubleshooting procedures in the commercial service manual 20077 101 for additional troubleshooting procedures Procedure 5 1 Troubleshooting the Keypad and Upper PCA 000 5 3 Procedure 5 2 Troubleshooting the Lift System SCR amp PWM Units 5 7 Procedure 5 3 Troubleshooting the Lift System i Units cccceeeeeees 5 11 Procedure 5 4 Troubleshooting the Speed Sensol seeeeeeeseeeeeeeeeeees 5 15 Procedure 5 5 Troubleshooting Hand Held Heart Rate ctteeeeeeeeeeees 5 17 Procedure 5 6 Troubleshooting the External A C Power Source 5 21 C960 Series Commercial Treadmill Procedure 5 1 Troubleshooting the Keypad and Upper PCA If the function keys on the electronic console are unresponsive the problem may be either the upper PCA or keypad This troubleshooting procedure gives you the information you need to determine which of these components is malfunctioning Procedure 1 Set the circuit breaker in the ioffi position WARNING Before continuing with this procedure review the Warning and Caution statements listed in Section One of the Residential Treadmill Service Manual 2 Remove the screws that secure the upper display assembly to the upper hand
7. Set the on off switch in the ioffi position Refer to Diagram 5 3 for the following measurements With an ohmmeter measure between the ilower right contacti pin on the J1 connector and the lower right hand held heart rate contact on the handlebar The reading should be 1 W or less Measure between the iupper right contact pin on the J1 connector and the upper right hand held heart rate contact on the handlebar The reading should be 1 W or less Measure between the iupper left contact pin on the J1 connector and the upper left hand held heart rate contact on the handlebar The reading should be 1 W or less Measure between the ilower left contact pin on the J1 connector and the lower left hand held heart rate contact on the handlebar The reading should be 1 W or less If any of the above readings are greater than 1 W replace the heart rate PCA to handlebar wire harness No hand held reading No chest strap reading 16 Set the on off switch in the ioni position and access the diagnostic program Procedure 2 1 or 2 2 Advance to the heart rate display portion of the diagnostic program Verify that neither a chest strap signal or a hand held signal is being accepted with either a heart rate test transmitter or a chest strap transmitter 17 Check the plug connector connections on both the heart rate PCA J4 and upper PCA J1 18 If neither a chest strap signal or a hand held signal is being accepted measure between the igroundi and i5 Vdci pi
8. Vac For operator safety considerations and to minimize electrostatic discharge conditions the A C frame ground continuity must also be verified to be a low resistance connection to the A C distribution ground bar Important If the A C circuit feeding a treadmill is found to be a non dedicated circuit or a circuit equipped with a circuit breaker with a capacity of less than 20 amps the A C circuit must be corrected to be a 20 amp dedicated circuit before any reliable troubleshooting can be performed on the treadmill More importantly a non dedicated circuit may constitute a safety hazard to the treadmill operator 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 The most common problems found are 1 the circuit is fed by a circuit breaker of less than 20 amp capacity 2 the circuit breaker correctly feeds a single A C outlet but the neutral is common between several A C outlets and 3 both the hot and neutral leads feed several A C outlets The appropriate correction action or actions see below must be followed if any of the above conditions exist Corrective actions should only be undertaken by a licensed electrician 1 The circuit breaker feeding the treadmill is not a 20 amp circuit breaker If the circuit breaker i
9. ates a lift error error 40 41 or 42 go to step 22 If the lift motor will not move continue with step 2 16 17 18 19 20 21 22 23 C960 Series Commercial Treadmill Put the treadmill in a condition in which the lift motor is ready to be operated for example quick start into the manual program Using an AC voltmeter monitor the voltage across the lift capacitor and press one of the incline keys Approximately 1 4 times the AC input voltage should appear on the lift capacitor when a incline key is pressed Approximately 170 Vac on a 120 Vac unit or approximately 340 Vac on a 240 Vac unit The actual lift capacitor voltage will vary with the AC input voltage If AC line voltage or 1 4 times line voltage is on the lift capacitor go to step 20 If no AC voltage is on the lift capacitor continue with step 17 Set the treadmill circuit breaker in the ioffi position Remove the 2 amp lift fuse F2 from the lower PCA Using an ohmmeter measure the fuse resistance The fuse should measure approximately 1W or less If the fuse is open or significantly higher than 1W replace the fuse If the fuse was bad perform the test in step 18 before applying power to the lift If the fuse was good continue with step 19 Using an ohmmeter measure the resistance across the lift capacitor terminals The lower PCA resistance should be extremely high megohms the capacitor resistance should be extremely high megohms and the lift
10. ble If the above procedures did not correct the problem replace the heart rate PCA No hand held reading Normal chest strap reading 6 10 11 12 13 Set the on off switch in the on position and access the diagnostic program Procedure 2 1 or 2 2 Advance to the heart rate display portion of the diagnostic program Verify that a hand held signal is not being accepted by firmly grasping both the right and left hand held contacts on the handlebars Cover as much of the contact surface area with your hands as possible without moving your hands you should receive a heart rate reading within ten seconds If a hand held signal is not being accepted set the on off switch in the off position Temporarily install a spare jumper on J14 of the heart rate PCA hand held priority Set the on off switch in the ion position and repeat the procedure in step 6 If the hand held signal is now being accept something in the near vicinity is radiating RF radio frequency energy that is being received by the chest strap portion of the heart rate PCA Disabling the chest strap signal proves that it is radiated energy that is causing the problem If a hand held signal still not being accepted skip to step 13 The source of the radiated energy must be determined and relocated so that it no longer affects the heart rate PCA Televisions cell phones Cardio theatre receivers etc are possible sources of radiated energy Set the
11. cantly low replace the lift capacitor 10 11 12 13 14 15 C960 Series Commercial Treadmill At this point the lift fuse is good but there is no AC voltage on the lift capacitor when the lift is actuated There are three potential causes for this condition They are lower logic lift PCA ribbon cable or upper PCA There are no good means of troubleshooting these components other than substituting known good components Replace only one component at a time If the component that you replaced does not correct the problem replace the original component Try substituting the lower PCA first the ribbon cable second and the upper PCA third If you have performed all of the above procedures and have been unable to correct the problem call Precor Customer Support Using an ohmmeter measure the resistance across the lift capacitor terminals The lower logic lift PCA resistance should be extremely high megohms the capacitor resistance should be extremely high megohms and the lift motor winding should read approximately 34W or 122W If it measures significantly high or open i replace the lift motor If the resistance measurement in step 6 was approximately 34W 120 VAC units or 122W 240 VAC units replace the lift capacitor If you have performed all of the above procedures and have been unable to correct the problem call Precor Customer Support Typically when the lift is able to physically move but causes a lift er
12. counting motor revolutions A hall effect sensor is mounted on a bracket that is next to a hub that is attached to the lift motor shaft As the lift motors operates a magnet mounted in the hub passes the hall effect sensor once per motor revolution The hall effect sensor send one pulse to the lift control system per revolution The system knows how far the lift travels per revolution and by counting revolutions hall effect sensor pulses knows the current lift position The other two position switches upper and lower limit do not come into play during normal operation If either switch is activated it means that the lift has moved beyond itis normal range of motion When either limit switch is activated power is removed from the lift motor Removing power from the lift motor protects the lift system from physical damage Note All resistance measurements must be performed with power removed from the treadmill Performing resistance measurements with voltage applied may damage your ohmmeter Procedure 1 If the lift motor operates but creates a lift error error 40 41 or 43 go to step 8 If the lift motor will not move continue with step 2 2 Put the treadmill in a condition in which the lift motor is ready to be operated for example quick start into the manual program Using an AC voltmeter monitor the voltage across the lift capacitor and press one of the incline keys Approximately 1 4 times the AC input voltage should appear on th
13. e driven lift motor 120 Vac or 240 Vac and an external 10 KW potentiometer The 10KW potentiometer rotates as the lift operates and indicates the current lift position The lift system is factory calibrated but will require re calibration whenever the upper PCA is replaced refer to procedure 4 2 Units built after April 19 2000 utilized a lift motor with an internal 1 KW potentiometer Use the procedure in steps 1 14 for trpubleshooting units manufactured prior to April 20 2000 Start with step 15 for units manufactured after April 19 2000 Note All resistance measurements must be performed with power removed from the treadmill Performing resistances measurements with voltage applied may damage your ohmmeter Whenever the upper PCA is replaced on a C962i or C964i manufactured prior April 20 2000 the lift system must be re calibrated 1 If the lift motor operates but creates a lift error error 40 41 or 42 go to step 8 If the lift motor will not move continue with step 2 2 Put the treadmill in a condition in which the lift motor is ready to be operated for example quick start into the manual program Using an AC voltmeter monitor the voltage across the lift capacitor and press one of the incline keys Approximately 1 4 times the AC input voltage should appear on the lift capacitor when a incline key is pressed Approximately 170 Vac on a 120 Vac unit or approximately 340 Vac on a 240 Vac unit The actual lift capacitor voltage w
14. e lift capacitor when an incline key is pressed Approximately 170 Vac on a 120 Vac unit or approximately 340 Vac on a 240 Vac unit The actual lift capacitor voltage will vary with the AC input voltage If AC line voltage or 1 4 times line voltage is on the lift capacitor go to step 6 If no AC voltage is on the lift capacitor continue with step 3 C960 Series Commercial Treadmill Set the treadmill circuit breaker in the ioffi position Remove the 2 amp lift fuse F2 from the lower PCA Using an ohmmeter measure the fuse resistance The fuse should measure approximately 1W or less If the fuse is open or significantly higher than 1W replace the fuse If the fuse was bad perform the test in step 4 before applying power to the lift If the fuse was good continue with step 5 Using an ohmmeter measure the resistance across the lift capacitor terminals The Lower PCA resistance should be extremely high megohms the capacitor resistance should be extremely high megohms and the lift motor winding should read approximately 34W 120 Vac units or 122W 240 Vac units Therefore if the measurement is significantly lower than 34W or 122W disconnect both red leads from the lift capacitor Measure the resistance between the black leads on the lift capacitor and red lead to the lower PCA If it measures significantly low replace the lower PCA Measure the resistance between the black leads on the lift capacitor and red lead to the lift motor If i
15. ess should read between Pin 1 of J4 Left CHANGE key 0 Vdc and 350 mVdc Pin 2 of J4 STOP key 0 Vdc and 350 mVdc Pin 3 of J4 SPEED VY key 0 Vdc and 350 mVdc Pin 4 of J4 SPEED A key 0 Vdc and 350 mVdc Pin 6 of J4 QUICK START key 0 Vdc and 350 mVdc Pin 7 of J4 ENTER key 0 Vdc and 350 mVdc Pin 8 of J4 Right CHANGE key 0 Vdc and 350 mVdc Pin 9 of J4 Center CHANGE key 0 Vdc and 350 mVdc Pin 4 of J2 RESET key 0 Vdc and 350 mVdc Pin 6 of J2 INCLINE wv key 0 Vdc and 350 mVdc Pin 7 of J2 INCLINE A Wkey 0 Vdc and 350 mVdc 10 11 12 13 14 C960 Series Commercial Treadmill If the voltage readings match those listed in Tables 5 1 and 5 2 and one or more keys do not function replace the upper PCA If the voltage readings in Table 5 1 are incorrect disconnect the keypad cable from the key pad connector and repeat the voltage measurements in 5 1 If the voltage readings are now correct replace the display housing keypad If the voltage readings are still incorrect replace the upper PCA If the voltage readings in Table 5 1 are correct and one or more voltage readings in Table 5 2 are incorrect replace the display housing keypad Set the circuit breaker in the ioffi position If necessary carefully re connect the keypad cable to the keypad connector Remove the ground lead of the wrist strap from the treadmill frame then remove the wrist strap from your arm Position the display enclosure on the display plate Install
16. ill vary with the AC input voltage If AC line voltage or 1 4 times line voltage is on the lift capacitor go to step 6 If no AC voltage is on the lift capacitor continue with step 3 3 Set the treadmill circuit breaker in the ioffi position Remove the 2 amp lift fuse F2 from the lower PCA Using an ohmmeter measure the fuse resistance The fuse should measure approximately 1W or less If the fuse is open or significantly higher than 1W replace the fuse If the fuse was bad perform the test in step 4 before applying power to the lift If the fuse was good continue with step 5 4 Using an ohmmeter measure the resistance across the lift capacitor terminals The lower PCA resistance should be extremely high megohms the capacitor resistance should be extremely high megohms and the lift motor winding should read approximately 34W 120 Vac units or 122W 240 Vac units Therefore if the measurement is significantly lower than 34W or 122W disconnect both red leads from the lift capacitor Measure the resistance between the black leads on the lift capacitor and red lead to the lower PCA If it measures significantly low replace the lower logic lift PCA Measure the resistance between the black leads on the lift capacitor and red lead to the lift motor If it measures significantly low replace the lift motor Measure the resistance between the black leads on the lift capacitor and other terminal of the lift capacitor If it measures signifi
17. logic lift PCA resistance should be extremely high megohms the capacitor resistance should be extremely high megohms and the lift motor winding should read approximately 32W or 115W If it measures significantly high or open i replace the lift motor If the resistance measurement in step 6 was approximately 32W 120 VAC units or 115W 240 VAC units replace the lift capacitor If you have performed all of the above procedures and have been unable to correct the problem call Precor Customer Support Typically when the lift is able to physically move but causes a lift error the problem is in the lift position identification system lift potentiometer or lift calibration 24 25 26 27 28 C960 Series Commercial Treadmill Measure the voltage between the red wire term 1 of J1 and the black wire term 3 of J1 on the lower PCA The voltage should measure approximately 5 Vdc If the voltage is 0 Vdc or significantly low continue with step 11 If the voltage is correct go to step 12 Disconnect the J1 connector from the lower logic lift PCA Measure the voltage between term 1 of J1 and term 3 of J1on the lower PCA If the voltage is still 0 Vdc or significantly low replace the lower logic lift PCA If the voltage is correct with the J1 connector disconnected replace the potentiometer assembly Disconnect the J1 connector from the lower logic lift PCA With an ohmmeter measure the resistance between the red wire term
18. n that the system is dedicated If any doubt exists about A C systems dedication point to point tracing of the A C wiring may be the only way to prove system dedication
19. ns on J4 for 5 Vdc If 5 Vdc is present replace the heart rate PCA 19 If 5 Vdc is not present remove the connector from J4 of the heart rate PCA Measure between the igroundi and i5 Vdci pins of the connector just removed from the heart rate PCA for 5 Vdc If 5 Vdc is present replace the heart rate PCA If the 5 Vdc is not present measure between the corresponding pins of J1 on the upper PCA red and black wires If 5 Vdc is not present replace the upper PCA If 5 Vdc is present replace the upper PCA to heart rate PCA cable Constant or intermittent readings when neither the hand held or chest strap is in use 20 Verify that a ferrite core is clamped around the heart rate PCA to upper PCA cable 21 Constant or intermittent heart rate readings when neither heart rate system is in use is caused by something in the near vicinity radiating RF energy that is being received by the chest strap portion of the heart rate PCA 22 Temporarily install a spare jumper on J14 of the heart rate PCA hand held priority Set the on off switch in the ioni position and repeat the procedure in step 6 C960 Series Commercial Treadmill 23 Ifthe hand held signal is now being accept something in the near vicinity is radiating RF energy that is being received by the chest strap portion of the heart rate PCA Disabling the chest strap signal proves that it is radiated energy that is causing the problem 24 The source of the radiated energy must be dete
20. on off switch in the ioffi position and remove the temporary jumper from J14 of the heart rate PCA Re locate all potential sources of radiation Set the on off switch in the ioni position and repeat the procedure in step 6 Set the on off switch in the ion position and access the diagnostic program Procedure 2 1 or 2 2 Advance to the heart rate display portion of the diagnostic program Verify that a hand held signal is not being accepted by firmly grasping both the right and left hand held contacts with the opposite hands right hand on the left handlebar contacts and left hand on the right handlebar contacts Cover as much of the contact surface area with your hands as possible you should receive a heart rate reading within ten seconds If a hand held signal is still not being accepted skip to step 15 C960 Series Commercial Treadmill 14 Ifa hand held signal was accepted in step 13 the hand held contact wiring is reversed The end of the wire harness that connects to the hand held contacts in the handlebar is segregated into two groups One group has blue shrink wrap around it and the other group has black shrink wrap around it The iblue7 group must go to the right hand contacts and the iblacki group must go to the left hand contacts In both groups the black wire must go to the lower contact and the red wire must go to the upper contact If necessary rewire the hand held contacts as described above and test as described in step 6 15
21. or is functioning normally but lift errors occur With a DC voltmeter measure the voltage across the zero sense center switch It should measure approximately 0 Vdc when the switch is not operated and approximately 5 Vdc when the switch is operated If the operated voltage is 0 Vdc or significantly low remove both blue wires from the zero sense switch Measure the voltage between the two blue wires If the voltage is now correct replace the zero sense switch If the voltage is still O Vdc or significantly low replace the lower PCA At this point the hall effect sensor and the zero sense switch are functioning normally but lift errors occur There are three potential causes for this condition They are lower PCA ribbon cable or upper PCA There are no good means of troubleshooting these components other than substituting known good components Replace only one component at a time If the component that you replaced does not correct the problem replace the original component Try substituting the lower PCA first the ribbon cable second and the upper PCA third If you have performed all of the above procedures and have been unable to correct the problem call Precor Customer Support C960 Series Commercial Treadmill Procedure 5 3 Troubleshooting the Lift System i Units Lift System Description The C962i and C964i treadmills were manufactured with two types of lift systems Units built prior to April 20 2000 consisted of an AC line voltag
22. ower PCA There are no good means of troubleshooting these components other than substituting known good components Replace only one component at a time If the component that you replaced does not correct the problem replace the original component Try substituting the ribbon cable first the upper PCA second and the lower PCA third 6 If you have performed all of the above procedures and have been unable to correct the problem call Precor Customer Support C960 Series Commercial Treadmill Procedure 5 5 Troubleshooting Hand Held Heart Rate Circuit Description The hand held heart rate system is actually a dual system that is it can accept a heart rate signal from either the hand held heart rate contacts on the unitis handlebar or from a Polar heart rate chest strap transmitter Refer to Diagram 5 3 and verify that no jumpers are equipped on J13 J14 J15 or J16 Also verify that there is a jumper equipped on the internal chest strap setting The internal chest strap setting is the two left hand pins on the three pin connector as shown below in Diagram 5 3 These settings allow the heart rate system to operate on the internal chest strap receiver with the chest strap heart rate priority That is if both a chest strap and hand heart rate signal is being received the system will accept the chest strap signal and ignore the hand held signal If a chest strap signal is not being received the system will accept the hand held signal Note
23. rail Carefully pull some excess interconnect cable out from the targa upright Rotate the display housing so that the rear of the upper PCA is facing upward and set the display housing on the upper handrail 3 Attach the wrist strap to your arm then connect the ground lead of the wrist strap to the treadmill frame Diagram 5 1 Removing the Upper PCA 4 Set the voltmeter to a range that will conveniently read 6 Vdc 5 Set the circuit breaker in the ion position 6 Use a DVM set for DC volts and read between pin 5 of J4 and the each of the pins in Table 5 1 no keys pressed and Table 5 2 with the appropriate key pressed C960 Series Commercial Treadmill Diagram 5 2 Upper PCA Component Layout big DI11 DI13 DI15 DI17 DNg D121 u4 Dd DI10 D2 DIit4 DI16 Dis DI20 D122 RNY O RNS CA Rm2 an4 C J2 J4 J5 Table 5 1 Voltage Test Points Function Keys Not Pressed PLACE THE POSITIVE LEAD OF THE THE VOLTMETER SHOULD VOLTMETER ON READ Pin 1 of J4 5 Vdc 500 mVdc Pin 2 of J4 5 Vdc 500 mVdc Pin 3 of J4 5 Vdc 500 mVdc Pin 4 of J4 5 Vdc 500 mVdc Pin 6 of J4 5 Vdc 500 mVdc Pin 7 of J4 5 Vdc 500 mVdc Pin 8 of J4 5 Vde 500 mVdc Pin 9 of J4 5 Vde 500 mVdc Pin 4 of J2 5 Vdc 500 mVdc Pin 5 of J2 5 Vde 500 mVdc Pin 6 of J2 5 Vde 500 mVdc Table 5 2 Voltage Test Points Function Keys Pressed Place the positive lead At the electronic The voltmeter of the voltmeter on console pr
24. rmined and relocated so that it no longer affects the heart rate PCA Televisions cell phones Cardio theatre receivers etc are possible sources of radiated energy 25 Set the on off switch in the ioffi position and remove the spare jumper from J14 of the heart rate PCA Re locate all potential sources of radiation Set the on off switch in the iont position and repeat the procedure in step 6 C960 Series Commercial Treadmill Procedure 5 6 Troubleshooting the External A C Power Source It is extremely important that any Precor treadmill be connected to and operated on a dedicated 20 amp A C circuit A 20 amp dedicated circuit is defined as a circuit fed by a 20 amp circuit breaker that feeds a single load A treadmill operating from a non dedicated circuit or a circuit breaker of less than 20 amps capacity will not have the necessary power available to operate normally under higher load conditions The lack of available power can cause any number of symptoms ranging from numerous intermittent seemingly inexplicable error conditions poor speed control or tripping the house circuit breaker If any of the above symptoms exist the external A C circuit must be checked and confirmed to be a 20 amp dedicated circuit before troubleshooting the treadmill In addition the A C voltage must be checked Nominal A C operating voltage on 120 Vac circuits is 105 Vac to 120 Vac Nominal A C operating voltage on 240 Vac circuits is 208 Vac to 240
25. ror the problem is in the lift position identification system lift potentiometer or lift calibration Measure the voltage between the red wire term 1 of J1 and the black wire term 3 of J1 on the lower PCA The voltage should measure approximately 5 Vdc If the voltage is 0 Vdc or significantly low continue with step 11 If the voltage is correct go to step 12 Disconnect the J1 connector from the lower logic lift PCA Measure the voltage between term 1 of J1 and term 3 of J10n the lower PCA If the voltage is still 0 Vdc or significantly low replace the lower logic lift PCA If the voltage is correct with the J1 connector disconnected replace the potentiometer assembly Disconnect the J1 connector from the lower logic lift PCA With an ohmmeter measure the resistance between the red wire term 1 of J1 and the black wire term 3 of J1 The measurement should be approximately 10KW With an ohmmeter measure the resistance between the red wire term 1 of J1 and the white wire term 2 of J1 and measure the resistance between the white wire term 2 of J1 and the black wire term 3 of J1 The sum of the last two measurements should total approximately 10 KW If either of the two 10 KW measurements are open or significantly low or high replace the potentiometer assembly If you have performed all of the above procedures and have been unable to correct the problem call Precor Customer Support If the lift motor operates but cre
26. s greater than 20 amps the circuit breaker should be replaced with a 20 amp circuit breaker If the circuit breaker is less than 20 amps the circuit breaker must be replaced with a 20 amp circuit breaker and the wiring from the A C distribution must be capable of safely handing 20 amps If the A C wiring is under sized it must be replaced with wire capable of safely handling 20 amps Please refer to local electrical codes when determining the appropriate wire size for a 20 amp circuit C960 Series Commercial Treadmill The circuit breaker correctly feeds a single A C outlet but the neutral is common between several A C outlets The common neutral lead must be removed from treadmillis A C outlet and a new neutral lead from the treadmillis A C outlet to the A C neutral distribution bar must be added Both the hot and neutral leads feed several A C outlets Both the common neutral and hot leads must be removed from treadmillis A C outlet and a new neutral lead and hot lead from the treadmillis A C outlet to the A C neutral distribution bar and circuit breaker must be added 240 Vac Systems 240 Vac distribution systems utilize a double pole circuit breaker two hot leads The A C safety ground green wire is connected to a ground bar in the distribution system The most common problems found are 1 the circuit is fed by a circuit breaker of less than 20 amp capacity and 2 both the hot leads feed several A C outlets The appropria
27. t measures significantly low replace the lift motor Measure the resistance between the black leads on the lift capacitor and other terminal of the lift capacitor If it measures significantly low replace the lift capacitor At this point the lift fuse is good but there is no AC voltage on the lift capacitor when the lift is actuated There are three potential causes for this condition They are lower PCA ribbon cable or upper PCA There are no good means of troubleshooting these components other than substituting known good components Replace only one component at a time If the component that you replaced does not correct the problem replace the original component Try substituting the lower PCA first the ribbon cable second and the upper PCA third If you have performed all of the above procedures and have been unable to correct the problem call Precor Customer Support Using an ohmmeter measure the resistance across the lift capacitor terminals The lower PCA resistance should be extremely high megohms the capacitor resistance should be extremely high megohms and the lift motor winding should read approximately 34W or 122W If it measures significantly high or open i replace the lift motor If the resistance measurement in step 6 was approximately 34W 120 VAC units or 122W 240 VAC units replace the lift capacitor If you have performed all of the above procedures and have been unable to correct the problem call Precor Customer
28. te correction action or actions see below must be followed if any of the above conditions exist Corrective actions should only be undertaken by a licensed electrician 1 The circuit breaker feeding the treadmill is not a 20 amp circuit breaker If the circuit breaker is greater than 20 amps the circuit breaker should be replaced with a 20 amp circuit breaker If the circuit breaker is less than 20 amps the circuit breaker must be replaced with a 20 amp circuit breaker and the wiring from the A C distribution must be capable of safely handing 20 amps If the A C wiring is under sized it must be replaced with wire capable of safely handling 20 amps Please refer to local electrical codes when determining the appropriate wire size for a 20 amp circuit Both the hot leads feed several A C outlets Both hot leads must be removed from treadmillis A C outlet and two new hot leads from the treadmillis A C outlet to the circuit breaker must be added A licensed electrician may use the followings hints to determine if an A C service is dedicated 1 If on a 120 Vac system the A C distribution panel contains more circuit breakers than neutral leads the system has shared neutral leads and is not dedicated If an A C outlet 120 or 240 Vac has multiple hot and or neutral leads it is not a dedicated If either of the above conditions exist the system is not dedicated However absence of the above conditions does not necessarily mea
29. the screws that secure the display enclosure to the display plate Check the operation of the treadmill as described in Section Three of this appendix C960 Series Commercial Treadmill Procedure 5 2 Troubleshooting the Lift System SCR amp PWM Units Lift System Description The lift system on these units consists of an AC line voltage driven lift motor 120 Vac or 240 Vac a hall effect rotation sensor and three position location switches The lift system orients itself by locating the zero sense switch when the treadmill is powered up When the zero sense switch is activated the system recognizes that physical position as 0 incline If the zero sense switch is activated when the treadmill is powered up the system proceeds directly into the normal program mode If the zero sense switch is not activated when the treadmill is powered up the system performs a self calibration procedure The purpose of the self calibration procedure is to locate the zero sense switch 0 incline The user will be prompted to press any key to commence the lift calibration The treadmill will go up 4 because the lowest the treadmill could have been at power up is 3 If the treadmill does not locate the zero sense switch by going up 4 it will stop and then go down until it activates the zero sense switch The system will then proceed to the normal program mode Once the 0 lift position has been located the system tracks any subsequent lift operations by
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