95T ELEVATION SERIES TREADMILLS - GYMPART.COM...This service manual provides safe and efficient test and service procedures for the 95T Elevation Series treadmills. The service manual

95T ELEVATION SERIES TREADMILLSService Manual

M051-00K65-A003 11/16/0911/16/09

11/16/09 11/16/09

11

11

2

Table of Contents

Table of Contents 2

Introduction 5

Using This Manual 6

Contact Information 7

System Level Troubleshooting 9

Preparation 10

Required Service Tools 11

Specialty Tools 12

Maintenance 13

Preventive Maintenance Schedule 14

Modules 19

Drive Motor (DS) 20

System Component 20

Problem Symptoms Table 21

How To’s 22

Base Frame Electronics (BE) 24

Theory of Operation 24

System Components 28

Problem Symptom Table 29

Troubleshooting Flow Diagrams 31

How To’s 34

Electrical Wiring Diagrams 38

Lift System (LS) 41




How To’s 46

Console & Activity Zone (CA) 51

3




Troubleshooting Flow Diagrams 61

How To’s 72

Electrical Wiring Diagrams 75

Heart Rate System (HR) 77

Lifepulse® Theory of Operation 77



How To’s 81

Stride (Walking) System (SS) 83




How To’s 88

Lower Frame (LF) 95



How To’s 97

Upper Frame (UF) 102



How To’s 104

Appendix 109

Engage / Inspire Console Diagnostic 110

Overview 110

System Options - Block Diagram Overview 111

System Options - Main Menu 112

System Test Menu 1 113

System Communication Check 114

Motor Modules (TR Only) 115

System Diagnostics Check (Non – TR only) 116

Key Pad Test 117

Heart Rate Test 118

Table of Contents

4

iPod® Test 119

Test Engineering 120

System Test Menu 2 121

Stride Sensor Test (TR only) 122

External Serial EE Test 123

CSAFE Network Test or Status 124

CSAFE Loopback Test 125

Information Menu 126

Information Statistics 127

Software Versions 129

Main Motor Information (TR Only) 130

Lift Motor Information (TR Only) 138

Belt / Deck Information (TR Only) 139

Date and Time Information 140

System Errors 141

Maintenance Information 142

Usage Log Report 143

Channel Usage Log 144

ConfigurationMenu 145

ManagerConfiguration1 146

ManagerConfiguration2 147

Manufacturer’sConfiguration 148

Video/FMRadioConfigurationMenu 151

Video Setup Screen 152

Channel Name / Sort Setup Screen 153

Secure Channel Setup Screen 154

Promo Channel Setup Screen 155

FM Radio Setup Screen 156

Custom Workouts Screen 157

Export / Import Settings 158

Create Your Own Screen 159

NetworkConfiguration 160

Clock Setup (Date and Time Information) 161

Maintenance 162

Error / Info Messages 163

Table of Contents

Introduction

6

Introduction

Using This Manual

Thisservicemanualprovidessafeandefficienttestandserviceproceduresforthe95TElevationSeriestreadmills.Theservice manual is arranged in the following sections:

IntroductionThissectionprovidestheusageguidelines,contactinformation,technicalspecificationsandglossaryoftermsusedinthismanual.

PreparationThissectionprovidesthelistofservicetoolsrequiredtoperformvariousserviceoperationsdescribedinthismanual.

MaintenanceThissectiondescribesasuggestedpreventivemaintenanceschedulefortheequipment.

Theory of OperationThis section describes the working principle of a treadmill, described for various components such as mechanical, electrical andsoftware.

Electrical Wiring DiagramsThissectioncontainsalltheelectricalwiringdiagramsforvariouscomponentsofthe95TElevationseriestreadmill.Abasicblockleveldiagramisexplained,followedbydetailedworkingofeachcomponent.

ModulesThis servicemanual has been organized by several operational modules of treadmill. Eachmodule contains its owntroubleshootingguides(symptomtablesandflowdiagrams),electricalwiringdiagrams(ifrequired)andHowTo’s.

IndexTofindinformationwhenaserviceproblemoccurs:

• Usethetop-leveltroubleshootingguidelinetodeterminethemodule.• Checkthecorrespondingmodulesection’stroubleshootingtozoomintotherootcause.• FollowtheserviceproceduresdescribedusingtheHowTo’ssectionforthemodule.

RefertoElectricalWiringDiagramssectionforvariousblockdiagramsandconnectorlocations.Unlessotherwisespecified,standardtoolslistedinthePreparationsectionshouldbeused.

M051-00K65-A003

7

Introduction

Contact Information

To speed Life Fitness Customer Support Service’s response, please provide the following information to the customer support technician:

•Modelnumber•Serialnumber(a3-letter,6-numbersequence)•Symptomofproblem

Location of model and serial numbers

Location of model and serial numbers

Corporate Headquarters5100RiverRoad,SchillerPark,Illinois60176U.S.A.Toll-Free:800.735.3867(withinU.S.A.,Canada)Tel: (847) 288 3300Fax: (847) 288 3703Global Website: www.lifefitness.com

InternationalOffices

AMERICA’SNORTH AMERICALife Fitness Inc.5100NRiverRoad,SchillerPark,IL60176U.S.A.Tel: (847) 288 3300Fax: (847) 288 3703Service Email:[email protected]/Marketing Email:[email protected] Hours: 7:00 am-6:00 pm (CST)

BRACTIVITY ZONEILLife Fitness Do BrActivity ZoneilAv.Dr.DibSauaiaNeto1478,Alphaville,Barueri,SP 06465-140, BrActivity ZoneilTel: (800) 773 8282Fax: (+55)11.4133.2893Service Email: [email protected]/Marketing Email:[email protected] Hours: 8:30 am-17:30 pm (BRT)

LATIN AMERICA & CARIBBEAN*Life Fitness Inc.5100NRiverRoad,SchillerPark,IL60176U.S.A.Tel: (847) 288 3300Fax: (847) 288 3703Service Email:[email protected]/Marketing Email: [email protected] Hours: 8:00am-5:00pm (CST)

M051-00K65-A003

Front View Rear View

8

Introduction

Contact Information

EUROPE, MIDDLE EAST & AFRICA (EMEA)

NETHERLANDS & LUXEMBURGLife Fitness Atlantic BVBijdorpplein 25-31, 2992 LB Barendrecht, The NetherlandsTel: (+31) 180 646 666Fax: (+31) 180 646 699Service Email:[email protected]/Marketing Email: [email protected] Hours:9.00h-17.00h(CET)

UNITED KINGDOM & IRELANDLife Fitness UK LTDQueen Adelaide, Ely, Cambs, CB7 4UBTel (GeneralOffice):(+44)1353.666017Tel (Customer Support):(+44)1353.665507Fax:(+44)1353.666018Service Email:[email protected]/Marketing Email:[email protected] Hours:GeneralOffice:9.00am-5.00pm(GMT)CustomerSupport:8.30am-5.00pm(GMT)

GERMANY & SWITZERLANDLife Fitness Europe GMBHSiemensstrasse 3, 85716 Unterschleissheim, GermanyTel (Germany):(+49)89.317751.0Tel (Switzerland): (+41) 0848 000 901Fax (Germany):(+49)89.317751.99Fax (Switzerland): (+41) 043 818 07 20Service Email:[email protected]/Marketing Email:[email protected] Hours:9.00h-17.00h(MEZ)

AUSTRIALife Fitness AustriaVertriebsG.m.b.H.,Dückegasse7-9/3/36,1220Vienna,AustriaTel:(+43)1.61.57.198Fax:(+43)1.61.57.198.20Service Email:[email protected]/Sales Email:[email protected] Hours:9.00h-17.00h(MEZ)

SPAINLife Fitness IBERIAC/Frederic Mompou 5,1º1ª,08960 Sant Just Desvern Barcelona, SpainTel: (+34) 936 724 660Fax: (+34) 936 724 670Service Email:[email protected]/Marketing Email:[email protected] Hours:9.00h-18.00h(Monday-Thursday)8.30h-15.00h(Friday)

ITALYLife Fitness ITALIA S.R.L.ViaCrivellin7/N,37010AffiVerona,ItalyTel:(+39)045.7237811Fax:(+39)045.7238197ServiceEmail: [email protected]/Marketing Email:[email protected] Hours: 8.30h-18.00h(CET)

BELGIUMLife Fitness Benelux NVParc Industrial de Petit-Rechain, 4800 Verviers, BelgiumTel: (+32) 87 300 942Fax: (+32) 87 300 943Service Email:[email protected]/Marketing Email:[email protected] Hours:9.00h-17.00h(CET)

ALL OTHER EMEA COUNTRIES &DISTRIBUTOR BUSINESS CEMEA*Bijdorpplein 25-31, 2992 LB Barendrecht, The NetherlandsTel: (+31) 180 646 666Fax: (+31) 180 646 699Service Email:[email protected]/Marketing Email:[email protected] Hours:9.00h-17.00h(CET)

ASIA PACIFIC (AP)

JAPANLife Fitness JapanNipponBrunswickBldg.,#8F5-27-7 SendagayaShibuya-Ku, TokyoJapan 151-0051Tel:(+81)3.3359.4309Fax:(+81)3.3359.4307Service Email:[email protected]/Marketing Email:[email protected] Hours:9.00h-17.00h(JAPAN)

CHINA AND HONG KONGLife Fitness Asia Pacific LTDRoom 2610, Miramar Tower, 132 Nathan Road,Tsimshatsui, Kowloon, Hong KongTel:(+852)2891.6677Fax:(+852)2575.6001Service Email:[email protected]/Marketing Email:[email protected] Hours:9.00h-18.00h

ALL OTHER ASIA PACIFIC COUNTRIES &DISTRIBUTOR BUSINESS ASIA PACIFIC*Room 2610, Miramar Tower, 132 Nathan RoadTsimshatsui, Kowloon, Hong KongTel: (+852)2891.6677Fax:(+852)2575.6001Service Email: [email protected]/Marketing Email:[email protected] Hours:9.00h-18.00h

*Alsocheckwww.lifefitness.comforlocalrepresentationordistribu-tor dealer

M051-00K65-A003

9

Introduction

System Level Troubleshooting M051-00K65-A003

SYMPTOM POSSIBLE CAUSE SECTION PAGE

Belt not moving Treadmill not powered Base Frame Electronics BE 8

Console operation Console and Activity Zone CA 11

Motor does not start upon workout start

Base Frame Electronics BE 8

Noise and vibration From the general striding belt area

Stride System SS 3

From the front end of the base

Drive Motor DS 2

During incline / decline Lift System LS 4

Structural noise fom the base

Lower Frame LF 2

Structural noise fom the upper frame

Upper Frame UF 2

Structural failure Console Console and Activity Zone CA 8

Upper structure Upper Frame UF 2

Base Lower Frame LF 2

Appearance issues Console Console and Activity Zone CA 8

Upper structure Upper Frame UF 2

Base Lower Frame LF 2

Error messages Error message displayed on the console

Error / Info Message Table Page 163

Heart rate issue Polar or LifePulse® Heart Rate System HR 4

Networking issues CSAFE connected devices Console and Activity Zone CA 8

iPod®, USB and headphone issues

Option panel Console and Activity Zone CA 17

Audio and video issues Console & console connections

Console and Activity Zone CA 13, CA 20

Base external connections Base Frame Electronics BE 6

User interfaceissues Console interface (display, touchscreen,etc.)

Console and Activity Zone CA 18

Software issues Installed software version is not the latest released

Latest software update Instructions - Look it uphere:https://www.lftechsupport.com/web/guest/software-releases

N/A

Preparation

11

Preparation

Required Service Tools

Unlessotherwisespecified,thesetoolsarerequiredtoperformtheserviceproceduresinthismanual:

1. Screwdrivers(Phillipsandflatblade)

2. Torxbitsanddrivers

3. Pliers(regularandneedlenose)

4. Rubberordeadblowmallet

5. Snap ring pliers (internal and external)

6. E-ringtools

7. Socketwrenches(Englishandmetric)

8. Ratchetwrenches(Englishandmetric)

9. Combination,open-end,orboxwrenches(Englishandmetric)

10.Allenheadwrenches(Englishandmetric)

11.Strapwrench

12.Miniflashlight

13.Scribeorinkpen

14.Straightedge

15.Nutdriver(1/4”drivesocketset)

16.Removablethreadlockingcompound–e.g.Loctite®242or243

17.Break Free®

18.Cordortwine

19.Diagonalcutters(smallandmedium)

20.2blocks(e.g.,scrap4”X4”[101mmx101mm]wood)

21.Multimeterwithtestleads

22.Tapemeasure

23.Telescopingmagnet

24.Stethoscope

25.Calibratedtorquewrenches

26.Lightlubricatingoil(i.e.3-in-1)

27.TF-1000grease(WhiteLithium)

28.Greasegun

29.Grabtool

30.Centerpunch

31.Anti-staticstrap

32.Outlettester

33.Dremel®

34.Drillandextractor(easy-out)Bits

35.Softcloth

NOTE: Specialized tools may be required to complete some service procedures safely. Using toolsimproperlycanresultindamagetoequipmentorpersonalinjury.

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Preparation

Specialty Tools

Life Fitness Tools:

1.Bearingremovaltoolkitp.n., bearing toolkit p.n.

NOTE:Partnumbersaresubjecttochange.

M051-00K65-A003

Maintenance

14

Maintenance

Preventive Maintenance Schedule M051-00K65-A003

ITEM WEEKLY MONTHLY QUARTERLY BIANNUALLY ANNUALLY

Display Console / Activity Zone Assembly

Hardware Inspect for loose or damaged hardware.Replace if necessary.Reapply Loctite 242/243 asneeded.Tighten torque bolts to recommended specificationsin the Service Manual.

Console / Activity Zone overlay

Clean with a mild soap and water, Original Dawn® dishwashing liquid recommended.

Accessory cups Clean with a mild soap and water, Original Dawn® dishwashing liquid recommended.Cups are dishwasher safe.

Inspect for damage, cracking, color fading,etc.Replace if necessary.

iPod® connector / cable

Clean with dry cloth.Inspectcable and connector for damage.

USB port Clean with drycloth.Inspect pins for damage.

Emergency switch / key

Clean with a mild soap and water, Original Dawn® dishwashing liquid recommended.Inspect for damage.Replace switch ifnecessary.

15

Maintenance



Ergo™ Front Handlebar Assembly

Hardware Inspect for loose or damaged hardware.Replace if necessary.Reapply Loctite 242/243 asneeded.Tighten torque bolts to recommended specifications.

Handlebar Inspect for cracking, color fading,etc.Replace if necessary.

Side handrails including shrouds

Inspect for cracking, color fading,etc.Replace if necessary.

Bridge cover Clean with a mild soap and water, Original Dawn® dishwashing liquid recommended using a damp towel, follow up another damp cloth rinsed with clean water to remove any residue.DONOT scrub or use brushes on theshrouds.


LifePulse® sensors

Clean with a mild soap and water, Original Dawn® dishwashing liquid recommended.Inspect for damage.Replace if necessary.

16

Maintenance



Frame Assembly

Hardware Inspect for loose or damaged hardware.Replace if necessary.Reapply Loctite 242/243 asneeded.Tighten torque bolts to recommended specifications.

Uprights and bolts to mount to the lower frame


Inspect for loose or damaged hardware.Replace if necessary.Reapply Loctite 242/243 asneeded.Tighten torque bolts to recommended specifications.

Motor cover Clean with a mild soap and water, Original Dawn® dishwashing liquid recommended using a damp towel, follow up another damp cloth rinsed with clean water to remove any residue.DONOT scrub or use brushes on theshrouds.Inspect for cracking, color fading,etc.Replace as needed.


17

Maintenance



Frame Assembly

Motor electronic compartment

Vacuum interior

Inspect flywheel,drivepulleys cables, connectors, Lift Motor, motor control board, etc.fordamage.Use a nylon brush to remove debris.Replacecomponents as needed.

Drive belt Inspect for excessive wear, e.g.cracking,beltdebris.Replace as needed.

Machine level / leg levelers

Inspect for any rocking on the unit.Adjustasneeded.

Front roller Inspect for excessive bearing axial andradialplay.Inspect roller for excessive wax buildup.Removeexcessive wax buildup.Inspectthe plastic drive pulley for cracks, warpage, or missinggrooves.Replace components as needed.

Rear roller Inspect for excessive bearing axial and radial play.Removeexcessive wax buildup.Replacecomponents as needed.

End caps Clean with a mild soap and water, Original Dawn® dishwashing liquid recommended.

Inspect to see if end caps are damaged, cracked, faded, or loose.Replaceifnecessary.

18

Maintenance



Frame Assembly

Side shrouds Clean with a mild soap and water, Original Dawn® dishwashing liquid recommended.Inspect for loose hardware.

Side extrusions Clean with a mild soap and water, Original Dawn® dishwashing liquid recommended.Inspect for loose hardware.

Anti-slip pads Clean with a mild soap and water, Original Dawn® dishwashing liquid recommended.Inspect signs of peelingoff.

Walking belt Inspect for belt alignment/tracking and correct accordingly.Inspect the edges of the belt between the belt barriers.Referto Stride System Module.

Inspect for excessive wear on the walking/running surface and edges for excessive fraying.Replace as needed.

Roller guards Inspect for damage usually caused by users stepping on them.Replaceasneeded.

Visible deck surface


Modules

20

Modules DS 1

Drive Motor:System Component

Nut(9-13 ft-lbs)[12-17N-m](Bolt for -03 models or higher)QTY 4

Nut(9-13 ft-lbs)[12-17N-m]QTY 4

MotorFlat WasherQTY 4

Shoulder WasherQTY 4

Flywheel Bolt(21-24 ft-lbs)[28-33N-m]

Insulating PadQTY 2

Clip(-03 models or higher)QTY 4

Flywheel

Set Screw Over Key(51-71 in-lbs)[59-82kg-cm]

KeyDrive Belt

Motor Pulley

Spring

Idler Support Bracket

Clevis Pin withShoulder Washer

Threaded Shaft

Idler Assembly

Drive Motor for -01 and -02 Models Drive Motor for -03 and higher

Idler Support Bracket

Idler Assembly

Clevis Pin

Tie Bar Frame Bracket(Never remove on -01 & -02 models)

M051-00K65-A003

21

Modules

Drive Motor:Problem Symptoms TableDS 2


Drive motor does not operate.

Drive motor cable connection to controller faulty.

Check drive motor cable connectiontocontroller.

BE 7

Wrong motor controller for power source (220 volt or 120volt).

Install proper motor controller.

BE 12

Failedmotorcontroller. Verify all connectionsReplace motor controller if required.

BE 12

Thermal switch on motor maybeopenordefective.

Inspect across thermal switch leads with ohm meter (verify not open, and resistance less than one ohm).

Is there an error message on the console?

See troubleshooting flowchart.

BE 6

Excessive vibration Motorflywheelunbalanced. Replaceflywheel. DS 3

Motorshaftbent. Replacemotor. DS 3

Flywheelboltloose. Tightenflywheelbolt. DS 3

Motor mounting hardware loose.

Check hardware and tightenaccordingly.

DS 3

Squeaking noise when drivebeltmoves.

Worn or damaged main drivebelt.

Inspect main drive belt for damageorwear.Replaceifnecessary.

DS 3

Drive motor pulley and front rollerpulleymisaligned.

Alignpulleys. DS 3

Noise from Drive motor Motor bearings bad Replacemotor. DS 3

Flywheel bolt loose and flywheelrubbing

Tightenflywheelbolt. DS 3

M051-00K65-A003

22

Modules

REMOVAL OF DRIVE MOTOR

1. Turnthetreadmillpowerswitchoff.

2. Unplugthelinecordfromthewalloutlet.

3. Disconnect the cables between the drive motor and the motor controller.

4. Insertaflatbladescrewdriverintotheslottedendoftheidlerbracket.

5. Raise idler bracket just enough to insert a screwdriver or an Allen wrenchintotheaccessholeoftheidlerbracket.Thiswillkeepitinaraisedposition.

6. Removethedrivebeltfromaroundmotorpulley.

7. Withtheflatbladescrewdriverintoslottedendofidler,holdonto this screwdriver and slowly remove other screwdriver or Allen wrench.

8. Slowlyloweridlerbracketwiththefirstscrewdriver.

9. Removespring,clevispinandidlerbracket.Nowyouarereadytoremovemotor.

NOTE: For -03 models or higher the Idler Support Bracket with the idlerassemblymustberemovedbeforeproceedingtothenextstep.

10.Remove and save the 4 hex nuts, the 4 washers and the 4 plastic shoulder washers that secure the drive motor to the motor mounting studsintheframe.

NOTE:-03modelsorhigherhaveboltsinsteadofnuts.

11.Lift the drive motor assembly up and off the studs and out of the motorpan.(Frameson-03modelsorhigherhaveweldnutsinsteadofweldstuds).

NOTE: Never remove the tie bar frame bracket on -01 and -02 models.

12.Loosenthesetscrewsonthedrivemotorpulley(sheave).

13.Removethepulleyfromthedrivemotor.

14.Removetheflywheel/fanassemblybyremovingflywheelboltandsetaside.UseTool#AK58-00632-0000(PartofTaperedFlywheelRemovalKit#GK65-00002-0014).

15.Installthepreviouslyremovedflywheel/fanassemblyanddrivepulley(sheave)ontothenewdrivemotor.Donottightenthedrivepulley set screws until the roller pulley and drive pulley have been alignedasshowninthestepsthatfollow.

Drive Motor:How To’sDS 3

Line up hole in idler and hole in support bracket and insert Allen wrench or screwdriver

Key Drive Sheave Set Screws (2)(51-71 in-lbs)[59-82kg-cm]

Drive Sheave

M051-00K65-A003

23

Modules

Motor Pulley (sheave)

Straight Edge

Roller Pulley

16.Installthenewdrivemotor.Reuseanyhardwareremovedandsavedinprevioussteps.

17.Slidethedrivemotorpulleyontothemotorshaftandinstallkeyintopulleyandmotorshaftkeyway.

18.To align the drive motor pulley (sheave) with the front roller pulley:

a.Usingastraightedge,aligntheouterfaceofthedrivemotorpulleywiththeouterfaceofthefrontrollerpulley.

b.Slidethedrivemotorpulley(sheave)inoroutontheshaftduringalignment.

c.Tightensetscrewoverthekeyonthedrivemotorpulleyfirst.Rotatemotorpulleybypushingontheflywheeltomakesurepulleyshavebeenproperlyalignedandbeltisrunningtrue.Tightensecondsetscrew.

19.Re-installtheIdlerbracketanddrivebelt.

Drive Motor:How To’sDS 4

M051-00K65-A003

24

1. Overview

The electronics in the base of Elevation Series treadmills control the main motor and Lift Motor, provides power to the consoleandmonitors thestridesensor.All thecircuitry is containedonasingleprintedcircuit board (PCB)assemblywhichconsistsofthePCBplusheatsinkandbracket.ThisDSPBoardassemblyisknownasthe“DSPcontroller”sinceaDigitalSignalProcessor(DSP)isattheheartofallthecontrolfunctionsofthisboard.Therearetwoversions of DSP controller used on Elevation series treadmills, one for low voltage (100-120 VAC) and another for high voltage(200-240VAC)inputpower.Theinputpowerconnector,P7,andtheliftactuatorconnector,P6,aredifferentonthelowandhighvoltageDSPcontrollersinordertohelppreventinstallingthewrongcontroller.Anotherdistinguishingfeature between the two versions is that FUSE2 and FUSE3 are replaced with jumper wires on the low voltage version sincetheyareonlyrequiredforEuropean230VAC.

2. Input Power

TheinputpowercomesinfromthelinecordattachedtoanIECconnectorandisroutedthroughapowerswitch.AftertheswitchanElectroMagneticInteference(EMI)filterisaddedtoreduceradiofrequencyconductedemissions.Adifferentfilter is used onmodelsmeetingEuropean requirements versusmodels design tomeetUS requirements.A cableassemblycontainingtransientsuppressiondevicescalledMOV’sormetaloxidevaristorsisattachedtothelinefilter.Thesedeviceshelppreventhightransientvoltagespikessuchasfromlightningfromdamaginginternalcircuitry.ThepowercablefromthefilterandMOVthengoestoconnectorP7ontheDSPcontroller.P7isathreepositionconnectorfor100-120VACtreadmillsandatwopositionconnectorfor200-240VACtreadmills.

OntheDSPcontrollertheinputpowergoesthroughaninrushlimitingcircuitandaninputpowerrelay.Theinrushlimitingcircuit adds series impedance to limit high peak currents when the large DC bus capacitors are being charged at turn on.TheinputpowerrelayispartoftheemergencystopswitchsystemandwillremovepowertothemotorcontrollerstoppingstridingbeltmovementwhentheEmergencyStopSwitch(ESS)lanyardispulledbytheuser.BoththeconsoleandtheDSPhavecontrolofthisrelaytoturnoffpowertothemotorcontroller.Thepowersupplyremainsonandtheconsolewillstillbepoweredwhenthisrelayisopened.

3. Motor Control

TheACpowerisrectifiedbyBR2whichismountedtotheheatsinkandfilteredbyfourlargeelectrolyticcapacitors.Inthecaseofthe100-120VAClowvoltageDSPcontroller,avoltagedoublerconfigurationisusedsothebusvoltageforthemotorcontrolleristhesameforbothhighandlowvoltageversions.TheDCbusvoltagegoestotheIGBTmodulewhichismountedontheheatsinkandisthemainpowerstage.Thismoduleisconfiguredasathreephasebridgeinverterwhich converts the DC bus voltage to three phase AC voltages at the appropriate amplitude and frequency to run the motoratthecorrectspeed.ThemotorcontrollersensestheIGBTbridgephasecurrentsandusesthisinformationtocalculatethemotorspeedsoaspeedsensorisnotrequired.

4. Lift Control

TheLiftactuatorwhichcontrolstreadmillinclineispoweredfromtheDSPcontroller.ThelinevoltageisswitchedtoeithertheinclineordeclinewindingsoftheACmotordependingonwhichdirectioniscommanded.TheDSPcontrolleralsoreadstheHomeSwitchwhichtellstheDSPtheinclineisat0%.TheontimeoftheLiftMotoriscontrolledtoprovidethecommandedincline.AfrequencydetectcircuitontheDSPcontrollerdetectswhethertheinputAClinefrequencyis50Hzor60Hzandadjuststheontimetoobtainthecorrectincline.

5. Power Supply

TheDSPcontrollercontainsaflybackpowersupplythatpowerstheconsolecircuitryaswellasallcircuitryontheDSPcontroller.Aflybackpowersupplyprovides6VDCand12VDCtotheconsole.ThesevoltagesareisolatedfromtheAClinevoltage.ThesameflybacksupplyalsoprovidessupplyvoltagestotherestoftheDSPcontroller.ThesevoltagesarenotisolatedfromAClinebutarereferencedtothemotorcontrollerbusvoltage.Thepowersupplyisauniversalinputsupplyandwilloperatefrom85VACto264VAC.

Modules

Base Frame Electronics:Theory of OperationBE 1

M051-00K65-A003

25

6. Stride Sensor

TheStridesensorisapiezoelectricsensorplacedunderthedeckwhichsensesmovementofthedeck.Thevoltagecoming out of the piezoelectric sensor goes to the DSP controller which has an opto-isolator isolating the stride sensor fromtheDSP.TheDSPmonitorsthisvoltageandsendstheinformationtotheconsolewhereitisusedtodeterminethepresenceofauser.

7. Console Interface

TheDSPcommunicates to theconsoleprocessorviaa twowireserial communications. (Note: JW3shouldnotbepresentforElevationtreadmills.OthertreadmillswhichusesinglewirecommunicationwillhaveJW3inontheDSPcontroller).Opto-isolatorsareprovidedontheDSPcontrollertoisolatethetransmitlineandreceivelinesincethegroundreferencefortheDSPcircuitryisnotthesameasthatoftheconsole.DSPcontrollersoftwareupdatescanbeperformedbyusingit’sbuiltinfieldre-programmabilitycapabilitydirectlyorviatheconsoleCsafeinterface.

An additional optically isolated signal the DSP controller receives from the console is the Emergency stop signal which controlstheinputpowerrelay.

8. DSP Controller Software

The Life Fitness motor controller uses proprietary control algorithms to control the ac induction motor to allow for maximumefficiency,noisecontrolandsmoothnessoverthefullrangeofoperation.

Onboard sensors monitor bus voltage, motor current and power module temperature ensuring component limits are not exceeded.

Linevoltagecompensationallowswidevoltagefluctuationstobetransparenttotheexerciser.

Maximumaveragepowerisregulatedallowingshorttermpeakswhilestillcontrollingaveragepower.

Motor Controller diagnostics keep track of 34 parameters and maximums to aid in appraising the health and performance ofthesystem.ThesecombinedwithindicatorLED’shelptheservicetechniciandiagnosingandcorrectinganysystemissues.

A serial communication link between the motor controller and Console provides seamless operation of the whole Treadmillsystem.

9. Indicators and Displays

TherearetenLED’sonthe92343PolarBoard.

•LED1 12V indicator

•LED2 6V indicator

•LED3 Tx Communication indicator

•LED4 Lift (Up) direction

•LED5 Lift ON

•LED6 V bus indicator

•LED7 +Vd indicator

•LED8 3.3Vindicator

•LED9 Incline 0 position indicator

•LED10 Incline Bottom position indicator

Modules


M051-00K65-A003

26

10. Connector

ConnectorP1isasixpositionfemaleMate-N-Lockconnectorformotor.

Modules

ConnectorP4isafourpositionMicro-fitconnectorforlimitswitches.

PIN # DESCRIPTION

P4-1 Zero position switch

P4-2 Zero position switch return (GND)

P4-3 Bottom limit switch

P4-4 Bottom limit switch return (GND)

ConnectorP5isatenpositionMini-fitjr.forconsolepowerandsignals.

PIN # DESCRIPTION

P5-1 RTN

P5-2 RTN

P5-3 6VDC (Elevation); 8VDC (Classic)

P5-4 6VDC (Elevation); 8VDC (Classic)

P5-5 12V(Elevation);N.C.(Classic)

P5-6 RXD

P5-7 TXD

P5-8 N.C.

P5-9 12VDC

P5-10 ESS

ConnectorP6isfourpositionMate-N-Lockconnectorforliftactuator.

PIN # DESCRIPTION

P6-1 Down

P6-2 Hot

P6-3 Up

P6-4 N.C.


PIN # DESCRIPTION

P1-1 Frame

P1-2 Phase W

P1-3 Phase V

P1-4 Phase U

P1-5 Not Used

P1-6 Not Used

M051-00K65-A003

27

Modules

ConnectorP146positionKK100Testconnector.

PIN # DESCRIPTION

P14-1 N.C.

P14-2 N.C.(key)

P14-3 GND

P14-4 +Vd (15Vdc) Internal Supply

P14-5 3.3VInternalSupply

P14-6 Reset

ConnectorP7isathreepositionMini-fitSeniorconnectorforinputpower.

PIN # DESCRIPTION

P7-1 Line

P7-2 Neutral

P7-3 Not used

ConnectorP8isa2positionMini-fitJr.formotorthermalswitch.

PIN # DESCRIPTION

P8-1 Therm1

P8-2 Therm2

ConnectorP9isafivepositionMini-FitJr.connectorforconsolevoltageselect.

PIN # DESCRIPTION

P9-1 8V

P9-2 6/8V

P9-3 6V

P9-4 12V

P9-5 12V(ESS)

PIN # DESCRIPTION

P10-1 RTN

P10-2 SSENSE

P10-3 +12VDC

ConnectorP10isa3positionC-gridconnectorforStrideSensorinterface.


M051-00K65-A003

28

Modules

Base Frame Electronics:System ComponentsBE 5

Main Cable

On/Off Switch

Line Cord

Motor Controller

Retaining Bracket

M051-00K65-A003

29

Modules

Base Frame Electronics:Problem Symptom TableBE 6


No power to treadmill Open or failure in line cord, cables,controller,etc.

Seeflowchart. BE 8

Maximum speed is reduced orerrormessage“Cannotattaintargetspeed”.

Insufficientlinevoltage. Refer Stride System Module.

SS 3

Worn deck and/or worn stridingbelt.

Unit resets randomly Or pauses.

Intermittent in line cables, stopswitchcircuit.

Seeflowchart. BE 10

Errormessage“ModuleCommunicationError”.

Power up Communication test to base failed or lost communicationwithbase.

Check/replace cabling downtotheM/C.

Error message “Notifymaintenancecommunication timeout (motorcontroller)”.

Broken communication lines, JW3 installed on DSP M/C.

RemoveJW3.Check/replace cabling down to the M/C.Vibrationiscausingintermittent operation from looseconnection.

Errormessage“Notifymaintenance motor controller error (thermal shutdown)”.

The M/C compartment airflowisrestricted.Hotairisbeingblownonit.It’slocatedindirectsunlight.There is excessive wear on thebeltordeck.

Clean the M/C compartment.Insureadequate ventilation is available and it is not being heated by a heating register.Movefromdirectsunlight.Replacebelt/deckifpowerlevelisexcessive.

Errormessage“Warning– step off belt, maximum voltagetrip”.

User is driving the belt with sufficientenergytoraisethe bus voltage, most likely athighinclines.Input line has voltage surge problems.

Instruct the user to stop driving the belt at high inclines, or to use a lowerincline.Contactanelectrician to diagnose/correct a power line problem.

Errormessage“Notifymaintenance motor controller error (hardware currenttrip).

Excessive motor current caused by a failed motor, intermittent motor or motor connection(s).A possible but unlikely cause would be a severely wornbelt/deck.

Verify that all motor connections and cables aresolid.Ifstart-uppoweris very weak a phase may befaulty.Performaphasetest to verify the system or diagnoseaphaseproblem.

Errormessage“Notifymaintenance Motor controller error (low voltage detected)

Line cord is not securely plugged into the wall or machine.Loose/intermittentreceptaclewiring.Machine is not plugged into aproperdedicatedline.Incoming voltage is fluctuatingdippingtoaninsufficientlevel.

Check that the cord is solidly plugged into the wall receptacle and also into the machine.Contact an electrician to diagnose/correct a power lineproblem.

M051-00K65-A003

30

Modules

Base Frame Electronics:Problem Symptom TableBE 7


Errormessage“Startuperror”

Motor unplugged or connectorloose.A possible but unlikely cause would be the user drivingthebeltatstartup.

Verify that the motor connectionsaresolid.Perform a phase test to verify the system or diagnoseaphaseproblem.

Errormessage“Motordisabled”

An intermittent console/motor controller cable or emergencystopswitch.

Confirmthatallconnectionsare solid, all wires are properly seated into the connector and that the cable is not pinched and beingshorted/open.Verifyproper operation of the emergencystopswitch.

Errormessage“Inclineinoperative – continue if desired”

Improper home or decline switch operation/adjustment/cable.Incline motor connection unplugged/loose.A possible but unlikely cause would be incline motor overheating from excessiveoperation.

Verify that all motor and switch connections and cablesaresolid.Verify incline switch operation using diagnostic switchLEDS(LED9&10).Verify incline motor activation using diagnostic LEDS(LED4&5).Re-adjustor replace switches/cables.

Line cord inoperative Damaged Checkconnections.

Not connected Replacelinecord.

Main cable inoperative Damaged Replacemaincable.

Not connected

Motor controller inoperative Damaged Replace motor controller board.

Not connected

On/Off switch inoperative Damaged ReplaceOn/Offswitch.

Not connected

Linefilterinoperative Damaged Replacelinefilter.

Not connected

IEC receptacle in inoperative

Damaged ReplaceIECreceptacle.

Not connected

M051-00K65-A003

31

Modules

Measure line voltage at outletStart

Check line cord at outlet and receptacle at

treadmill

Inspect line cord

Check power switch

Check main cable harness

Check DSP controller

Check linefilter

Switch the treadmill to other outlet

Reseating the line cord

Replace line cord

Replace power switch

Replace line filter

Replace main cable harness

Replace motor controller

Line voltage at outlet ok?

Seated property?

Line cord is ok?

Power switch ok?

Linefilterok?

Main cable harness ok?

Are LEDs illuminating?

Testtoconfirmfix.

Base Frame Electronics:Troubleshooting Flow DiagramsBE 8

No Power on Treadmill

Yes

Yes

Yes

Yes

Yes

Yes

No voltage at outlet

No voltage at TP1

No voltage at TP2

No

No

No

No

Yes

M051-00K65-A003

32

Modules

Measure line voltage at outletStart

Perform belt/decktest.

Check line voltage

Heavy users at high speed

Replace belt, flipthedeckifnecessary.

Problem with incoming line

power or not a dedicated line

It is normal for high speed

use to degrade asbeltages.Belt and deck may needs to be changed frequently in clubs where

there is significantusageby heavier users athighspeeds.

Worn belt or deck?

Excess power indicated?

Insufficientvoltage?

OK with lighter weight users?

Testtoconfirmfix.

Reduce Maximum Speed

No

No

No

Yes

Yes

No

Yes


M051-00K65-A003

33

Modules

Check whether the treadmill is on a dedicated

line

Start

Check power cord at outlet

Check ground prong on power

cord

Check stop switch

Check display console

connection

Check main cable harness

Inspect, then tighten tthe connection

Connect to a dedicated line,

see manual

Properly seat the power cord

Replace the power cord

Replace the stop switch

Test the cable with multimeter, replace it when necessary.

On dedicated line?

Seated properly?

Ground ok on cord?

Triggering is ok?

Connection is ok?

Damaged or shorted cable?

Testtoconfirmfix.

Treadmill Pauses or Reset Randomly

No

No

No

No

No

Yes

Yes

Yes

Yes

No

Yes


M051-00K65-A003

34

Modules

REPLACEMENT OF LINE CORD



3. Liftthefrontendofthetreadmillapproximately4inchesoffthefloor andplaceablockofwoodunderneathbothsidestosupportit.

4. Remove and save the two screws that secure the line cord retaining brackettothemotorpan.

5. Unplugthedefectivelinecord.

6. Install the new line cord, using the screws removed and saved in Step4.

REPLACEMENT OF MAIN CABLE



3. Removethetopmotorcover(See LF3).

4. RemovetheActivityZoneassembly(See CA 22).

5. Removethelowerbridgecover(See UF4).

6. Disconnectoneendofthemaincablefromthemotorcontroller.

7. Disconnect the cable between the top of the left upright and the console.

8. Pullthemaincableoutoftheleftupright.

9. Installthenewmaincable.

Main Cable

Added torque

Line CordRetaining Bracket

12-18 lb*in[13.8-20.7kg*cm]

Base Frame Electronics:How To’sBE 11

M051-00K65-A003

35

REPLACEMENT OF MOTOR CONTROLLER (DSP)



3. Removethetopmotorcover(SeeLF3).

4. Recordthecableconnectionlocations.

5. Removethelowerbridgecover(SeeUF4).

6. Loosen the three hex nuts that secure the motor controller to the motorpan.

7. Remove and save the two bolts that secure the motor controller brackettotheLiftMotorbracket.

8. Removethemotorcontroller.

9. Install the new motor controller using hardware saved in the previoussteps.

Recommended Tools:Phillipsscrewdriver,8mmsocket,long¼”extension,¼”ratchet

Motor Pan

Motor Controller

Hex Nut

Modules

12-18 lb*in[13.8-20.7kg*cm]


M051-00K65-A003

36

Modules

REPLACEMENT OF THE ON/OFF SWITCH



3. Removethetopmotorcover(See LF 3).

4. Recordthelocationofwireconnectionstotheon/offswitch.

5. Disconnectthewires.Useneedlenosepliersifnecessary.(Youmay need to remove the motor controller to allow more room to access theon/offswitch.).

6. Squeeze the tabs on the top and bottom of the on/off switch and pushoutfrominsidetheframe.

7. Installthenewon/offswitch.

REPLACEMENT OF LINE FILTER



3. Removethetopmotorcover(SeeLF 3).


5. Recordthelocationofthewiresconnectedtothelinefilter.

6. Removethewires.

7. RemoveandsavethetwoPhilipsscrewsthatsecurethelinefilterto themotorpanassembly.

8. Removethelinefilter.

9. Installthenewlinefilter,usingthehardwaresavedinStep7.

On/Off Switch

Line FilterPhilips Screw (1 of 2)12-18 lb*in[13.8-20.7kg*cm]


M051-00K65-A003

37

Modules

REPLACEMENT OF IEC RECEPTACLE



3. Lifttheendofthetreadmillaboutfourinchesoffthefloorandplace blocksofwoodunderbothsidestosupportit.

4. Remove and save the two screws that secure the line cord retaining brackettothemotorpan.Settheretainingbracketaside.

5. Unplugthelinecordformtheunitandsave.

6. Removethetopmotorshroudcover(See LF 3).


IEC Receptacle12-18 lb*in[13.8-20.7kg*cm]


M051-00K65-A003

38

Modules

Console Opto-isolatedInterface

Digital SignalProcessor

(DSP)

Power Supply

EmergencyStop Relay

Power SupplyPower SupplyPower SupplyPower SupplyPower SupplyPower SupplyPower SupplyPower SupplyPower SupplyPower SupplyPower Supply

EMI Filter

Power Switch

Line AC Power

LiftActuator

Incline Switch(s)

Stride Sensor Piezo-ElectricStride Sensor

Lift ActuatorControl Circuit

Inrush LimitingCircuit

Rectifier/BusCapacitor

DSP Controller

3 Phase ACInduction

MotorController 4HP AC Motor

DSP Controller Block Diagram

High VoltageLow VoltageIsolated Low VoltageControl

Base Frame Electronics:Electrical Wiring DiagramsBE 15

M051-00K65-A003

39

Modules

DSP Controller Functional Description


P7: AC Input120V: 3POS230V: 2POS

P4: Home SW LED9 & 10

JW10 on P17Welded Frame:InClassic Frame:Out

Relay 2AC Input Power Rly

P10: Stride Sensor

LED1:12VDCLED2: 6V OR 8VLED3: Communication

P5: Console Cable1.ConsolePower2.Communication3.EmengencyStop

P9: PS JumperLED: 8V & 12VLCD: 6V & 12V

JW3: Communication JumperElevation: OutClassic: In

P8:Motor Thermal SwitchLow Voltage Power SupplyTransformer

Fuses present on high voltage boards only

DC BusCapacitor

LED 6DC Bus Voltage

P1 Motor Plug

IGBT Module(underneath board)

LED8:3.3VDCLED9: VD

LED 4 & 5Lift Up & Down

Inrush Limiter

P6: Actuator120V:4POS230V:3POS

M051-00K65-A003

40

Modules

Base Electronics Wiring Diagram


M051-00K65-A003

41

TheLiftMotorSystemiscomprisedoftheLiftMotor,theliftframeandtheHomeSwitch.(seepageLS-4)

In order for the lift system to be operational, the Emergency Stop Switch located on the console area must be properly engaged.TheLiftMotorispinnedtotheLiftMotorsupportbracketonthetreadmillframeononeendandispinnedontheotherendtotheliftframe.TheLiftFrameisalsopinnedtothetreadmillframe.(seepageLS-4)

TheLiftMotorconsistsofagearbox,asteelACMEscrewandasteeltube.Thesteeltubehasanengineeredplasticnutthatisfixedononeendofthetube.TheACMEscrewispinnedtotheoutputgearonthegearboxononeendandscrewsintothenutonthesteeltubeontheotherend.AstheACMEscrewrotatesthesteeltubeextendsorretractswhichraisesorlowersthetreadmill.Thereareinternallimitsswitchesonthegearboxtopreventover-travel.

TheLiftMotorisprogrammedtoinclinethetreadmillupto15%at0.5%increments.Thedesiredinclineiscommandedthroughtheinclineupordownarrowsorthroughthekeypadontheconsole.WhenauserfirststartsthetreadmilltheLiftMotor will lower the treadmill until the Home Switch is activated (this is 0% incline or level) unless the treadmill is already at0%incline.IftheHomeSwitchcannotbeactivated,theconsolewilldisplayamessageafteragivenduration,stating“inclineinoperativecontinueifdesired”.

One way of determining if a Lift Motor or a Home Switch is electrically defective is by observing whether or not certain LED’sonthemotorcontrollerlightup.Similarly,knowingthatboththeLiftMotorandtheHomeSwitchareelectricallygoodand the LED’s do light up but the treadmill is not able to be inclined or lowered may be an indication that the Lift Motor is mechanicallydefectiveorthecontrollerisbad.ThesetestsaredescribedindetailintheBaseElectronics(BE)section.

LS 1Modules

Lift System: Theory of Operation M051-00K65-A003

42

Cross-section View Of Lift System (-01 And -02 Models Only)

Modules

Bolt, Nut, Washer (2 Places)(16-20 ft-lbs)[21.7-27.1N-m]

Bolt, Nut, Washer (2), Nut(4-8 ft-lbs)[5.4-10.8N-m]

Lift Frame Wheel and E-Ring(2 places)

Lift Motor Tube

Frame Tie Bar

Lift MotorSupport Bracket

Clevis Pin

Lift Motor


Cross-section View Of Lift System (-01 And -02 Models Only)

Cross-section View Of Lift System (-03 Models And Higher)

Lift System: System ComponentsLS 2

Home Switch

M051-00K65-A003

43

Modules

Lift System (-01 And -02 Models Only)

Tie Bar Bolt, Flat Washer, Split Washer(4 places)(5-9 ft-lbs)[8-12N-m]

Nut, Flat Washer(3 places)(9-13 ft-lbs)[12-17.6N-m]

Bolt, Flat Washer(2 places)(25-36 ft-lbs)[34-49N-m]

Frame Tie Bar

Frame Tie(Neverremovethis.)

Clevis Pan


Lift System (-03 Models And Higher)


Lift System: System ComponentsLS 3

M051-00K65-A003

44

Modules

Lift System: Problem Symptom TableLS 4


Lift Motor does not raise or lowerunit.

Broken internal components in Lift Motor gear box (motor runs but ACMEscrewdoesnot.

ReplaceLiftMotor. LS 6

Thermal cutout switch open due to overheating of LiftMotor.

Allow Lift Motor to cool for 15minutesandconfirmproper operation,Otherwise replace Lift Motor.

LS 6

Broken/worn plastic nut on Lift Motor tube (ACME screw rotates but does not raiseunit).

ReplaceLiftMotor. LS 6

Failed clevis pin or failed mountingbolt.

Replace mounting bolt or clevispin.

LS 6

Emergency stop switch is removed.

Install emergency stop switch.

Motor controller lift circuit failure.

Perform test on motor controller#4and#5LEDand replace Lift Motor if LED’sdonotlightup.

Lift Motor does not raise unit.

UnitcannotfindHomeSwitch due to improper installation which causes Lift Motor to bottom out before activating Home Switch.

Remove and re-install Lift Motor at proper extended length.

LS 6

Home Switch not connected.

Connect Home Switch cable.

LS 9

FaultyHomeSwitch. When Home Switch is manually pressed the #9LEDonthecontrollershouldbeON.Ifnotcheckcable and replace Home Switchifrequired.

LS 9

M051-00K65-A003

45

LS 5


Lift Motor operates intermittently.

OverheatingofLiftMotor. ReplaceLiftMotor. LS 6

Broken internal components in Lift Motor gear box (ACME screw rotates intermittently while motorisrunning).

Allow Lift Motor to cool for 15minutesandconfirmproper operation,Otherwise replace Lift Motor.

LS 6

Failed clevis pin or mounting bolt causing Lift Motortositatanangle.

Inspect clevis pin and mountingbolt.

Difficulttomoveunitwithliftframewheels.

Liftframewheelsflatteneddue to wear or broken or cracked.

Replacewheels.

Modules

Lift System: Problem Symptom Table M051-00K65-A003

46

LS 6

(4-8 ft-lbs)[5.4-10.8N-m]

Ground Screw(12-18 in-lbs)[1.3-2N-m]

REMOVAL OF LIFT MOTOR



3. DisconnectLiftMotorconnectorfrommotorcontroller.

4. RemoveFrameTieBar(-01and-02modelsonly).

NOTE: Do not remove any other frame brackets

Modules

5. DisconnectLiftMotorgroundwire.

6. Turnunitonitsside.

7. RemoveLiftMotorlowerpivothardware.

Tie Bar on -01 and -02 models only

Lift System: How To’s M051-00K65-A003

47

LS 7

Home Switch

Modules

Clevis Pin

Lift Motor Lower Pivot

8. RemoveClevisPin.RemoveLiftmotor

9. InstallnewLiftMotorandholdinplacewithClevisPin.

10.Align hole in Lift Motor Tube with pivot hole in lift frame so that HomeSwitchisactuated.(Listen/feelforactuationofHomeSwitch)

11. InstallLiftMotorlowerpivothardware.

12.Turnunitupright.

13.Connect ground wire and plug in Lift Motor connector to motor controller.

14.Powerupunitandtesttravel.

a) Whenunitispoweredup,unitmustfindHomeSwitchandthen stop.

b) Command15%inclineandwaituntilincliningstops.Depress HomeSwitch.Unitshouldinclinemomentarilyandquicklystop. If this occurs, the Lift Motor has reached its internal limit switch andisoperatingproperly.Ifunitdoesnotinclinemomentarily implies that internal limit switch was reached before unit was abletoreach15%incline.

Go back to Step 10 and adjust Lift Motor tube pivot to lift frame pivot by turning Lift Motor tube clockwise and repeat above teststeps. (4-8 ft-lbs)

[5.4-10.8N-m]


LS 8

48

Modules

REMOVAL OF LIFT FRAME

1. Turnunitonitssideandlayagainstuprightframe.

2. RemoveLiftMotorlowerpivothardware.

3. RemoveLiftFramepivothardware.

4. RemoveE-Ringtoremovewheels.

5. Installnewliftframe.

Lift Motor Lower Pivot Lift Frame Pivot

E-Ring

Bushing

WheelLift Motor Lower Pivot

Lift FramePivot

Lift Frame for -01 and -02 Models Lift Frame for -03 and higher

Lift Frame Pivot for -01 and -02 Models Lift Frame Pivot for -03 and higher

(16-20 ft-lbs)[21.7-27.1N-m]

(16-20 ft-lbs)[21.7-27.1N-m]

(4-8 ft-lbs)[5.4-10.8N-m]

(4-8 ft-lbs)[5.4-10.8N-m]


49

LS 9

REMOVAL OF HOME SWITCH (FOR -01 AND -02 MODELS)

1. Operateinclineandraiseunitto15percentincline.



4. Removetopmotorcover.

5. RemoveFrameTieBar.

Modules

Tabs on Home Switch

Nut (2 places) (25-34 in-lbs)[22-30kg-cm]

Frame Tie Bar

Tie Bar bolt,flatwasher,split washer(4 places)(5-9 ft-lbs)[8-12N-m]

Nut, Flat washer(3 places)(9-13 ft-lbs)[12-17.6N-m]

Bolt,flatwasher(2 places)(25-36 ft-lbs)[34-49N-m]

6. RemovebracketwithHomeSwitch.

7. Remove cable from Home Switch leads

8. RemoveHomeSwitchbypushingontabs.

9. Install new Home Switch in bracket and connect cable to Home Switchleads.

10. Install Home Switch with bracket to treadmill frame

11. InstallFrameTieBar.


50

LS 10

REMOVAL OF HOME SWITCH (FOR -03 AND HIGHER)

1. Operateinclineandraiseunitto15percentincline.



4. Removetopmotorcover.

5. DisconnectcablefromHomeSwitchleads.

Modules

Home Switch

Home Switch

6. Push on Home Switch tabs and push switch down and out to remove.

7. InstallnewHomeSwitchandconnectcable.


51

Modules

Console & Activity Zone: Theory of OperationCA 1

GENERAL CONSOLE

TheLCD-equipped(7-and15-inch)elevationseriesconsolessharealotofthesamebasicfunctionality.

The console provides all user interface functions, user workout programs, entertainment processing, and control messages tothebase.Theactivityzoneisfunctionallyapartoftheconsole;thekeypadandemergencystoparedirectlywiredtotheconsolemachineinterfaceboard.

7- and 15-inch Differences

The7-inchLCD(a.k.a.thei-console)andthe15-inchLCD(a.k.a.thee-console)controlthemachineinsimilarwaysbuthavedifferententertainmentanduserinterfaceimplementations.

The“e”(15-inchLCD)dependssolelyonLCDtouchscreen“softbuttons”foruserinputs.ItalsoincludesananalogTVtuner,whichhasabuilt-iniPodAuthenticationCoprocessor.

The“i”(7-inchLCD)hasakeypadthatsurroundsthescreen.Sincetheanalogtunerboardisnotpresent inthe7-inchconsole,iPodAuthenticationCoprocessorisplacedontheseparateboard.

This picture shows the printed circuit boards used intheproduction15-inchLCDtreadmillconsole.

This picture shows the printed circuit boards mounted intheproduction7-inchLCDtreadmillconsole.

15-inch LCD 7-inch LCD

M051-00K65-A003

52

Modules


SBC THEORY OF OPERATION

TherearetwotypesoftheSBC.Oneworkswiththe7-inchdisplay(SBC-i),theotheronewiththe15-inchdisplay(SBC-e).Notethatthetwomodulesarenotinterchangeable.

The SBC-i is responsible for the following functions:

1. CommunicationtoMIB

2. Controlthe7-inchLCD&BacklightforLCD

3. Touchscreencontroller

4. Provide3.3Vdcand+5VdcforallPCBs

5. SupportUSB(communicationwiththeUSB,charging)

6. SupportiPod® (communication with the iPod®, audio / video input, charging)

7. ReceiveAudioinputs(fromAttachableTV,iPod®, Virtual Trainer)

8. ProvideAudiooutputtoheadphones

9. InterfacewithAppleAuthenticationPCB

10. InterfacewithAttachableTV(receiveaudio,issuecommands,routeiPod® video to TV)

The SBC-e is responsible for the following functions:

1. Communication to MIB

2. Controlthe15-inchLCD&BacklightforLCD

3. Touchscreencontroller

4. Generate3.3VDCand+5VDCforallPCBs

5. SupportUSB(communication,charging)

6. SupportiPod® (communication, audio / video input, charging)

7. ReceiveAudioinputs(fromTuner,iPod®, Virtual Trainer)

8. ProvideAudiooutputtoheadphones

9. InterfacetoAnalogTunerw/AppleAuthentication

10. GenerateClosedCaption

11. ImplementhardwareforEthernetconnectivity(futurefunctionality,notsupportedbysoftware)

M051-00K65-A003

53

Modules


MIB THEORY OF OPERATION

ThereisonlyonekindoftheMIB.Itworkswithboththe7-andthe15-inchdisplays.

The functions of the MIB include:

1.ProcessLifePulse® (LP) Heart Rate signal from sensors

2.ReceiveTelemetry(Polar)HeartRatesignal

3.CalculateHeartRate(LP&Polar)

4.Interfacetomembraneswitchkeypad

5.RespondtoEmergencyStopSwitch

6.RedundantCSAFEports(forSerialCommoraccessorypower)

7.SerialComm(+5VDC)toGBC/MC

8.SerialComm(+3.3VDC)toSBC

9.ProvideBatteryVoltage/switchforNormalOperation

10.ProvideBatteryVoltage/switchforSleepMode

11.Drivespeaker(monotonebeep)

12.LowsidedriveforallLEDs

13.DrivetheLEDsoftheDataDisplayandKeypad

14.GenerateIRcommandsforattachableTV

DATA DISPLAY THEORY OF OPERATION (USED ON THE 7-INCH LCD ONLY)

Provides7-segmentdisplaystocreate3datafieldsof4,3,4numerals.DrivesallLEDs.

ANALOG TUNER THEORY OF OPERATION

The functions provided by the tuner are: Right angle adapter to convert F-connector to RCA,

Receive NTSC or PAL/SECAM Analog video via RCA input

Implement NTSC or PAL/SECAM Tuner,

Provide Audio and Video outputs to SBC-e,

Implement I2C for Apple Authentication co-processor

M051-00K65-A003

54

Modules


APPLE AUTHENTICATION THEORY OF OPERATION

This board allows for positive authentication of Apple devices like iPod® and iPhone® (collectively known as an i-product) in ordertoaccessaudioandvideoplaylists.

This functionality is implement via an I2C communication between the i-product, the SBC, and the authentication co-processor.

HEADPHONE ESD PRINTED CIRCUIT BOARD

This board protects the Single Board Computer (SBC) board from Electrostatic Discharges (ESD) that may reach the SBC viatheheadphonejack.

LIFEPULSE ESD PRINTED CIRCUIT BOARD

This board protects the Machine Interface Board (MIB) from Electrostatic Discharge (ESD) that may reach the board via LifePulsesensorinputs.

CODED RECEIVER

ThisboardreceivesTelemetryHeartRatepulsesfromcheststrap.Thisboardimplementsvariablegaincontroltoensurecodedoperationwiththeintendedtransmitter.

BACKLIGHT INVERTER (7-INCH LCD)

This board converts 12VDCto more than 500 VAC for the back light known as the Cold Cathode Flourescent Light (CCFL) light.

BACKLIGHT INVERTER (15-INCH LCD)

This board converts 12VDC to more than 500 Vac for the back light known as the Cold Cathode Flourescent Light (CCFL) light.

M051-00K65-A003

55

Modules

Console & Activity Zone: System ComponentsCA 5

Activity Zone

Emergency Stop Switch

M051-00K65-A003

56

Modules


15-INCH LCD CONSOLE SYSTEM COMPONENT

7-INCH LCD CONSOLE SYSTEM COMPONENT

M051-00K65-A003

57

Modules


ACTIVITY ZONE

POLAR TELEMETRY BOARD

M051-00K65-A003

Trail from Keypad

Mounting Screws Accessible from Rear

Mounting Bracket

Emergency StopReed Switch

58

Modules

Console & Activity Zone: Problem Symptom TableCA 8


No power to console No power to base Check that there is power at the outlet, breaker and switchallOK.

Faulty main cable or bad cable connection

Check +12VDC at Pins 11 and 12 of main cable that goestoMIB.Replacecableifnecessary.

No audio, screen does not turn on

Faulty main cable Check for power to console.

Defective SBC ReplaceSBC.

Defective LCD screen ReplaceLCDpanel.

No backlight, screen is dark Defective inverter Test inverter – replace if necessary.


Defective backlights ReplaceLCDpanel.

Touchscreen not accurate Touchscreen needs calibration

Calibratetouchscreen.

Defective LCD touchscreen Replacethetouchscreen.

Touchscreen does not respond

Defective LCD touchscreen Replacethetouchscreen.

Safety key not seated properly

Reseatsafetykey.

Snow and noise appear on screen

Air / cable setting incorrect Change setup to proper setting.

Defective coax – no signal Verifysignalpresent.

Defective tuner board Replacetunerboard.

Unable to receive cable channels

Air / cable setting incorrect Change setup to proper setting.

Defective coax – no signal defective

Verifysignalpresent.

Channels do not change Touchscreen needs calibration

Calibratetouchscreen.

Defective LCD touchscreen Replacetouchscreen.


Defective MIB ReplaceMIB.

Defective analog tuner Replacetuner.

CONSOLE

M051-00K65-A003

59

Modules



Sound does not change Touchscreen needs calibration

Calibrate touchscreen

Defective MIB Replace MIB

No sound Air/Cable setting incorrect Change setup to proper setting

Defective headphones Try different headphones

Defective headphone jack or cable

Inspect and replace as appropriate.

iPoddoesnotwork. Defective iPod® cable on option panel

Replace option panel

Defective iPod® Verify iPod® function

Defective tuner board – Authenticationfails.

Replace tuner board

Ghost HR – on engage treads power cable routing, or receiver too sensitive, happened with early productionnon-coded.

Non updated cable being used, frame not properly grounded, early non-coded receiverinstalled.

Cable should be AK65-00043-0001A2orlater.See service Bulletin on framegrounding.Installcodedreceiver.

Emergency stop not working

MIB defective, magnet misplaced in holder

Check that the magnet is properly located in the plasticholder.ReplaceMIBifcableandmagnetgood.

Video lockup Old revision of tuner and / or SBC

Try tuner revision F or later, if still bad then try SBC revisionEorlater.

Distorted audio Option panel not updated Install latest revision option panel.

Headphone jack loose Option panel not updated Installlatestoptionpanel.

iPod® not charging Defective iPod® cable or connection from option panel to MIB, option panel not updated

Check cable and connections, replace, repair asappropriate.Installlatestrevisionoptionpanel.

Console does not recognize USB memory drive inserted into connector.

Defective USB drive or connector / cable / connection

Verify functionality of USB drive.Checkcableandconnections, replace, repair asappropriate.

CONSOLE

M051-00K65-A003

60

Modules



Buttons not registering Damage Checkconnections. CA 22

Not Connected ReplaceActivityZone.

Need to replace Activity Zone.

Damage ReplaceActivityZone. CA 22

Cosmeticflaws

Need to replace console neckspacer.

Damage Replace console neck spacer.

CA 23

Cosmeticflaws

Console inoperative Misconnection Replaceconsole. CA 23

Damaged

Rear console cover requiresreplacement.

Damage Replaceconsolecover. CA 24

Cosmetic Flaws

ACTIVITY ZONE

M051-00K65-A003

61

Modules

Console & Activity Zone: Troubleshooting Flow DiagramsCA 11

NO POWER

Checkemergencystop. Replace magnet

Troubleshoot Base Electronics.

ReplaceCable.

Replace SBC.

Remove cover to reveal motor controlboard.

Check main cable to MIB for power.

Replace MIB.

ChangeLCDpanel.

Finished

START Magnet in place?

Base powered up?

Powerpresent on cable

connector?

Beeps heard on power-up?

Yes

Yes

Yes

No

No

No

No

M051-00K65-A003

62

CA 12Modules

TV NOT WORKING

Verify that air/cable setting is correct.

Verify that television signal is goodattuner.

Replaceanalogtunerboard.

Replace SBC.

ReplaceLCD.

Verify that coax jumper is in place between tuner board and SBC insideconsole(ifequipped).

Seebadvideo.

Replace cable, adapter or repairsource.

Finished

Replace or reconnect coax jumper cable between SBC

andtunerboard.

Done - reinstall analog tuner board-itwasprobablyOK.

Done.Reinstallanalogtuner and SBC.Theywere

probablyOK.

Replaceconsole.

START Video OK but no TV?

Signal good at Tuner?

Coax jumper in place if required?

Recheck function TV still bad?



No

No

No

No

No

No

Yes

Yes

Yes

Yes

Yes

Console & Activity Zone: Troubleshooting Flow Diagrams M051-00K65-A003

63

CA 13Modules

NO VIDEO ON LCD

DISTORTION / NOISE IN AUDIO

Look for power from base or other signs of life, audio beeps

or LED lighted

Try a fully functional pair of earphones.

Check for other machine func-tions - for example, keypads or

touch screen function

Switch between TV audio, VT audio and iPod® audio

Replace LCD panel

Repair no power problem

Replacedefectiveearphones.

Replace SBC

TV only noisy > replace tuner board VT/ iPod®

only noisy > replace SBC.

Finished

Replace console

Finished

Install new option panel

Replace 92353 Polar Board orreplace cables (Hd Ph ext) or

option panel SBCcable.

START

START

Does console have power?

Noise in good earphones?

Does keypad or touch screen

function?

Both noisy?

Still noisy?

Video working?

No

No

No

No

No

No

Yes

Yes

Yes

Yes

Yes

Yes


64

CA 14

No

No

No

No

No

Modules

TELEMETRY HR NOT WORKING

Check manager’s settings in diagnostics.

Produce HR signal with

Polar SimulatorFinished

Change settings

to enable telemetry HR

Finished

Finished

Finished

Finished

Unexpected error, contact

LF.

Replace telemetry receiver.

Replace AE wiring MIB S/B AK65-00043-

0001 Rev Activity Zone or

later.

Verify/fixgrounding

through frame andatconsole.

Replace cable between

receiver and console.

Done

Done

Replace MIB.

Reposition telemetry receiver.

STARTTelemetry HR

enabled in Manager’s settings?

Correct HR shown on HR test page?

Correct HR shown on HR test page?Correct HR?

Correct HR?




No

No

Yes

Yes

Yes

Yes

Yes

No

Yes

Console & Activity Zone: Troubleshooting Flow Diagrams

Yes

Yes

M051-00K65-A003

65

CA 15

Passes keypad test?

Modules

KEYPAD NOT RESPONDING

ReplaceCheck

emergency stopmagnet.

START In place? No

Run diagnostics.

Replace keypad.

Verify/fixkeypadconnected inside ActivityZone.

Done

Isolate between console keypad or

ActivityZonekeypad.

Finished

Finished

FinishedReplace MIB.

Just Activity Zone keypad BAD?

Passkeypadtest.

Yes

Yes

No

Yes

Unexpectederror,contactLF.

Yes


TIP: All hard keys (keypads) are connected to and processed by the MIBboard.AnytimeakeyispressedtheMIB will issueaconfirmation‘beep’unlesstheClubhasturnedOff‘SystemSounds’inManager’sConfiguration.

Just console keypad BAD?

Yes

No

Yes

Yes

Yes

No

No

Passes keypad test?

Passes keypad test?

M051-00K65-A003

66

CA 16Modules

LIFEPULSE® HR NOT WORKING

Open Heart Rate Test in Diagnostic, place left hand on

contacts.Swapsensorcables.START

Left hand-onindicated in Diagnostic

screen?No

Placerighthandon.

Placebothhandson.

Replace cable between receiverandconsole.

Replace MIB.

Replace cable

Finished

Finished

Finished

Right hand-on indicated?


Correct HR shownon test page?

Correct HR shownon test page?

No

Yes

Yes

Yes

Yes

Yes

No

No


No


67

CA 17Modules

LCD SCREEN IMAGES ARE DIM/DARK

iPod® DOES NOT WORK

Look for dim images on screen (nobacklight).

Reposition CCFL inverter input cableawayfrominverter.START Dim images present? Yes

NoYes

No

Replace SBC. ReplaceLCDpanel.

Done

Done ReplaceCCFLinvertercable.

Video good now?

Video good?Video good?

No

Finished

Yes

If possible try iPod® in another machine. Problem in iPod®START iPod® works in

othermachines. No

Change option panel and cables.

Changetunerboard.

Change SBC.

Finished

Finished

Finished

iPod® works?

iPod® works?

iPod® works?

Yes

Yes

Yes

Yes

No

No


No


Yes

No

M051-00K65-A003

68

CA 18Modules

TOUCH SCREEN NOT RESPONDING

InsertUSBdrivewithsoftware. Replace SBC.STARTConsole boots

to software install page.

No

Touch Calibrate Touch Screen largebutton.

Re-insert USB drive and try again to calibrate touch

screen.

Replacetouchscreen.

Repeat calibration, slowly and carefully, press and hold; wait

forcursortomove.


Enters calibration routine?

Touch screen calibration terminate

successfully?

Calibration successful?

No

No

Yes

Yes

Yes

Finished

Yes

No


69

CA 19Modules

CHANNELS DO NOT CHANGE

Check touch screen calibration. Replacetouchscreen.START

Calibrates successfully.

No

Replacetunerboard.

Replace SBC.

Replace MIB.

Finished

Finished

Finished

Channels Change?

Channels Change?

Channels Change?

Yes

Yes

Yes

Yes

No

No


No


70

CA 20Modules

AUDIO DOES NOT CHANGE

Check touch screen calibration. Replacetouchscreen.START

Calibrates successfully.

No

Replacetunerboard.

Replace SBC.

Replace MIB.

Finished

Finished

Finished

Audio Changes?

Audio Changes?

Audio Changes?

Yes

Yes

Yes

Yes

No

No


No


71

CA 21Modules

USB DRIVE NOT RECOGNIZED

InsertUSBDrive. FinishedSTARTSoftware update screen appears?

Yes

VerifythatUSBdriveisgood.

Replace option panel or cable between SBC and option

panel.

Replace SBC.

Replacedrive.

Finished

Finished

Drive good?

Software update screen appears?

Software update screen appears?

No

Yes

Yes

No

Yes

No


No


72

CA 22

REPLACEMENT OF ACTIVITY ZONE



3. Remove the bezel access located on the bottom of the lower bridge cover.

Modules

Bezel Access Door

4. Remove and save the two bolts that secure the Activity Zone assemblytothebridgeweldment.Useaflashlighttolocatethebolts.

5. DisconnectthecableconnectionstotheActivityZone.

6. RemovetheActivityZoneassembly.

7. Install the new Activity Zone assembly, using the bolts and saved in Step4.

Screws

Console & Activity Zone: How To’s M051-00K65-A003

73

CA 23

REPLACEMENT OF CONSOLE NECK SPACER



3. Removetherearconsolecover.

4. Removetheconsoleassembly.

5. Remove and save the two Allen bolt heads that secure the console neckspacertotheconsolemountingbracket.

6. Removetheconsoleneckspacer.

7. InstallthenewconsoleneckspacerusingtheboltssavedinStep5.

REPLACEMENT OF THE CONSOLE ASSEMBLY




4. Remove and save the four Phillips screws that secure the console assemblytothecounsolemountingbracket.

5. Disconnectallcablestotheconsoleassembly.

6. InstallthenewconsoleassemblyusingthescrewssavedinStep4.

Modules

Console Neck Spacer

Console Bracket

Neck Spacer Screws (2)

Torque to25-35in*lb.[29-40kg*cm]

Rear ConsoleCover Screws (2)

Rear Console Cover

Console Console Bracket

Console Mounting Screws (4)



74

CA 24

REPLACEMENT OF REAR CONSOLE COVER

1. Remove and save the two Allen screws that secure the rear console covertotheconsolemountingbracket.


3. InstallthenewrearconsolecoverusingthescrewssavedinStep1.

REPLACEMENT OF OPTION PANEL

1. Usinga#1Phillipsscrewdriver,removethetwoscrewsthatsecuretheoptionpanel.Savethesescrews.

2. GentlypullconnectorthroughFrontPlastics.

3. Disconnect the headphone, USB and iPod®connections.

4. Installnewoptionpanelandverifyallconnections.

Modules

Rear Console Cover Screws (2)

Option Panel Assembly

Optional Panel Mounting Screws

Rear Console Cover



75

Modules

Console & Activity Zone: Electrical Wiring DiagramsCA 25

BLOCK DIAGRAM - 15 INCH CONSOLE

BLOCK DIAGRAM - 7 INCH CONSOLE

M051-00K65-A003

76

Modules

Console & Activity Zone: Electrical Wiring DiagramsCA 26

M051-00K65-A003

77

HR 1

The LifePulse® contact heart rate system is designed to sense the electrical signals originating from the heart as it beats and, usingsoftware,computeanddisplaythecorrespondingheartratevalueontheconsolereadout.Thetwopairsofelectrodeson the Treadmill Ergo bar (left and right) are the point of contact at which these signals are picked up and transmitted from the body to the LifePulse®circuitry.Ahands-ondetectcircuitmonitorsforachangeinvoltagecorrespondingtotheinputforeachoftheleftandrightsensorpairstodetermineifeitherorbotharebeingheld.Bothsensorsmustbeheldinorderfortheelectricalsignalfromthehearttobemeasured.Thisissimilartomeasuringthevoltageofabatterywithavoltmeter.In order to measure a battery the voltmeter must be connected across the battery terminals (one lead to the positive and oneleadtothenegative).Similarly,theheartcanbethoughtofasavoltagesourceorbatteryandinordertomeasureit’svoltageyoumustmeasureacrossitsterminals.Essentially,whentheleftandrightsensorsareheldtheyactliketheleadsofthevoltmeter.Sinceanelectricalpathexistsfromtheelectrodesheldinonehand,upthearm,acrossthebody(andtheheart),downtheotherarmandintotheotherhandholdingtheotherpairofelectrodes,avoltagecanbemeasured.Thisishow the LifePulse®signalismeasured.Andjustlikemeasuringabattery,thepolarityofthevoltageisimportantsotheleftandrightelectrodesmustcorrespondtotheleftandrightuserhands.

To pick up the heart signal LifePulse®mustuseaverysensitivehighgaindifferentialamplifier.Thisisprimarilyduetothesignal’s initial low amplitude as it originates from the heart (typically less than 2 millivolts peak to peak) and the resultant attenuation,orsignaldrop,asittravelsthroughthebodyandintotheelectrodes.Thistypeofamplifierisdifferentfroma regularamplifier in thatonly thedifferencesbetween the inputsareamplified. In thiswaycommonsignals, typicallyelectricalnoise,appearingonbothinputscanbesimultaneouslyignoredwhilethedifferencesareamplified.

Theoutputofthishighgaindifferentialamplifier,whenneitheroronlyoneelectrodepairisheld,ismeaninglessbecausetheinputstotheamplifierbasicallyactasantennapickingupandamplifyingstrayelectricalsignalsfromtheenvironment.Ideally,oncebothelectrodepairsareheld,asdetectedbythehands-oncircuitry,theheartsignalcanbeisolated,amplifiedandpresentedtothesoftwareforanalysis.Inpracticehowever,additionalunwantedsignalsexist.Someofthesesignalscomefromothermuscleswhichlayalongthe“voltage”pathtotheheartbeingmeasured(suchasarmandchestmuscles).Similarly, hand to electrode contact problems which tend to weaken the signal or even introduce new signals which hide theactualheartsignalcanoccur.TheLifePulse® software attempts to isolate just the heart signal from all other unwanted signalsandnoiseusingcomplexsoftwaretechniques.

Basically, the LifePulse®softwaresamplestheamplifiedsignalpickedupattheelectrodesmanytimesasecondlookingfortheheartpulses.Dependingupontheamountofnoise,sizeofsignaland/orirregularityoftheheartpulse,itmaytakemanyseconds(from4to20ormore)toconfidentlydetermineavalue.Andifavaluecannotbeconfidentlydetermined,aheartratewillnotbedisplayed.Toincreasethedetectionofaheartsignal,theLifePulse® software attempts to expand thesampledsignaltomaximizetheimportantfeatures.AGainvaluewhichrepresentstherelativeamountthesignalwasexpanded is displayed in the LifePulse®diagnosticscreenandcanrangefrom1to99.Anassessmentofthestrengthofthesignalcanbedirectlyrelatedtothisgainvalue.

Input signals already at maximum levels require a low gain because their features cannot be further expanded without losinginformation.Veryweaksignalsrequiremoregainthusexpandingthemtofullscalesotheirfeaturescanbeeasilypickedout.Thisscalingisdonedynamicallyoverconsecutiveblocksofsampleswitheachgaincomputedrelativetothehighestsignalcomponentwithinthatblock.Thestrengthofthesignaldeterminestheeffectivenessofthescaling.

Ingeneral,weaksignalsarelessdesirablethanstrongonesandverystrongsignalsarelessdesirablethanweakerones.Obviously, weak signals requiring high gain values means that the weak heart pulses will be competing with other low level backgroundnoisewhenbotharescaledupmakingithardtodeterminetheheartsignalfromthebackgroundsignals.Onthe other hand, strong signals, usually not from the heart pulse itself, will ultimately limit the amount of scaling that can be applied.TypicalgainvaluesforlownoisesignalswhichproducegoodLifePulse® heart rates are generally between 10 and 30.Above30meanstheheartsignalisweakerandbelow10meansothernoisesignalsaretoostrongthusoverpoweringtheheartpulses.Justas thegainvalue indicates thestrengthof theheartsignal theConfidencenumber indicates thequalityoftheheartratereadingwhenoneisdisplayed.

Modules

Heart Rate System: Lifepulse® Theory of Operation M051-00K65-A003

78

HR 2

The LifePulse® software usesmanymethods to analyze the heart signal and zero in on the heart rate reading. TheConfidencenumberwhichisalsodisplayedintheLifePulse® diagnostic display indicates the agreement in the computed heartratenumberamongthesedifferentmethodsandthereforetheconfidencetheheartratedisplayediscorrect.Thisisimportant when Cardio workouts, which change the load based on the difference between the current and target heart rates, areused.IfaconfidentheartratecannotbedeterminedCardioworkoutprogramscannotautomaticallyadjusttheloadtoreachthetargetheartrate.Confidencevaluescanrangefrom0to9with0beingtheleastconfidentreadingand9beingthemostconfident.Cardioprogramloadchangesoccurwhenheartratereadingshaveconfidencevaluesof5orhigher.

Some factors which affect LifePulse®’s ability to determine a heart rate:

• Hand slip and/or grip pressure changes on electrodes

This can produce noise spikes which drives up gain values and lowers the ability to detect the features of the actual heart pulses.

• Dry and/or calloused hands

This can further reduce the already low amplitude heart signal picked up from the hands by the electrodes.

• Dirty and/or contaminated hands

This can also reduce the signal being measured.

• Amount of upper body movement

This can add signals which must be evaluated and filtered out in the software. Sometimes these signals can be regular enough to look like heart pulses.

• Individual’s own heart pulse amplitude

Other noise signals compete with the low heart signals.

• Irregular heart rhythms

Missing, skipped or irregular heart beats require longer sample times to compute.

Modules

Heart Rate System: Lifepulse® Theory of Operation M051-00K65-A003

79

View of Polar on Bottom Shroud

HR 3

Polar Board (hidden from view-within Bottom shroud assembly)Electrodes

Polar Board in bottom shroud assembly

Heart Rate System: System Components M051-00K65-A003

Modules

80

HR 4Modules


Heart rate system inoperative

Damage Check connections HR 5

Not connected Replace heart rate sensors

Polar issues Inadequate groundingCosmeticflaws

Replace Polar Board assembly

HR 6

No/erratic heart rate No/erratic heart rate diagnostic

Ghost heart rate Ghost heart rate diagnostic

Heart symbol displayed without hands on

Hardware diagnostics screening

Heart Rate System: Problem Symptom Table M051-00K65-A003

81

HR 5

REPLACEMENT OF HEART RATE SENSORS

1. Remove and save the two Phillips screws that secure each set of rateelectrodestotheErgobar.

2. Note which wires go to the top electrode and which go to the bottomelectrode.

3. Disconnectthewiresfrombothelectrodes.

4. Plugthewiresintothenewelectrodes.

5. Position the electrode gaskets between the electrodes and the Ergo bar.PleasenotethatsomeErgobargasketsareadheredtotheErgobars(Alaterdesignchange).

6. Install the new electrodes in the Ergo bar, using the screws removedandsavedinStep1.

7. Test the unit to verify that the new electrodes are working properly byoperatingtheheartratesystem.

Modules

Upper Heart Rate Assembly

Upper Gasket

Ergo bar

Lower Gasket

Lower Heart Rate Assembly

Phillips Screws (2)

Torque to7-11in*lb.[8-12.7kg*cm]

Heart Rate System: How To’s M051-00K65-A003

82

HR 6

REPLACEMENT OF POLAR BOARD ASSEMBLY

1. RemoveActivityZone(See CA 22).

2. Removethebottomshroud(See UF 4).

3. Remove/replaceboardandtape.

4. Replacebottomshroud.

5. ReplaceActivityZone.

Modules

Please be statically grounded when han-dlingthePrintedCircuitBoard(.e.g.anti-staticwristband).

Board is taped to bottom of this shroud

Bridge Weldment

Upright Bolt Heads (2 on each side)

Allen Screws (10)

Non-coded Polar Board Receiver

Coded Polar Board Receiver

Lower Bridge Cover

Torque to 42in*lb.[48kg*cm]

Heart Rate System: How To’s M051-00K65-A003

83

SS 1

The Stride System is comprised of the striding belt, the deck, the belt barrier, the Life Spring suspension components, the frontandrearrollers,therearrollerguardsandthestridesensorassembly.(seepageSS-4).

Thestridingbeltisimpregnatedwithalubricant.Thedeckisalsocoatedwithaparaffinwaxonbothfaces.Thiscombinationallowsforlowfrictionbetweenthestridingbeltandthedeckwhichresultsinincreasedbelt/decklife.Thestridingbeltanddeck arewear items andwhen the friction becomes large enough, the usermay experience speed slow-downs.Thisslowdownisanindicationthatthebeltanddeckneedtobereplaced.Thedeckmaybeflippedoverifithasneverbeenflippedpreviously.Inadditiontheconsolemaydisplaythemessage“UNABLETOATTAINTARGETSPEED”.

Thestridingbelt is initially tensionedandcenteredabout therollersat thefactory.Thestridingbeltmayhavetobere-centeredat the customer site during installationbecauseof customer floor irregularities.These irregularitiesmayalsorequirethelevelingofthetreadmillbyadjustingtherearlevelerfeet.Thecenteringadjustmentisdoneviatwoadjustingscrewsattherearroller.Withnormalusage,thestridingbeltstretchesovertimewhichmaycausethefrontrollertoslip.Thisisanindicationthatthestridingbelthastobere-tensioned.Re-tensioningisdonebyturningtheadjustingscrews.Asimplemethodofdeterminingifabeltislooseisthe2mphstalltest.Thistestrequiresthetreadmilltorunat2mphandthe technician stomps hard on the striding belt to try to stall the motor while observing whether the front roller spins when thestridingbeltmomentarilystops.

During treadmill use and depending how a user runs on the treadmill, the striding belt may move to either side causing the belttogooffcenter.Toaidwiththisthefrontandrearrollersaretaperedattheends.Thisfeaturehelpsthestridingbeltcenteritselfduringuse.Inaddition,thetreadmillframehasbeltguidesateachsideknownasbeltbarriers.Thepurposeofthebeltbarriersistocontainthestridingbeltfromwalkingofftheedgeoftherollersandbeingdamagedduringuse.

ThestridingbelthasaLifeFitnesslogoontheedgeofeachsidewhichidentifiesthebeltasanauthenticLifeFitnesspart.The purpose of the logo is a visual warning that indicates whether the striding belt is moving in the event that a user gets offthetreadmillduringtheworkoutanddoesnotpressthestopbuttontoendtheworkout.Inordertominimizehowlongaunitisrunningwithoutauseronit,thereisasensorwhichsensesdeckmovement.Itislocatedonthetreadmillframeunderthedeck.ThisistheStrideSensorassembly.Deckmovementsaresensedbythestridesensorassemblywhichareconvertedtovoltagesignalsandsenttothecontroller.Iftherearenodeckmovements,thecontrollersendsasignaltotheconsoleindicatingtheabsenceofausertoendtheworkout.

The Life Spring suspension system is comprised of a set of eight proprietary elastomers that work in combination with the decktoreducestresstobonesandjointsbyabsorbingsomeoftheimpactloadsassociatedwithrunning.

Modules

Stride (Walking) System:Theory of Operation M051-00K65-A003

84

SS 2Modules

Belt Tensioning/Centering Screw (both sides)

Rear Roller

Deck(cutaway)

Striding Belt (cutaway)

Front Roller Assembly

Belt BarrierStrideSensor

LifeSpring(8 places)

Roller Guard(both sides)

Stride (Walking) System:System Components M051-00K65-A003

85

SS 3


Selected or maximum speed is reduced during workout.

Insufficientlinevoltage/current at the outlet due to unit plugged into a shared (non-dedicated)outlet.

Unplug the treadmill and carefully open outlet cover and count number of conductors going to outlet.Iftherearemorethan three wires on a single outletormorethanfivewires on a dual outlet the outletisasharedoutlet.Unit must be plugged into adedicatedoutlet.Seeoperation manual for power requirements.

N/A

Worn deck and/or worn stridingbelt.

Setunitto15%incline.While standing on striding belt close to the Ergo bar,pushoffErgobar.Ifsteady, continuous sliding occurs down the incline, the belt/deck wear is acceptable.Ifslidingisnotcontinuous replace striding beltanddeck(orflipdeckif deck has never been flippedbefore).

SS 8

Drivemotorbinding. Check drive motor shaft forbindingorroughness.Replacemotorifnecessary.

DS 3

Frontorrearrollerbinding. Inspect rollers for binding orroughness.Replaceifnecessary.

SS 6

Stridingbeltslips. Incorrect striding belt tension.

Do the two mph stall test by stomping on the striding belthardattwomph.Ifthefront roller spins when the striding belt momentarily stops the belt tension must beincreased.

SS 8

Modules

Stride (Walking) System:Problem Symptom Table M051-00K65-A003

86

SS 4


Striding belt not centered or traveling close to roller edges.

Treadmillnotlevel. Level treadmill by adjusting theleglevelers.

Striding belt not within belt barriers.

Position striding belt inside belt barrier on both sides of theframe.

SS 8

Striding belt not tracking properly (belt is off to the leftortheright).

Adjust the tracking of stridingbelt.

SS 8

Wornstridingbelt. Setunitto15%incline.While standing on striding belt close to the Ergo bar pushoffErgobar.Ifsteadycontinuous sliding occurs down the incline, the belt/deckwearisacceptable.If sliding is not continuous replace striding belt and deck(orflipdeckifdeckhasneverbeenflippedbefore).

SS 8

Grindingnoiseonfootfall. Excessive friction between deckandstridingbelt.

Setunitto15%incline.While standing on striding belt close to the Ergo bar pushoffErgobar.Ifsteadycontinuous sliding occurs down the incline, the belt/deckwearisacceptable.If sliding is not continuous replace striding belt and deck(orflipdeckifdeckhasneverbeenflippedbefore).

SS 8

Squeaking noise when stridingbeltmoves.

Worn or damaged main motordrivebelt.

Inspect the main drive belt for damage or wear and replaceifnecessary.

DS 3

Drive motor pulley and front rollerpulleymisaligned.

Align pulleys as described indrivemotormodule.

Rubbing sound from under the treadmill when striding beltismoving.

Striding belt not positioned properly between the belt barrier.

Position striding belt edges tobebetweenbeltbarrier.

Striding belt not centered and off to the left or to the right.

Centerstridingbelt.

Modules

Stride (Walking) System:Troubleshooting M051-00K65-A003

87

SS 5


Knocking noise Treadmillnotlevel. Level treadmill by adjusting theleglevelers.

Faulty front and/or rear rollerbearings.

Inspect rollers for binding orroughness.Replaceifnecessary.

Lifesprings incorrectly positioned and/or have loosemountinghardware.

Inspect lifesprings and mounting hardware and repositionortighten.

Treadmill goes into pause modeduringworkout.

Physical damage to stride sensor.

Check stride sensor for physical damage and replace stride sensor if necessary.

Stride sensor not sensing user.

Go into diagnostics and check stride sensor operation.

Modules

Stride (Walking) System:Troubleshooting M051-00K65-A003

88

SS 6

REMOVAL OF FRONT AND REAR ROLLER



3. Remove motor cover and rear end caps (See LF 3)

4. Removerearendcaps.

Modules

End Cap Screws(25-35in-lbs)[29-40kg-cm]

Roller Guard Screws(25-35in-lbs)[29-40kg-cm]

5. Remove rear roller guards

6. Loosenwalkingbeltbyturningtensioningscrewscounterclockwise.Count the number of turns to remove the screw This will simplify re-tensioningthestridingbelttothesametension.

Tensioning screw and washer

Plastic grommet (nut) typical

Stride (Walking) System:How To’s M051-00K65-A003

89

SS 7

7. Removerearroller.

Modules

Rear Roller Striding Belt

8. Remove drive belt from motor pulley (See DS 3) and walk drivebeltoffoffrontrollerpulley.

9. Remove front roller mounting bolt and washers and slide front roller towards the left until roller shaft isclear off the mounting hole in frame.

Front Roller Bolt, Washer, Flat Washer (12-14ft-lbs)[16-19N-m]

Screw, split washer,flatwasher(69-73 in-lbs)[79-84kg-cm]

10.Removefrontrollerassemblyfromrightside.


90

SS 8

REMOVAL & INSTALLATION OF STRIDING BELT AND DECK

1. With the front and rear rollers and other components removed as described in the previous section remove the 4 deck screws and removethedeckfrombetweenthebelt.

CAUTION: Be careful not to damage the stride sensor with the deck.

2. Removestridingbelt.

CAUTION: Be careful not to damage the stride sensor when removingthestridingbelt.

Modules

Be Careful Not To Damage Stride SensorWhenRemovingDeck.

Deck Screw at4 corners(25-35in-lbs)[29-40kg-cm]

Deck Screw at 4 corners(25-35in-lbs)[29-40kg-cm]

3. InstallnewTinnermanclipsonthe4cornerLifeSprings.

NOTE: Proper assembly

Bent Corner of Tinnerman Clip


91

SS 9

4. To install new striding belt, place new belt with arrow on belt pointinginthedirectionofbelttravel.

5. Scrape off any wax build up on the front roller surface using a plastic spatula.

6. Installfrontrollerassemblywithdrivebeltoverrollerpulley.Tightenmountingboltto12-14ft-lbs[16-19N-m]

7. Scrape off any wax build up on the rear roller using a plastic spatula.

Deck Screws (4)Rear Roller

Rear Roller Adjusting Screws (2)

Belt BarrierFront Roller

Striding BeltRear Roller

Front Roller Mounting Bolt, Lock Washer, Flat Washer

Striding Belt

Deck

Modules

8. Position rear roller through striding belt and let it rest on rear roller brackets.

9. Insert new deck through the striding belt and place on the LifeSpringscarefullywithoutdamagingthestridesensor.Existingdeckmaybeflippedifithasneverbeenflippedbefore.

CAUTION:Cleanundersideofdeckofanydebrisifbeingflipped.

DeckStriding Belt


92

SS 10

10.Securethedeckwithdeckscrews.LineupholesindeckwithTinnermanclipholes.Pushdownondeckandinstallscrew.

CAUTION: Apply light pressure on screw to avoid bending the Tinnerman clip

Modules

Orientation of deck with cutout facing the rear

Tensioning Bolt

½ inch

Deck screw at 4 corners (25-35in-lbs)[29-40kg-cm]

11.Center the striding belt about the front and rear rollers at approximately½inchfromrearrolleredge.Alsopositionthebeltedgeswithinthebeltbarrier.


93

SS 11

12.To properly tension a new striding belt without the use of tension gauges,placetwopiecesofmaskingtapeexactly38.75inchesapartontherightandleftedgesasshown(fourpiecestotal).Alternativelyyoucanmarktwolines38.75inchesapartonthemaskingtape.

13.To tension the new striding belt, rotate the tension bolts clockwise until the distance between the pieces of tape (or lines on the tape) is increased to 39 inches for a NEW striding belt (38 15/16 inches foranexistingbelt).

14.Startthetreadmillandrunitatsevenmph.

Modules

Masking Tape

383/4”LooseLength

39”TensionedLengthforNew Belt

3815/16”TensionedLength for Used Belt

15. If the striding belt moves to the right, using a 5/16 inch Allen wrench, turn the right tension bolt 1/8-turn clockwise and the left tension bolt 1/8-turn counterclockwise to start centering the striding beltabouttherearroller.

16. If the striding belt moves to the left, turn the left tension bolt 1/8-turn clockwise and the right tension bolt 1/8-turn counterclockwise to startcenteringthestridingbeltabouttherearroller.

17.Continue adjusting belt until it is centered and does not move to onesideortheother.

18.Run treadmill at two mph and while on treadmill come down hard onthestridingbelt.Ifthefrontrollerspinswhenthestridingbeltmomentarilystops,thebeltisloose.

19. If the belt is loose, tighten it by rotating each tensioning bolt 1/4 turn clockwise and repeat steps 14 to 16 until the front roller does not spin.

Pivot PointStriding Belt

Rear Roller

equal equal


94

SS 12Modules

REMOVAL OF STRIDE SENSOR ASSEMBLY

1. Loosenstridingbelt.(SeeSS 8)

NOTE: Don’t forget to count the number of turns on the tensioning boltrequiredtoloosenthebeltandremovethedeck.Thiswillsimplifyre-tensioningthebelttothesametension.

2. Removedeck.(SeeSS 8)

CAUTION:Becarefulnottodropthedeckonthestridesensor.

Stride Sensor Connector at Controller

Stride Sensor Cable Routing Through 3 Grommets in Frame

5/8”[5.9mm]

Stride Sensor Assembly

Screw and Flat Washer (25-35 in-lbs)[29-40kg-cm]

3. Disconnect stride sensor cable connector from controller in motor pan.

4. Fishcablethroughframe.

NOTE: Tyingacordontheendoftheconnectorwillhelptofishthenewcablethroughtheframe.

5. Removeexistingstridesensor.

6. Installnewstridesensor.

7. NOTE: Mountstridesensorparalleltoframeasshown.

NOTE:Becarefulnottodamagethecablewhenfishingitthroughtheframe.

8. Re-installthedeck(SeeSS 8)

9. Re-tensionthestridingbelt(SeeSS 8)


95

LF 1Modules

Side ShroudBottom Motor Shroud

Top Motor Shroud Anti-Slip Pad End Cap

Lower Plastic Extrusion Extrusion

Lower Frame: System Components M051-00K65-A003

96

LF 2


Anti-slip pad assemblies are loose

Pad not properly placed or damaged.

Replaceanti-slippad. LF 7

Motor shroud cover is off or loose

Improper placement Replace motor shroud cover.

LF 3 (Top)

Damage LF 5 (Bottom)

Loose upright covers Improper placement Replaceuprightcovers. LF 4

Damage

Loose uprights Damage Replaceuprights. LF 3

Loose end caps Improper placement Replaceendcaps. LF 5

Damage

Lower extrusion loose or off Improper placement Replacelowerextrusion. LF 6

Customer abuse

Modules

Lower Frame: Problem Symptom Table M051-00K65-A003

97

Modules

REPLACEMENT OF TOP MOTOR SHROUD COVER

1. Remove and save the six Phillips screws that secure the top motor shroudcovertothemotorcovermountingbracketsandframe.

2. Install the new top motor shroud cover using the Phillips screws savedinStep1.

25-35 lb*in[29-40kg*cm]

REPLACEMENT OF UPRIGHTS



3. Removethetopmotorcover.

4. Remove either right or left upright shroud depending on which uprightisbeingreplaced.

5. Removetheinsidehandrailcovers(See UF 3)

6. RemovetheActivityZoneassembly(See CA 22).

7. Removetheouterhandrailcovers(See UF 5).

8. Removethelowerbridgecover(See UF 4).

9. Remove and save the six upper bolts (three per upright) that secure thebridgetotheuprights.

10.Cablesrunthroughbothoftheuprights.Determiningwhichcablewillbedisconnectedwilldependonwhichuprightisbeingreplaced.If replacing the left upright, this will require disconnecting the power cables to the attachable TV and re-routing them through the new upright.Thetransformercablemustberemovedandreroutediftheleftuprightisbeingreplaced.

Bridge Left Upright Right Upright

11.Carefully lift the bridge frame assembly up and out of the uprights andsetittotheside.

12.Remove and save the three lower bolts that secure the upright to thebaseframe.

13.Install the new upright using the hardware removed in the previous steps.

Lower Frame: How To’sLF 3

M051-00K65-A003

98

REPLACEMENT OF UPRIGHT COVERS

1. Removethetopmotorshroudcover.

2. RemoveandsavethetwoPhillipsscrewsthatsecuretheuprightcovertotheupright.

3. Loosenthescrewsecuringtheuprightcovertothemainframe(infrontoftheupright).

4. Removetheuprightcover.

Screw (2) Right Upright Cover

Example of a Good GapExample of a Bad Gap

Modules

5. Installthenewuprightcover,usingthescrewsremovedinStep2.

All Screws: Torque to25-35in*lb.[29-40kg*cm]


Example of a good gap

Bottom Side Shroud

Upright

Top Motor Cover

Mismatch

M051-00K65-A003

99

REPLACEMENT OF END CAPS

1. Remove and save the two Phillips screws that secure the right or leftrearendcaptotheframe.

2. InstallthenewrearendcapusingthescrewssavedinStep1.

Modules

Lower Motor Shroud Screws (2 of 4 shown)

Lower Motor Shroud

Lower Motor Shroud

REPLACEMENT OF BOTTOM MOTOR SHROUD COVER


2. Remove and save the four Phillips screws that secure the bottom motorshroudcovertothemotorcovermountingbrackets.

3. Install the new bottom motor shroud cover using the screws removedinStep2.




M051-00K65-A003

100

Upper Extrusion

Upper Extrusion

Velcro Strip (one of four)

Foam Strip Lower Extrusion

Upper Extrusion

Rear End Cap

Modules

REPLACEMENT OF LOWER EXTRUSIONS

1. Removethecorrespondingrightorleftrearendcap(See LF 5).

2. The lower frame extrusion is attached to the frame by a series of Velcrostripsmountedalongthelengthoftheframe.SeparatetheVelcro strips and pull the lower frame extrusion out and away from thesideofthetreadmill.

3. Save the foam strip that is positioned between the upper and lower extrusions.

4. Installthenewlowerframeextrusion.

5. Install the foam strip by pressing it into the space between the lower andupperframeextrusions.


M051-00K65-A003

101

Upright Cover

Locating Tab

Anti-slip Pad

Upper Extrusion

Modules

REPLACEMENT OF UPPER EXTRUSION/ANTI-SLIP ASSEMBLY


2. Removetheuprightshroud(See LF 4).

3. Remove the Phillips screws that secure the motor cover mounting brackettotheupperextrusion.

4. Notethelocationoftheanti-slippad.

5. Usingasmallflatbladescrewdriver,carefullypryuponeendoftheanti-slippad.

6. Continue to peel the anti-slip pad until it is completely removed from theextrusion.

7. Removethelowerextrusion(See LF 6).

8. Remove and save the nine screws that secure the upper extrusion totheframe.

9. Installtheupperextrusiontotheframe.

10.Peelthebackingofftheanti-slippad.


11.Position the pad on the upper extrusion, using the locating tabs on thebackoftheanti-slippad.

12.Pressdownfirmlyontheanti-slippadtoadhereitsecurelytotheextrusion.


M051-00K65-A003

102

UF 1Modules

Outer Handrail CoverUpper Bridge Cover

Console Ergo bar and Activity Zone

Inner Handrail Cover

Lower Bridge Cover

Upper Frame: System Components M051-00K65-A003

103

UF 2


Inside handrail shroud looseormisaligned.

Improper assembly Replace inside handrail shroud.

UF 3

Damaged component

Outside handrail shroud looseormisaligned.

Improper assembly Replace outside handrail shroud.

UF 5

Damaged component

Upper bridge cover loose ormisaligned.

Improper assembly Replace upper bridge cover.

UF 6

Damaged component

Lower bridge cover loose or misaligned.

Improper assembly Replace lower bridge cover.

UF 4

Damaged component

Handrail need loose or misaligned.

Improper assembly Replacehandrail. UF 3

Damaged component

Modules

Upper Frame: Problem Symptom Table M051-00K65-A003

104

Plug (5)

Allen Screw (5)

Modules

REPLACEMENT OF INSIDE HANDRAIL COVERS

1. Removeandsavethefiveplugsintheinsidehandrailcoversthatconcealthemountingbolts.

2. RemoveandsavethefiveAllenboltsthatsecuretheinsidehandrailcovertothehandrail.

3. Remove the cover by tilting it forward the inside of the unit, then pullingdown.

4. Install the new Inside Handrail Cover, using the bolts removed and savedinStep2.

Torque to 42 in-lb[48kg*cm]

Upper Frame: How To’sUF 3

M051-00K65-A003

105

REPLACEMENT OF LOWER BRIDGE COVER



3. Removethecupholders.

4. RemovetheActivityZoneassembly(SeeCA 22).

5. RemoveandsavethetwoAllenboltsthatsecurethelowerbridgecovertothebridgeweldment.

6. RemoveandsavethetwoAllenboltsthatsecurethelowerbridgecovertotheupperbridgecover.

7. Tiltthelowerbridgecovertoeithersideoftheunittoenablethelowerbridgecovertocleartheuprightboltheads.

8. Removethelowerbridgecover.

9. InstallthenewlowerbridgecoverusingtheboltsremovedandsavedinSteps5and6.

Modules

Bridge Weldment

Upright Bolt Heads (2 on each side)

Lower Bridge Cover

Allen Screws (10)



Example of a Good GapExample of a Bad Gap

Outer Arm Shroud

Bottom Bridge Cover

Mismatch

M051-00K65-A003

106

Allen Bolts (6)

Modules

REPLACEMENT OF OUTSIDE HANDRAIL COVERS




4. Removethehandrailcover(SeeUF 7).


6. Removethelowerbridgecover(SeeUF 4).

7. Remove and save the six Allen bolts that secure the outer handrail covertothehandrail.

8. Removetheouterhandrailcover.

9. Install the new outer handrail cover using the bolts removed and savedinStep7.


Outer Handrail Cover

Handrail

Right Handrail Overmold

Right Handrail Outer Shroud

Example of a Bad Gap

Example of a Good Gap


M051-00K65-A003

107

REPLACEMENT OF UPPER BRIDGE COVER




4. Removetheconsoleassembly.

5. Removetheconsoleneckassembly.

6. Removetheinsidehandrailcovers(SeeUF 3).



9. Removetheouterhandrailcovers (SeeUF 5).

10.Removeandsavethesixbolts.

11.Removetheupperbridgecover.

12.Install new upper bridge cover using the bolts removed and saved inStep8.


Modules

Example of a good gap


M051-00K65-A003

108

Allen Bolt (2)

Screw (2)

Screw toBridge Frame (3)

Screw to Handrails(2 on each side)

Washers (3)

Washers(2 on each side)

Handrail

Ergo bar

Torque to62 ft-lb [84N-m]

Modules

REPLACEMENT OF HANDRAILS







7. Removetheouterhandrailcovers(SeeUF 5).

8. Remove and save the two bolts that secure the handrail to the Ergo bar.

9. Remove and save the two Allen bolts that secure the handrail to the upright.

10.Removethehandrail.

11. Install the new handrail using the bolts removed and saved in Steps 8&9.

REPLACEMENT OF ERGO BAR







7. Removetheouterhandrailcovers (See UF 5).

8. Remove and save the two bolts that secure the handrail to the Ergo bar.

9. Remove and save the three bolts that secure the Ergo bar to the bridgeframe.

10.DisconnecttheheartratecablefromtheErgobartotheconsole.

11. Install the new Ergo bar assembly using the hardware removed and savedinSteps8and9.

Torque to2.91ft-lb[3.97N-m]

Torque to 2.5ft-lb[3.4N-m]


M051-00K65-A003

Appendix

110

Appendix

OverviewEngage / Inspire Console Diagnostic:

ThisdocumentisintendedtoprovideahighleveloverviewofSystemDiagnosticflowsaswellasscreen-by-screenlayoutanddescriptionsoftheirintendedfunctionalityfortheEngage/Inspireconsoles.

M051-00K65-A003

111

Appendix

System Options - Block Diagram Overview

System Flows

System Options Main

Menu

System Test

ManagerStatisticsStatistics

Software Versions

Motor Modules (TR only) or System

Diagnostics (Non-TR)

Main Motor Information (TR only)

Lift Motor Information (TR only)

Keypad Test

Belt / Deck Information (TR only)

Heart Rate Test

iPod®

Test Engineering

VIVO/Network

Date and Time

Information

Stride Sensor Test

System Errors

External Serial EE

Test

Maintenance Information

Usage LogCSAFE

Network Test Status

Channel Usage Log

CSAFE Loopback

Test

Information Configuration Maintenance

Manufacturer Clock

Video / FM Radio

Custom Workouts

Touch Screen Configuration

Export / Import Settings

NOTE:“TRonly”meansforTreadmillonly.OnBikesandCrossTrainers,thosemodulesmarkedwith“TRonly”willnotbevisible.

Engage / Inspire Console Diagnostic:M051-00K65-A003

112

Appendix

System Options - Main Menu

User Interface

Object Table


LABEL DESCRIPTION

System Test Button DisplaystheSystemTestMenuScreen.

Information Button DisplaystheInformationMenuScreen.

ConfigurationButton DisplaystheConfigurationMenuScreen.

Maintenance Button DisplaystheMaintenanceScreen.

Exit Button ExitsoutoftheSystemOptions–MainMenuandreturnstotheAttractScreen.

Readouts Model:Displaysthecurrentmodelnumber.

Base Assembly Serial #:Displaysthebaseassemblyserialnumber.

Console Version: Displays the current installed console software version number (buildnumber).

Interface Board Version:Displaysthecurrentinterfaceboardsoftwareversion.

113

M051-00K65-A003Appendix

System Test Menu 1

User Interface

Object Table

LABEL DESCRIPTION

System Communication Test Button

Displays System Communication Checks Screen and executes system communication check.

Motor Modules (TR only) or System Diagnostics Button (Non-TR only)

DisplaystheMotorModulesScreenforTRorSystemDiagnosticScreenfornon-TR.

Key Pad Test Button DisplaystheKeyPadTestScreen.

Heart Rate Test Button DisplaystheHeartRateTestScreen.

iPod® Button Displays the iPod®TestScreen.

Test Engineering Button DisplaystheTestEngineeringScreen.

Back Button Displaysthepreviousscreen.

Forward Button DisplaystheSystemTestMenu2Screen.

Engage / Inspire Console Diagnostic:

114

NOTE: This test checks the communications between the MIBandMotorControllerboards(i.e.SystemCommunication).TheLiftSystemandExternalSerialEESystemarepartoftheMotorControllerboard.Torepeattest,pressBackbuttonandthenSystemCommunicationTestbutton.


System Communication Check

User Interface

Object Table

LABEL DESCRIPTION

Motor Controller DisplaysthestatusoftheMotorController(i.e.Checking,Detected,Failed)

Lift System DisplaystheMotorModulesScreen.

External Serial EE System DisplaystheKeyPadTestScreen.

Information DisplaysanyadditionalinformationregardingtheSystemCommunicationcheck(i.e.System Communication OK, System Communication Failed, Error - Communication TestResultsNotAvailable).

iPod® Button Displays the iPod®TestScreen.

Back Button DisplaysthepreviousScreen.

Main Menu Button Goes back to the System Options – Main Menu


115

NOTE:Theinformationbelowthemessagecenterisforengineeringuseandisrelatedtospecificcommunicationmodules(i.e.“IC”=inclinecontroller,MC=motorcontroller,etc.)

Appendix

Motor Modules (TR Only)

User Interface

Object Table

LABEL DESCRIPTION

Module Errors Lift: Displays module error for incline

Motor: Displays module error for motor controllerNote:Iftherearenoerrors,themessagecenterreports“NoMotorModuleErrors”,etc.Onlyerrorsoccurringinrealtimeareshownhere.Toseeanypasterrorsgotothe“SystemErrors”section.

Mode Auto: Automatically switch the incline (Incline will move and automatically stop at the commanded value as selected using the incline Up/Down keys)

Manual: Manually adjust the incline up/down (incline moves when either the Incline Up or Downarrowkeysareheldandstopsmovingwhenthesekeysarereleased.Notethattheincline movements will not stop even if the incline Home Switch (or incline negative switch, if equipped)isencountered.

Console Temperature Displaysthecurrentconsoletemperature.

Actual Actual incline:Displaysthecurrentandactualinclinepercentage.

Actual RPM and MPH: Displays the current and actual RPM if the RPM radio button is selectedorMPHiftheMPHradiobuttonisselected.

Current Trip If lift, then a dynamic or temporary current trip has been detected by the motor controller typically due to an excessive load

Info Watts:Displaysthecurrentwattage.

Power: Displaysthecurrentpowerconsumption.

Temperature: Displays the current temperature of the motor controller board and surrounding area’s.

Bus Voltage:DisplaysthecurrentBusvoltage.

Back Button Goesbacktothepreviousscreen.



116


System Diagnostics Check (Non – TR only)

User Interface

Object Table

LABEL DESCRIPTION

Readouts Battery Voltage: Displays the current battery voltage

Console Current (mA): Displaysthecurrentoftheconsoleinmilli-amps.

Brake Current (mA):Displaysthebreakcurrentinmilli-amps.

GBC Bus Voltage:DisplaysthecurrentvoltageoftheGBC.

RPM:DisplaysthecurrentRPM.

External Powered: Yes or No

Console Temperature:DisplaysthecurrentconsoletemperatureinCelcius.

GBC Temperature: DisplaysthecurrentGBCtemperatureinCelcius.

Watts Control InputstheamountofWattagetobetested.

Back Goesbacktothepreviousscreen.

Main Menu Button GoesbacktotheSystemOptions–MainMenu.


117

NOTE: The additional information at the bottom of the screen is for engineering use and represents communication data between the MIB and SBCconcerninghardkeypressevents.


Key Pad Test

User Interface

Object Table

LABEL DESCRIPTION

Readouts Activity Zone Status: Displays the Activity Zone keypad status (Detected or Unplugged).WhenkeysarepressonthiskeypadtheywillshownupintheKeyPadValuearea.

Key Pad Value:Displaysthenameofthekeypadbuttonthatisbeingpressed.

Emergency Stop Switch: DisplaysthestatusoftheESS(i.e.AttachedorNotAttached).

Back Goesbacktothepreviousscreen.



118

NOTE: You can use the Activity Zone Incline/Speed Up/Down arrow keys to control the belt and incline motors in this testmode.

Appendix

Heart Rate Test

User Interface

Object Table

LABEL DESCRIPTION

Confidence 0-9:Displaystheconfidencelevelfrom0–9fortheheartratereadingontheLifePulse® sensors

Readouts Telemetry HR: Shows the telemetry strap heart rate reading If Telemetry(OFF) is shown thentelemetryhasbeendisabledinManager’sConfiguration.

Hands on:Showsdetectionofhandson/offontheleftandrightLifePulsesensors.L(0)/R(0)=nohandsondetected,L(1)/R(1)=handsondetected.

LifePulse® HR: Shows the LifePulse®heartratereading.IfLifePulse®(OFF) is shown thenLifePulsehasbeendisabledinManufacturer’sConfiguration.

Confidence:Showstheconfidenceleveloftheheartratedetectionsignal.

Gain:ShowstheamplificationleveloftheLifePulseheartratesignal.Astrongsignalresultsinlessrequiredgain.Weakersignalsresultsinahighergain.

Packets:Showsthedatapacketthatisbeingtransmitted.

Incline: Showsthecurrentincline(TRonly).

Speed:Showthecurrentspeed.




119

Appendix

iPod® Test

User Interface

Object Table

LABEL DESCRIPTION

Readouts iPod®: Displays the status of the iPod®(i.e.Unpluggedordetected).

CP:Displaysthestatusoftheco-processor/authenticationchip(i.e.detectedornotdetected).




120

Appendix

Test Engineering

User Interface

Object Table

LABEL DESCRIPTION

Phase Test Readouts NULL Report:Checksthebalanceofthephases.Thisvalueshouldbe<=3(0.3a).

Phase U/W/V Low/High:Checkstheindividualphasesandtransistors.Thesevaluesshouldbeinthe30’s(~3a-4a).Ifonephasepair(Low/High)showsverylow,thecable/connectorormotorneedstobechecked.Ifindividualphase(s)aresubstantiallydifferent,theDSPboardneedstobechecked.

Start Test Button Runsthetestengineeringphasetest.




121

Appendix

System Test Menu 2

User Interface

Object Table

LABEL DESCRIPTION

Stride Sensor Test Button (TR only) Displays Stride Sensor Test Screen and executes the stride sensor test (TRonly).

External Serial EE Test Button DisplaystheExternalSerialEETestScreen.

CASFE Network Test / Status Button Displays CSAFE Network Test / Status Screen and executes the CSAFE NetworkTest.

CSAFE Loopback Test Button Displays the CSAFE LoopbackTestScreen.




122

NOTE: You can use the Activity Zone Incline/Speed Up/Down arrow keys to control the belt and incline motors in this testmode.

Appendix

Stride Sensor Test (TR only)

User Interface

Object Table

LABEL SPECIFICATION

User Status Shows the detection status of a user on the belt (User Detected On Belt or User Not Detected OnBelt).Additionalstatusinfo:“StrideSensorDisabled”(seeStrideSensorSystembelow)or“StrideSensorUnplugged”.Ifsensorisdetectedasunpluggedthesoftwarewillperiodicallytryandre-detectsensorwhileinthistestmode.Whilere-detectinga“GettingStatus…”messagewillbeshown.

Adjust Belt Stop Triggerpointadjustment.Zero=useinternaldefaulttriggerpoint(value=62).WhentheAveragevaluedecaystothetriggerpointthestatuswillchangeto“UserNotDetectedOnBelt”.HigherAdjustvaluesresultsinaquickeractingsystem.Alowervalueresultsintakingmoretimetodetectauserhasleftthebelt.Adjustingvaluesthataretoolowcanresultinsystemneverdetectingthatauserhasleftthebelt.Changethisadjustmentonlywhenrecommendedtodoso.

Stride Sensor System

AllowstheStrideSensorSystemtobeenabledordisabled.WhendisabledUserStatus=“StrideSensorDisabled”

Average Runningaverageofrawreading(filteredvalue).Whenthisslower,changingvaluedecaystothetriggerpoint(seeAdjustBeltStop)theUserStatuschangesto“UserNotDetectedOnBelt”

Raw Thisistherawreadingfromthestridesensor.Readingrepresentsrealtimeactuationsofthestridesensor.Thisisafastchangingvalue(asopposedtotheAveragevalueabove).Whensensordeflectsrawreadingjumpstomaxorclosetomax.Max=100.

Readouts The information in this section is for engineering purposes and represents data being received fromthemotorcontrolleraswellasinternalholdoffandgraceperiodtimers.




123

Appendix

External Serial EE Test

User Interface

Object Table

LABEL SPECIFICATION

External Serial EE Test Button

Executesanddisplaysthetestinprogresspop-upwindow.

Testresultwillbedisplayedinapop-upwithastatusofPassorFailed.

This test will verify the proper operation of the serial EE storage chip located on the motorcontrollerwhichisusedtostoretheMainMotorInfoandbasicconfigurationinformation(producttype,etc.).




124

Appendix

CSAFE Network Test or Status

User Interface

Object Table

LABEL SPECIFICATION

Information Readouts Rx Packets:Displaysthenumberofdatapacketsreceived.

Tx Packets:Displaysthenumberofdatapacketstransmitted.

Timeout Timer:Displaysthetimeoutinseconds.

CSAFE State:DisplaysthecurrentstateoftheCSAFEnetwork.

Previous Bads: Displays the number of bad requests

Net Down Timer:Displaysthedowntimeofthenetworkinseconds.

ConfigurationReadouts ID Length:DisplaystheIDlengthnumber.

Timeout Period:Displaysthetimeoutinseconds.

Up-List:Displaysthenumberofup-listitems.

CSAFE Version Readouts Manufacturer:Displaysthemanufacturer’sIDnumber.

CID:DisplaystheconnectionIDnumber.

Model:Displaysthemodelnumber.

Version:Displaystheversionnumber.

Release: Displays the release number

Reset Connection Button ResetstheconnectiontotheCSAFEnetwork.



NOTE:ThistestshowsmanyCSAFEcommunicationspecificationparametersandisintendedtoprovidemoredetailedinformationforengineeringandthirdpartycompaniesthatmakecompatibleCSAFEdevices.Usethe“CSAFELoopbackTest”totesttheconsole’sCSAFEport.


125

Appendix

CSAFE Loopback Test

User Interface

Object Table

LABEL SPECIFICATION

Instructions Displays the seven steps instructions to perform the CSAFE LoopbackTest.

Test Log Displaysandlogsthestatusofallthetestingstepsandresults.

CSAFE Loopback Status Displays the status of the loopbacktest(i.e.PassorFail).



NOTE: This test is used to verify the console’s CSAFE port and to provide instructions on how to use and diagnose portproblems.


126

User Interface

Object Table

LABEL DESCRIPTION

Statistics Button DisplaystheInformationStatisticsScreen.

Software Versions Button DisplaystheSoftwareVersionsScreen.

Main Motor Information Button DisplaystheMainMotorInformationScreen.

Lift Motor Information Button DisplaystheLiftMotorInformationScreen.

Belt / Deck Information Button DisplaystheBelt/DeckInformationScreen.

Date and Time Information Button DisplaystheSystemDateandTimeInformationScreen.

System Errors Button DisplaystheSystemErrorsScreen.

Maintenance Information Button DisplaystheMaintenanceInformationScreen.

Usage Log Button DisplaystheUsageLogReportScreen.

Channel Usage Log Button DisplaystheTVChannelUsageLogScreen.



Appendix

Information Menu

User Interface

Object Table

LABEL DESCRIPTION

Statistics Button DisplaystheInformationStatisticsScreen.

Software Versions Button DisplaystheSoftwareVersionsScreen.

Main Motor Information Button DisplaystheMainMotorInformationScreen.

Lift Motor Information Button DisplaystheLiftMotorInformationScreen.

Belt / Deck Information Button DisplaystheBelt/DeckInformationScreen.

Date and Time Information Button DisplaystheSystemDateandTimeInformationScreen.

System Errors Button DisplaystheSystemErrorsScreen.

Maintenance Information Button DisplaystheMaintenanceInformationScreen.

Usage Log Button DisplaystheUsageLogReportScreen.

Channel Usage Log Button DisplaystheTVChannelUsageLogScreen.




127

Appendix

Information Statistics

User Interface

Object Table

LABEL DESCRIPTION

Information Readouts POWER-UP COUNT:Showsmanytimesthesystemhasbeenpowered-up.

TOTAL HOURS:Showsthetotalhoursofmachineusage.

TOTAL MILES:Showsthetotalmilesaccumulatedforthemachine.

BELT HOURS:Showsthetotalnumberofhoursaccumulatedforthebeltusage.

BELT MILES:Showsthetotalnumberofmilesaccumulatedforthebeltusage.

LIFT HOURS:Showsthetotalnumberofhoursofupinclineoperations.

CHANGE WORKOUTS: Show the total number of times this feature was invoked.

QUICK:Showsthetotalnumberoftimesthisprogram(QuickStart)wasinvoked.

MANUAL:Showsthetotalnumberoftimesthisprogramwasinvoked.

HILL:Showsthetotalnumberoftimethisprogramwasinvoked.

RANDOM:Showsthetotalnumberoftimesthisprogramwasinvoked.

FAT BURN:Showsthetotalnumberoftimesthisprogramwasinvoked.

PRESET COUNT:Showsthetotalnumberoftimesthisprogramwasinvoked.

Nike + iPod® Accepted: Shows the total number of times this feature was accepted.

CARDIO:Showsthetotalnumberoftimesthisprogramwasinvoked.

HR HILL:Showsthetotalnumberoftimesthisprogramwasinvoked.

HR INTERVAL: Showsthetotalnumberoftimesthisprogramwasinvoked.

EXTREME HR: Showsthetotalnumberoftimesthisprogramwasinvoked.

SPEED INTERVAL:Showsthetotalnumberoftimesthisprogramwasinvoked.


128

Object Table

LABEL DESCRIPTION

Information Readouts SPORT TRAINING 5K: Shows the total number of times this program was invoked.

SPORT TRAINING 10K: Shows the total number of times this program was invoked.

SPORT TRAINING:Showsthetotalnumberoftimesthisprogramwasinvoked.

LF FIT TEST: Showsthetotalnumberoftimesthisprogramwasinvoked.

GERKIN: Showsthetotalnumberoftimesthisprogramwasinvoked.

Nike + iPod® Rejected: Shows the total number of times this feature was rejected.

WORKOUT COUNT: Showsthetotalnumberoftimesthisprogramwasinvoked.

ARMY:Showsthetotalnumberoftimesthisprogramwasinvoked.

NAVY PRT: Showsthetotalnumberoftimesthisprogramwasinvoked.

MARINE:Showsthetotalnumberoftimesthisprogramwasinvoked.

AIR FORCE:Showsthetotalnumberoftimesthisprogramwasinvoked.

NETWORKED: Shows the total number of times a network workout program was invoked.

CUSTOM:Showsthetotalnumberoftimesthisprogramwasinvoked.

TIME GOALS:Showsthetotalnumberoftimesthisfeaturewasinvoked.

DISTANCE GOALS:Showsthetotalnumberoftimesthisfeaturewasinvoked.

CALORIES GOALS:Showsthetotalnumberoftimesthisfeaturewasinvoked.

TIME-IN-ZONE GOALS: Shows the total number of times this feature was invoked.

MARATHON MODE:Showsthetotalnumberoftimesthisfeaturewasinvoked.

VIDEO:Showsthetotalnumberoftimesthisfeaturewasinvoked.

Export to USB Button ExportalltheinformationonthescreentoaUSBstickina.CSV(commaseparatedvalue)file.



Appendix

Information StatisticsM051-00K65-A003

129

Appendix

Software Versions

User Interface

Object Table

LABEL DESCRIPTION

Readouts Base Assembly Serial #:Displaysthebaseassemblyserialnumber.

Console Serial #: Displaystheconsoleserialnumber.

Console Version / Part #: Displays the software version number and part number.

Motor Version / Serial #: Displays the software version number and part number.

LifePulse® Version:Displaysthesoftwareversionnumber.

CSAFE Version:Displaysthesoftwareversionnumber.

Interface Boot Version:Displaysthesoftwareversionnumber.

Interface Board Version / Part #: Displays the software version number and part number.

Console Boot Version:Displaysthesoftwareversionnumber.

Apploader Version:Displaysthesoftwareversionnumber.

Media Manager Version:Displaysthesoftwareversionnumber.

Treadmill/Bike/CT: Date and time of the console software build

WinCE Version: Displays the version number of the Windows CE operating system.

Export to USB Button ExportalltheinformationonthescreentoaUSBstickina.CSV(commaseparatedvalue)file.




130

Appendix

Main Motor Information (TR Only)

User Interface

Object Table

LABEL DESCRIPTION

Readouts DescriptionandValue:Displayshutdownerrors,health,power,andvoltageinformation.

Export To USB Button ExportalltheinformationonthescreentoaUSBstickina.CSV(commaseparatedvalue)file.



Shutdown Errors

ShutdownErrorsrecordseventsthatcausedthemotortostopandreportanerrortotheconsole.

Machine Health Info records events that have not stopped the motor that the system recovered from, but may be an indicationofapotentialprobleminthefuture.

Maximumsshowmonitoredsignalextremesandmaybeusefulindiagnosingproblems.

When analyzing the Main Motor Information keep in mind that a Shutdown Error actually caused the belt to stop in a safe mannerbutnonetheless(andmostlikely)whenauserwasonit.LowvalueMachineHealthInfocountsingeneralarenotaconcernbutcombinationsofthemcanhelpdetermineamachines’condition,i.e.anytypeofI-Hitcombinedwithhighmaximumphasecurrents(>10a)canbeanindicationofawornbelt.


131

Appendix


LABEL DESCRIPTION

PLL Clock Lost Ifthephaselockedloopcircuitrydetectsnoclock,thiserrorwilloccur.Ifthemotorisrunningandthisoccursthemotorstopsquickly,turningoffthedrive.Thestateofthephaselockismonitoredevery75us.

CAUSENoisysystemordefectiveDSPboard.

ACTIONCheckallgroundsandcablesfirst.Ifthenumberis>3theDSPboardshouldbechecked.

Drive Low-V Trips NotUsed.

Low Voltage Resets Theprocessorhasdetectedavoltage<2.7vtotheprocessorbutithasn’tshutdown.Ifthemotorisrunningandthisoccursthemotorstopsimmediately,turningoffthedrive.

CAUSEPowerlinesurgesoranintermittentlinecordorwalloutlet.

ACTIONCheckthepowersourceandlinecord.Sameactionas“Low-VTrips”below.

Communication Trips If the motor controller stops receiving transmissions from the console for more than5seconds,themotorwillcometoastopatitsnormalrate.Theinclinewillbeheldatitspresentposition.

CAUSEVibration can cause the connection to become intermittent and disrupt communicationbetweentheconsoleandM/C.

ACTIONChecktheconsolecableandconnectors.Makesuretheyarefullyseated.ObservecommunicationLED#3.Itshouldbeflashingataveryhighrate(~5/sec).Ifyouwigglethecablearoundandtheflashingischangedorevenstopped,thereisastrongindicationthatthecableistheproblem.

Shutdown Errors

ShutdownErrorsrecordseventsthatcausedthemotortostopandreportanerrortotheconsole.

Machine Health Info records events that have not stopped the motor that the system recovered from but may be an indicationofapotentialprobleminthefuture.

Maximumsshowmonitoredsignalextremesandmaybeusefulindiagnosingproblems.

When analyzing the Main Motor Information keep in mind that a Shutdown Error actually caused the belt to stop in a safemannerbutnonethelessmostlikelywhenauserwasonit.LowvalueMachineHealthInfocountsingeneralarenotaconcernbutcombinationsofthemcanhelpdetermineamachines’condition,i.e.anytypeofI-Hitcombinedwithhighmaximumphasecurrents(>10a)canbeanindicationofawornbelt.


132

Appendix


LABEL DESCRIPTION

Temperature Trips If the current limit reduction scheme fails to control the module temperature, 100c anover-temperaturetripwilloccurat100C.Themotorwillcometoastopatitsnormalrate.

CAUSE•Airflowrestrictionintothemotorcompartmentcausedbyblockageorlintbuildup.Theunitislocatedoveraheatingventandhotairisbeingblownintoit.•Directsunlightontheunitcancausethiseffectalthoughtoalesserdegree.•Aseverelywornbelt.

ACTIONClean in and around the compartment and insure the above conditions are not occurring.

Over-V Powerdowns If the bus voltage is over 460v and the motor is running, this mode will disengage the motor by gradually removing the drive voltage over a period of approximately asecond,dependingonitspresentexcitationlevel.Thisisthefinalmeasuretopreventover-voltageonthebuscapacitors.

CAUSEUsers actively pushing the belt at running speeds and maximum incline can overcomethefrictionofthebelt/decksufficientlytodeliverpowerintothesystem.

ACTIONObserve if this is actually happening and if so recommend that the user uses a lowerinclinewithpossiblyahigherspeed.

Over-V Trips Ifthebusvoltageisover460vthiserrorwillbedetected.IfthemotorisrunningthesystemwillgointoOvervoltagePowerdownMode(above).Otherwisethepowerrelaywillbeopenedimmediately.

CAUSEAsdescribedabove(iftheuserpushesthebelt)aswellasanypowerlineissue.

ACTIONIf users are not pushing the belt the power line needs to be monitored for dramaticallypoorvoltageregulation.

Low-V Trips If the bus voltage is lower than the 190v limit when the relay is closed and ESS switchisonan,errorconditionwillbetripped.Thepowerrelaywillbeopenedandthemotorwillbedisabled,forcingittoacontrolledstop.

CAUSEThebusvoltagehasdroppedbelowitsminimumoperatingvalue.

ACTIONAn improperly seated power cord or badly installed outlet (loose screws holding thewires)willcausethevoltagetomomentarilysagtriggeringthiserror.Insurethattheproductisdirectlyconnectedtoadedicatedcircuit.Usinganextensioncordcancausethiserror.


133

LABEL DESCRIPTION

Hardware I-Trips The hardware overcurrent limit has been hit consistently for over 250ms, which causedamotorshutdown.

CAUSEPersistent,excessivemotorcurrentover24awillcausethistrip.

ACTIONCheckthatthemotorwiringisnotbeingshorted.Checkthatthemotorplugandallitswiresareseatedproperlyandthatthereisnocontaminationonthepins.Runthephasetesttoisolateatroubledphase(s).

Running Errors If after four seconds the motor hasn’t drawn over 1a motor current this error will betripped.Themotorwillbedisabledforcingittoacontrolledremovalofthemotorvoltage.

CAUSEAnunpluggedmotorcableordamagedmotor.

ACTIONMakesurethemotorisproperlypluggedin,thenrunthephasetest.

Dynamic I-Trips Excessivemotororlinecurrenthasbeendetected.Anappropriatemotorrpmdropwillbecommandedtotrytokeepthecurrentwithinitslimit.Inthiscasethemotorsloweddowntoapointwhereitactuallywentintoapausestate.

CAUSEExcessivebeltanddeckwearorveryhighuserweightathighspeeds.

ACTIONCheckthebelt/deckandreplaceifworn.

Appendix

Main Motor Information (TR Only)Engage / Inspire Console Diagnostic:M051-00K65-A003

134

Appendix


LABEL DESCRIPTION

Drive Low-V Hits This mechanism, which detects low power supply voltage to the power driver chip,hadahit.

CAUSEPowercyclingandoccasionallynoiseinduced.

ACTIONThiseventisrecordedonly;noactionistakenbytheDSP.Ifmany are present (>25)thegroundsandcablesshouldbechecked.

PLL Lost Lock If the phase locked loop circuitry detects a mismatch in desired speed this hit will occur.Itwillonlyberecorded.Thestateofthephaselockisalsomonitoredevery75us.

CAUSEBecauseofnoiseandotherdisturbancestheclockmayvaryslightlyinspeed.Nonoticeableaffectswillbefeltbytheuser.

ACTIONNoactionisrequiredifthenumberisrelativelylow(<25).Ifmany,thengroundsshouldbechecked,followedbyacheckoftheDSP.

EE Communication Errors TheprocessorisunabletocommunicatewiththeEEPROM.

CAUSEAdamagedDSPboardorEEPROMchip.

ACTIONIfoccurrencesarehigh(>10)replacetheDSPboardorrunasitis.ConsolewillnotbeabletosavedataiftheDSPisfaulty.

EE Access Errors AwritetotheEEPROMwasnotacknowledgedin30msorawriteverifyfailed.

CAUSE•PowerremovedwhilewritingtoEEPROM.•AdamagedDSPboardorEEPROMchip.

ACTIONIfoccurrencesarehigh(>10)replacetheDSPboardorrunasitis.ConsolewillnotbeabletosavedataiftheDSPisfaulty.

IC - No AC Errors Thefrequencydetectioncircuitrydidnotdetect60hzor50hz.Theinclinewillstilloperatehoweverusingthedefaultparametersfor60hz.

CAUSEPowercyclingoradamagedDSPboard.

ACTIONIfoccurrencesarehigh(>10)checktheDSPboard.

Machine Health Info


135

Appendix


LABEL DESCRIPTION

Communication Hits ThereceivemoduleoftheDSPdetectedanerrorinadatapacket.Thispacketwillbediscardedbutthesystemwillcontinuetofunction.

CAUSEAdamagedorintermittentconsolecablecancausethese.Afewofthesearenormal because of occasional power sequencing differences or drive and incline motornoise.

ACTIONChecktheconsolecableandwiring.Makesureallgroundsaresolid.

Communication Noise Hits ThereceivemoduleoftheDSPdetectednoiseonthecommunicationline.Ifthenoisedidnotcauseachecksumerror,everythingcontinuednormally.Ifitdidthenthepacketwasdiscardedbutthesystemcontinuedtofunction.

CAUSEAlessseverecasethanabovebutwiththesamecauses.

ACTIONChecktheconsolecableandwiring.Makesureallgroundsaresolid.

Dynamic Start I-Hits Excessivemotorcurrenthasbeendetectedwhilethemotorisstarting.Anappropriate motor rpm drop will be commanded to try to keep the current within itslimit.TheDSPwillcontinuemonitoringtheconditionforfourseconds.Iftheexcessivecurrentisnotreducedtoanacceptablelevel,themotorwillstop.

CAUSEAstalledbeltcondition,possiblybeingtheresultofawornbelt/deck.

ACTIONCheckforanexcessivelywornbelt/deck.

Hardware I-Hits Ahardwarecurrentlimitoccurred.Nosoftwareactionoccursotherthanrecordingtheeventamaximumofonceevery250ms.Thehardwarelimitsthecurrentonacyclebycyclebasis.

CAUSEAnexcessivemotorcurrentover24awillcausethishit.

ACTIONAsintheabove“HardwareI-Trips”condition,checkthatthemotorwiringisnotbeingshorted.Checkthatthemotorplugandallitswiresareseatedproperlyandthatthereisnocontaminationonthepins.Runthephasetesttoisolateatroubledphase(s).

Line I-Hits Thelinecurrentexceededtheallowablelimit.Anappropriatemotorrpmdropwillbecommandedtotrytokeepthecurrentwithinitslimit.

CAUSEExcessive motor current draw caused by a bad belt/deck or a high user weight combinedwithahighspeed.



136

Appendix


LABEL DESCRIPTION

Phase I-Hits The largest individual peak phase current has exceeded 17a; this is relatively quicklimit.Anappropriatemotorrpmdropwillbecommandedtotrytokeepthecurrentwithinitslimit.

CAUSEUsers intentionally stomping on the belt can cause these and are considered normal.Excessivemotorcurrentdrawcausedbyabadbelt/deckorahighuserweightcombinedwithahighspeed.


RMS I-Hits Theeffectivemaximumrmscurrentofthemotorhasexceeded21.3a.Anappropriate motor rpm drop will be commanded to try to keep the current within itslimit.

CAUSEExcessive motor current draw caused by a bad belt/deck or a high user weight combinedwithahighspeed.


Dynamic I-Hits One of the above occurred:

Line I-Hits

Phase I-Hits

RMS I-Hits

IC – Neg Switch Errors Thenegativeswitchlogicreportedanerror.Becauseofnoiseandthermaltrips,afewoccurrencesareacceptable.

CAUSE An invalid combination of incline switch states occurred, or a timeout occurred goingtoorawayfromthenegativeswitch.

ACTIONIf a substantial amount (>9) of these are recorded, the negative switch and associatedwiringshouldbechecked.

IC – Home Switch Errors TheHomeSwitchlogicreportedanerror.Becauseofnoiseandthermaltrips,afewoccurrencesareacceptable.

CAUSEAn invalid combination of incline switch states occurred or a timeout occurred goingtoorawayfromtheHomeSwitch.

ACTIONIf a substantial amount (>9) of these are recorded, the Home Switch and associatedwiringshouldbechecked.


137

Appendix


LABEL DESCRIPTION

Motor Minutes Motorrunningtimeinminutes.

Power & External Resets HowmanytimestheDSPhasgonethougharesetoperation.

COP Resets Theinternal“computeroperatingproperly”watchdogtimerdetectedanabnormalconditionandcausedthesystemtoreset.Thiscanonlyoccurwhenreprogrammingaboardortestingatthefactory.Onlyafew(<5)shouldeverbeseen.

Phase V Max ThehighestmagnitudepeakcurrentmeasuredinphaseV.

Phase W Max ThehighestmagnitudepeakcurrentmeasuredinphaseW.

Phase U Max ThehighestmagnitudepeakcurrentmeasuredinphaseU.

NOTE: The above three should always be approximately the same within approximately1a.Ifnotthemotorphasewiringandconnectorsshouldbechecked.

Bus Voltage Thehighestvoltagemeasuredonthebus.Anythingover400visapossibleindicationofusersdrivingthebeltathigherinclineandhigherspeed.

Max Frequency Delta

Max Amplitude Delta

A/D 3 Max

A/D 6 Max

A/D 7 Max

Misc Item 1

Misc Item 2

Misc Item 3

Thesearediagnosticsforthemanufactureronly.

Maximums


138

Appendix

Lift Motor Information (TR Only)

User Interface

Object Table

LABEL DESCRIPTION

Readouts Incline Range and Lift Time:Displaytheinclinerangesandlifttimefrom-3.0%to15.0%.Ifaproductonlysupportspositiveinclinetherangewillshowupas0.0%to15.0%.Themaximumallowableinclinecanbesetbelow15.0%usingthe“Max%Incline”configurationsettingintheManager’sConfiguration2screen.LiftTimeshowsthetotallifttime(LiftMotorontime)reportedbythemotorcontroller.Theliftranges(i.e.0.0%Time)showstheamountoftimeauserworkedoutinthegiveninclinerange.





139

Appendix

Belt / Deck Information (TR Only)

User Interface

Object Table

LABEL DESCRIPTION

Statistics Readouts Total Treadmill Hours:Displaythetotaloperatinghours.

Total Treadmill Miles:Displaythetotaloperatingmiles.

Belt Hours:Displaythetotalbeltoperatinghours.

Belt Miles:Displaythetotalbeltoperatingmiles.

Event History Displaysalleventshistoryinformationforbeltanddeck.




NOTE:Thistestwillreportanybeltwearnotificationsviathepopupmessage“PleaseCheckBelt/DeckforSignsofExcessiveWear”.Thismessageisclearedonceithasbeenshown.TheEventHistorywillreportanyeventsthatcanledtoanotification.Theeventcanbeeitheraslowdown(whereuserwouldseethe“UnabletoAttainTargetSpeed”)oradistance(mileage)basedevent(whereanotificationisissuedduetohighBeltMiles).Whenabelt/deckisreplaceda“ReplacingBeltandDeck”proceduremustbesubmittedintheMaintenancescreenforthebeltwearnotificationfeaturetocontinuetoworkproperly.


140

Appendix

Date and Time Information

User Interface

Object Table

LABEL DESCRIPTION

Date and Time Information Calendar: Shows the current system date and time

Mode:Indicatesthecurrenttimeformatin12Houror24Hourmode.

AM/PM:IndicatesthecurrenttimeinAM/PM.

Time Zone: Shows the set time zone for the system and allows user to view all availabletimezonefromthedropdown.

Cancel Button ClosestheDateandTimeInformationpop-upandreturnstothepreviousscreen.


141

Appendix

System Errors

User Interface

Object Table

LABEL DESCRIPTION

Error Readouts Error #: Displays the number of the error log (last/most recent error log is shown at the topofthelist,firsterrorlogwillbeError#1).

Type: Displays the type of error (see Details section for an expanded description of the errortype).

Occurrences:Displaysthenumberofoccurrences.

Time Stamp:Displaysthedateandtimeoftheoccurrederrors(firstandlasterroriftherehasbeenmorethanoneoccurrenceoftheerror).

Total System Errors:Displaysthetotalerrorsregisteredbythesystem.

Details:Displaytheerrordetails.Notethatmanydetailsareforengineeringuse.Usethe scroll bar to the right of this area to scroll down to see additional details, if applicable

Clear System Errors Button Displays a pass code entry pop-up and allows the user to enter a correct pass code entry.Thiswillallowthesystemtowipeoutallregisteredsystemerrors.





142

Appendix

Maintenance Information

User Interface

Object Table

LABEL DESCRIPTION

Maintenance Information Readouts

Repair #:Displaysthenumberofrepairs.

Type:Displaysthetypeofrepairs.

Time Stamp:Displaysthedateandtimeoftheoccurredrepairs.

Total System Repairs:Displaysthetotalrepairsregisteredbythesystem.

Details:Displaytherepairdetails.

Clear System Repairs Button

Displays a pass code entry pop-up and allows the user to enter a correct pass code entrywhichwillallowthesystemtowipeoutallregisteredsystemrepairs.

Export To USB Button ExportalltheinformationonthescreentoaUSBstickina.CSV(commaseparatedvalue)file




143

Appendix

Usage Log Report

User Interface

Object Table

LABEL DESCRIPTION

Usage Log Readouts MPH: Displaysandreportrecordsofspeedusageinmileperhourfrom0–15MPH.

Weight 0 – 400: Displays and report records of weight usage ranges from 0 – 400 pounds.




NOTE:Thislogreportsthenumberofminutesaworkouthasbeenusedatagivenspeedrange(i.e.2mph=workoutspeedsbetween1.1mphto2.0mph,3mph=2.1to3.0mph,etc.)atagivenuserweight.


144

Appendix

Channel Usage Log

User Interface

Object Table

LABEL DESCRIPTION

Channel Usage Log Readouts

Channel Index:Displaysandreportrecordsofallavailablechannels.

Channel Name:Displaysandreportthename/numberofallavailablechannels.

Hours Watched: Displays and report the number of hours watched per channel for all availablechannels.

Reset Hours Button Resetsallthehourswatchedtozero.





145

Appendix

ConfigurationMenu

User Interface

Object Table

LABEL DESCRIPTION

Manager Button DisplaystheManagerConfiguration1Screen.

Manufacturer Button DisplaysthePassCodeEntryscreen.IfavalidpasscodeisenteredthesystemwilldisplaytheManufacturer’sConfigurationscreen.

Video / FM Radio Button DisplaystheVideo/FMRadioConfigurationMenuScreen.

Custom Workouts Buttons DisplaystheCustomWorkoutsSetupScreen.

TouchScreenConfigurationButton

ExecutesanddisplaystheTouchScreenCalibrationprogram.

Export / Import Settings Button

DisplaystheExport/ImportSettingsScreen.

VIVO / Network Button DisplaystheNetworkConfigurationScreen.

Clock Button DisplaystheDateandTimeInformationScreen.

Create Your Own DisplaystheCreateYourOwnScreen.




146

Appendix

ManagerConfiguration1

User Interface

Object Table

LABEL DESCRIPTION

Language Allowsthemanagertoselect,specify,re-order,enable/disableandsetthelanguageflagfortheuser.

Units Allowsthemanagertosettheunitofmeasurementforthesystem.NotethatiftheunitsarechangedtheMaximumandMinimumSpeedsettingsareresettodefaults.

Maximum Speed (TR only) Allowsthemanagertosetthemaximumspeedforthesystem.

Minimum Speed (TR only) Allowsthemanagertosettheminimumspeedforthesystem.

Workout Duration Configuration

Basic Mode: AllowsthemanagertosettheMaxWorkoutDuration(1–99).

Advanced Mode:•Peak Time Max Workout Duration: Allows the manager to specify the max workout durationinminutesduringpeaktime.

•Off-Peak Time Max Workout Duration: Allows the manager to specify the max workout durationinminutesduringoff-peaktime.

•Peak Time 1 & 2: Allow the manager to specify the starting hour/minutes in the AM/PM

StandByConfiguration Inactivity Timer: Allows the manager to enable/disable and set the Inactivity Timer in hoursandminutes.

Auto Off / Auto On: Allows the manager to specify the AM/PM hour and minutes at whichtheunitshouldbeautomaticallyturnon/off.


Defaults Button Resetallsettingstothemanufacturer’sdefaults.

Forward Button DisplaysManager’sConfiguration2Screen.


147

Appendix

User Interface

Object Table

LABEL SPECIFICATION

Activity Zone 3 Speed Keys (TR only)

AllowsthemanagertoenableanddisabletheActivityZonespeedkeys(TRonly).

Fit Test Plus Allowsthemanagertoturnon/offtheFitTestPlusprograms.IfOntheMilitray,GerkinandPEBfittestworkoutsareshownandavailabletotheuser.

Virtual Trainer Allowsthemanagertoturnon/offthevirtualtrainerfeature.

System Sounds Allowsthemanagertoturnon/offthesystemsounds.

Pause Time Allowsthemanagertosetthepausetimeoftheworkoutprogramfrom1–60minutes.

Max % Incline Allowsthemanagertospecifythemaximuminclinepercentage.

Marathon Mode AllowsthemanagertoenableordisabletheMarathonModeduringaworkoutsetup.

Telemetry Allowsthemanagertoenableordisablethetelemetryreading.

Accel Rate 3 Allowsthemanagertospecifytheaccelerationrateofthebelt(TRonly).Range=1to5where1=sloweraccelerationrateand5isfasteraccelerationrate.

Decel Rate 3 Allowsthemanagertospecifythedecelerationrateofthebelt(TRonly).Range=1to5where1=slowerdecelerationrateand5isfasterdecelerationrate.

Custom Message Allows the manager to enable or disable the scrolling custom message on the Attract Screen.Setup button: Displays the custom message setup screen and allows the managertoaddnewormodifyexistingcustomscrollingmessage.

Stride Sensor Allowsthemanagertoturnon/offthestridesensor(TROnly).

Program Timeout Allowsthemanagertospecifythetimeoutofaworkoutprogramfrom20–255seconds.

BeltNotificationIcon Allowsthemanagertoenableordisablethebeltnotificationicon(TRonly).

iPod® /Nike+ Allows the manager to enable or disable the iPod®/Nike+feature.

Defaults Button Resetallsettingstothemanufacturer’sdefaults.



ManagerConfiguration2

User Interface

Object Table


148

Appendix

Manufacturer’sConfiguration

User Interface

Object Table

LABEL DESCRIPTION

Drive Ratio Usedtochangeorenterthedriveratiobetween7000-9999.

Smart Stop Adjust (TR only) Used to change or enter the smart stop (Stride Sensor trigger point) adjustment between0–100(TRonly).Default=0.

LifePulse® Used to turn on/off the LifePulse®detection.

Model Usedtoselectthemodelnumberfortheunit.

CC UsedtoturntheCC(ClosedCaptioning)on/off.

DEBUG INFO Usedtoturnon/offdebugginginformation.

Advanced Button Displays the pass code entry screen and if a correct pass code is entered, the system willdisplaytheAdvanceManufacturer’sConfigurationScreen.

Exit Application Button Shutdowntheconsoleapplicationandreturntothedesktop.

Clear Accum Data Button Usedtocleartheaccumulateddatainthesystem.

ReinitConfigDataButton Usedtoreinitializethesystemconfigurationdataandresettheconsolewhentheoperationiscompleted.

Clear System Errors Button Usedtoclearallsystemerrors.


NOTE:Theseoptionsaremainlyforproductionuseandshouldn’tbeusedunlessdirectedtodoso.


149

Appendix

Manufacturer’sConfiguration

User Interface

Object Table

LABEL DESCRIPTION

Mem Load Reset Count Displaysthememoryloadresetcount.

Drive Ratio Usedtochangeorenterthedriveratiobetween7000-9999.

Smart Stop Adjust (TR only) Usedtochangeorenterthesmartstopadjustmentbetween0–100(TRonly).

Belt Minutes Usedtoread,changeorenterthebeltminutes(TRonly).

LifePulse® Used to turn on/off the LifePulse®detection.

Model Usedtoselectthemodelnumberfortheunit.

CC UsedtoturntheCC(ClosedCaptioning)on/off.

DEBUG INFO Usedtoturnon/offdebugginginformation.

HC12 Reset Count DisplaystheHC12resetcount.

LP PC Communication TurnstheLP(LifePulse)PCCommunicationon/off.

LP UsedtoselecttheLifePulseRecordorPlaybackmode.

Advanced Button Displays the pass code entry screen and if a correct pass code is entered, the system willdisplaytheAdvanceManufacturer’sConfigurationScreen.


150

NOTE:Theseoptionsaremainlyforproductionuseandshouldn’tbeusedunlessdirectedtodoso.

Object Table

LABEL DESCRIPTION

Exit Application Button Shutdowntheconsoleapplicationandreturntothedesktop.

Clear Accum Data Button Usedtocleartheaccumulateddatainthesystem.

ReinitConfigDataButton Usedtoreinitializethesystemconfigurationdataandresettheconsolewhentheoperationiscompleted.

Clear System Errors Button Usedtoclearallsystemerrors.

Erase Local EEPROM Button

Used to erase the Electrically Erasable Programmable Read-Only Memory (Application settings and logs stored in the console) and automatically reset the console after the operationiscompleted.

Erase External Serial EE Button

Used to erase the frame Electrically Erasable Programmable Read-Only Memory (Application settings and logs stored in the motor controller) and automatically reset the consoleaftertheoperationiscompleted.

Clear Usage Log Button UsedtocleartheusagelogunderInformationMenu.



Appendix

Manufacturer’sConfigurationEngage / Inspire Console Diagnostic:M051-00K65-A003

151

Appendix

Video/FMRadioConfigurationMenu

User Interface

Object Table

LABEL DESCRIPTION

Video AllowsthemanagertoenableordisabletheTVVideo.

Video Setup Button DisplaystheVideoSetupScreeniftheVideooptionisenabled.

Video Channel Favorites Button DisplaystheVideoChannelFavoritesScreeniftheVideooptionisenabled.

Video Channel Name / Sort Button

DisplaystheVideoChannelName/SortScreeniftheVideooptionisenabled.

Secure Channel Button DisplaystheSecureChannelScreeniftheVideooptionisenabled.

Promo Channel Setup Button DisplaysthePromoChannelSetupScreeniftheVideooptionisenabled.

FM Radio Setup Button DisplaystheFMRadioSetupScreen.





This will be changed to Media Center Configuration Menu

M051-00K65-A003

152

Appendix

Video Setup Screen

User Interface

Object Table

LABEL DESCRIPTION

Picture Setup Allows the manager to setup the TV picture by adjusting the Brightness, Contrast, SaturationandHueusingthearrowkeysortheDefault.

Channel Up/Down Allowsthemanagertoscrollup/downtoavailablechannel(s).

Video Format Allows the manager to change the video format by selecting the country, format of the tuner(NTSC,PAL,etc.)andsoundformat.

Antenna Setup AllowsthemanagertoselecteitherCableorAirfortheantennasource.

Channel Setup AllowsthemanagertoselecteitherAutoorManualFrequencyTuning.

Start Button: Enables if the Auto radio button is selected and allows the manager to selectStarttoautomaticallydetecttheavailablechannel(s).

Frequency Tuning Button: Displays the Frequency Tuning Screen and allows the manager to scan for available frequency and automatically add channel(s) or manually add/deletechannel(s).

Add Button:Allowsthemanagertoaddachannel.Thisbuttonwillenableonlyifthechannelisnotalreadyinthelistofaddedchannel(s).

Delete:Allowsthemanagertodeleteachannel.Thisbuttonwillenableonlyifthechannelisalreadyaddedinthelistofavailablechannel(s).

Audio Only:Allowsthemanagertoturnonaudioonlyfortheselectedchannel.




153

Appendix

Channel Name / Sort Setup Screen

User Interface

Object Table

LABEL DESCRIPTION

Channel Name / Sort Setup Ch # / Sort Order: Displays the channel number in a sort order from low to high and allowsthemanagertoselecttheradiobuttonandenterthenameofthechannel.

Name: Allowsthemanagertoenterthenameofthechannel.

Presorted Ch #:Displaysthechannel#thatarepresortedbythesystem

Valid:Allowsthemanagertocheckforvalidorunchecktheboxforinvalidchannel.Invalidchannelwillnotbedisplayed.

Page Up/Down:Pageupanddownthelistofsortedchannel(s).

Enter Name Button Displays the Enter Channel Name keyboard and allows the manager to enter a channel name.

Clear Name Button Clearthenameoftheselectedchannel.

OK Button Goesbacktothepreviousscreenandsavesallchanges.

Cancel Button Goesbacktothepreviousscreenandcancelsallchanges.


154

Appendix

Secure Channel Setup Screen

User Interface

Object Table

LABEL DESCRIPTION

Secure Channel Allowsthemanagertoenable/disablethesecurechannel.

Channel Allows the manager to specify the secure channel number or change an existing secure channel.

Button Name Allowsthemanagertospecifythenameofbutton.Bydefault,thenameissetto“SecureChannel”.

Password Allows the manager to specify/change a password required to view the secure channel orenable/disablethepasswordprotection.




155

Appendix

Promo Channel Setup Screen

User Interface

Object Table

LABEL DESCRIPTION

Promo Channel Setup Allowsthemanagertoenable/disablethepromochannelsetupfeature.

Promo Channel Allowsthemanagertochange/specifythepromochannelnumber.

Advanced Promo Channel Settings

Allows the manager to select Promo Channel as the starting channel or specify the time limitforreturningtothepromochannelinminutes.




156

Appendix

FM Radio Setup Screen

User Interface

Object Table

LABEL DESCRIPTION

FM Radio Setup Allowsthemanagertoenable/disabletheFMradio.

Preset Setup Allows the manager to enable/disable the preset or to set the preset to Auto or Manual setup.

•Start:PullsthepresetchannelautomaticallyiftheAutooptionischecked.•Manual: Allows the manager to manually select the add/delete button, to add or delete apreset.•Ch UP/DOWN arrow keys:ScanstheavailableFMradiofrequencies.

Back Button Goesbacktothepreviousscreenandsavesallchanges.

Main Menu GoesbacktotheSystemOptions–MainMenu.


157

Appendix

Custom Workouts Screen

User Interface

Object Table

LABEL DESCRIPTION

Password Allows the manager to enable/disable the password protection for gaining access to the customworkoutprograms.

•View button:Viewsthecurrentpassword.•Change button:Allowsthemanagertochangethecurrentpassword.

Enter Name Button Displays the Enter Channel Name keyboard and allows the manager to enter a channel name.




158

Appendix

Export / Import Settings

User Interface

Object Table

LABEL DESCRIPTION

Settings Allows the manager to select All Settings or TV and Radio Settings Only to be exported toorimportedfromaUSBstick.

•Export Setting To USB Stick Button: Exports all settings or TV and Radio Settings OnlytotheinsertedUSBstick.•Import Settings From USB Stick: Imports all Settings or TV and Radio Settings Only fromtheinsertedUSBstickandrestoresthosesettingstothesystem.Oncetheimportoperationiscompletedthesystemwillautomaticallyberebooted.




159

Appendix

Create Your Own Screen

User Interface

Object Table

LABEL DESCRIPTION

Create Your Own Allowsthemanagertoenable/disabletheCreateYourOwnworkoutprograms.




160

Appendix

NetworkConfiguration

User Interface

Object Table

LABEL DESCRIPTION

Network AllowsthemanagertoselecteitherVIVO,OtherorNoneforthenetworksetup.

Edit VIVO Preset Allows the manager to enable/disable the ability to edit VIVO preset if the VIVO Network isselected.

VIVO Lockout Allows the manager to enable/disable the VIVO Lockout feature if the VIVO Network is selected.

Other AllowsthemanagertospecifyotherastheNetworkofchoice.

None Allowsthemanagertospecifynonefornonetworkisavailable.




161

Appendix

Clock Setup (Date and Time Information)

User Interface

Object Table

LABEL DESCRIPTION

Date and Time Information Calendar: Shows and allows the manager to change the current system date and time

Mode: Indicates and allows the manger to change the current time format in 12 Hour or 24Hourmode.

AM/PM:IndicatesandallowsthemanagertochangethecurrenttimeinAM/PM.

Time Zone: Shows the set time zone for the system and allows the manager to view or changethetimezone.

OK Button Acceptallthechangesandreturnstothepreviousscreen.

Cancel Button ClosestheDateandTimeInformationpop-upandreturnstothepreviousscreen.


162

Appendix

Maintenance

User Interface

Object Table

LABEL DESCRIPTION

Replacing Belt and Deck Allowsthetechniciantoindicatethereplacementofbeltanddeck(TRonly).

Replacing Console Allowsthetechniciantoindicatethereplacementoftheunit’sconsole.

Replacing Motor Controller Allowsthetechniciantoindicatethereplacementoftheunit’smotorcontroller(TRonly).

Replacing GBC Allows the technician to indicate the replacement of the unit’s generator break controller (NonTRonly).

Replacing Stop Switch Allowsthetechniciantoindicatethereplacementoftheunit’semergencystopswitch.

Replacing Overlay Bezel Allowsthetechniciantoindicatethereplacementoftheunit’soverlaybezel.

Replacing Main Motor Allows the technician to indicate the replacement of the unit’s main motor (TR Only)

Replacing Lift Motor Allows the technician to indicate the replacement of the unit’s Lift Motor (TR only)

Telemetry Allowsthemanagertoenableordisablethetelemetryreading.

Submit Button Submitandsavethemaintenanceactivitytothemaintenancelog.



NOTE:Forproperoperationofsomefeaturestechniciansmustsubmitrepairsonthisscreen(i.e.Mustsubmita“ReplacingBeltandDeck”togetthebeltwearnotificationfeature(seeBelt/DeckInfo)toworkproperlyaswellasthebelthoursandmileagereadouts).


163

M051-00K65-A003

MESSAGE DESCRIPTION POSSIBLE CAUSE SECTION PAGE

“Errorlaunchingapplication.Pleasereload using USB memorystick.”

SBC application was unabletolaunch.

Application missing Reload application using USB setup utility.

"Interface board in Boot mode - please start Flash update now"

MIB application checksum error detected.

Software update was interrupted via a power failure or bad connection with the USB stick, PC update application or widget box.

Re-flash/updatetheMIBsoftware.

"Motor controller in Boot mode - please start Flash update now"

Motor controller checksum error detected.

Software update was interrupted via a power failure or bad connection with the USB stick, PC update application or widget box.

Re-flash/updatethe motor controller software.

"Stuck hard key detected"

Indicates at least one hard key on any of the keypads is being detected as closed when the MIB initially powersup.Intentis to detect a faulty keypad and prevent any subsequent key events from being sent to the SBC.

One or more keys are either shorted closed or are being held down at power up.

Replace keypad(s) or if user is purposely holding down a key at power up then cycle power to recover.

"Interface board not detected"

Communications between the SBC and MIB board were not able to be established.

Faulty connection between SBC and MIBboards.

Check board to board connection.

"Module communicationerror" 2

MIB (or Achieve console) is unable to communicate with the motor controller module(i.e.modulenocommunication).

Power up communication test to base failed or lost communication with base.

Check/replace cabling down to the M/C.

Appendix

Error / Info Messages

Overview

The following table lists the error or informational messages a user or service can see including a description of what they mean.AppliestothecurrentElevationbasedtreadmillproducts(Engage,Inspire).Thisinformationisintendedtobeusedintheservicemanualswithinputfromthesoftwareandhardwaregroup.ItisbasedonthecurrentSBC(v1.10),MIB (w/ RevEsupport)andDSPmotorcontrollersoftwarereleases.

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M051-00K65-A003


"Module communicationerror.RetroFit DSP MC detected”

SBC has detected thata“RetroFit”DSP motor controller hasbeeninstalled.RetroFit controllers are not to be used on Elevationproducts.

SBC has detected that an invalid DSP motor controller has beeninstalled.

Replace the M/C with one with the correct assemblynumber.

“Editbaseassemblyserial#”

This is a prompt to enter in the base serial number and then the product type.

The prompt will occur if there is no validconfigurationdata in both the SBC registry and themotorcontroller.This will also occur if both the console and motor controller are replaced at the same time.

Enter the base serial number located on the label attached to the frame and set the correct product type whenprompted.

“Maintenance”atthetop of the screen

This is a data entry prompt that willaskthetech.to select either “ReplacingConsole”or“ReplacingMotorController”.

This prompt occurs if the basic configurationdatastored in both the registry and motor controller doesn’t match.Thiswilloccur if the console or motor controller is replaced with assemblies that already have configurationdatastored in them (These assemblies are typically sent out with blank basic configurationdatain which case you wouldn’t see this prompt).

If you replaced the console, then select “ReplacingConsole”.Otherwise select “ReplacingMotorController”.

“Pleasepedal” 2 Initialization does not finish(stuckinthismode) due to lack of communication between MIB & motor controller.

Most likely: JW3 installed on DSP M/C.Less likely: Broken Rx/Tx lines in cable, MIBorM/C.

RemoveJW3.Check/replace cabling down to the M/C.

Appendix


165

M051-00K65-A003


“Notifymaintenancecommunication timeout (motor controller)” 2

Lost communications with the motor controller(i.e.modulecommunication timeout).

Broken communication lines, JW3 installed on DSPM/C.

RemoveJW3.Check/replace cabling down to the M/C.Vibrationiscausing intermittent operation from loose connection.

“Notifymaintenancemotor controller error (thermalshutdown)”

Motor controller shut down due to excessive temperature.

M/C compartment airflowrestricted,hotair is being blown on it, located in direct sunlight.Excessively worn belt/deck.

Clean the M/C compartment, insure adequate ventilation is available and it is not being heated by a heating register, move from direct sunlight.Replacebelt/deck if power levelisexcessive.

“Notifymaintenancemotor temperature trip”

Motor shut down due to excessive temperature.

Faulty/intermittent thermal switch in motor.M/C compartment airflowrestricted,hotair is being blown on it, located in direct sunlight.Excessively worn belt/deck.

Check motor thermal switchconnections.Check clean the M/C compartment, insure adequate ventilation is available and it is not being heated by a heating register, move from direct sunlight.Replacebelt/deck if power levelisexcessive.Replace motor if error keeps occurring after the motor has cooled down and no other solution has worked.

“Warning-stepoff belt, maximum voltagetrip”

Excessive belt motor busvoltagedetected.

User is driving the beltwithsufficientenergy to raise the bus voltage, most likelyathighinclines.Input line has voltage surgeproblems.

Instruct the user to not drive the belt at high inclines or use a lowerincline.Contact an electrician to diagnose/correct a powerlineproblem.

“Notifymaintenancemotor controller error (hardware current trip)”

Excessive motor currentdetected.

Excessive motor current caused by a failed motor, intermittent motor or motorconnection(s).A possible but unlikely cause would be a severely worn belt/deck.

Verify that all motor connections and cablesaresolid.Ifstart-up power is very weak a phase may befaulty.Performa phase test to verify the system or diagnoseaproblem.

Appendix


166

M051-00K65-A003


“Notifymaintenancemotor controller error (low voltage detected)

Non-fatalerror.Line voltage dropped toaninsufficientlevelto sustain proper operation.

Line cord is not securely plugged into thewallormachine.Loose/intermittent receptaclewiring.Machine is not plugged into a proper dedicatedline.Incoming voltage is fluctuating,dippingtoaninsufficientlevel.

Confirmthatthecordis solidly plugged into the wall receptacle andthemachine.Contact an electrician to diagnose/correct a powerlineproblem.

“Startuperror” Non-fatalerror.No/low motor current is detected at start-up.

Motor unplugged or connectorloose.A possible but unlikely cause would be the user driving thebeltatstartup.

Verify that the motor connections aresolid.Performa phase test to verify the system or diagnose a phase problem.

“Motordisabled” Non-fatalerror.The M/C has detected an open stop switch when operating that the console has not detected.

An intermittent console/motor controller cable or emergency stop switch.

Confirmthatallconnections are solid, all wires are properly seated into the connector and the cable is not pinched and being shorted/open.Verifyproper operation of the emergency stop switch.

“Inclineinoperative-continueifdesired”

Indicates the incline system has a problem but system can still be used.OccursifDSP reports a lift Home Switch error or timeouterror.

Improper home or decline switch operation / adjustment / cable.Inclinemotor connection unplugged/loose.A possible but unlikely cause would be incline motor overheating from excessive operation.

Verify that all motor and switch connections and cablesaresolid.Verify incline switch operation using diagnostic switch LEDS(LED9&10).Verify incline motor activation using diagnostic LEDS (LED4&5).Readjust or replace switches/cables.

Appendix


167

M051-00K65-A003


“Unexpectedinterfaceboardreset”

Indicates the MIB board has gone through an unexpectedreset.

MIB board lost and then regained powerorwasreset.This can be caused by electrostatic discharge.

Verify connection from console’s rear plastic to 92353 Polar Boardistight.Verifythat the lower right screw (viewed from rear) that holds the console to the base is tight, has a star washer, and is 8mm long.

“ActivityZonekeypadnotdetected”

The absence of a loopback signal indicates the Activity Zone keypad is not properlyconnected.

If it used to work, and now doesn’t, it is likely due to an intermittent or unplugged Activity Zoneconnector.If it has not worked since the console or MIB was replaced (which automatically enables the Activity Zone detect feature), the console - Activity Zone cable may be outofdate.

Confirmthatallconnections are solid, all wires are properly seated into the connector and the cable is not pinched.If the console (or MIB) has been replaced with a newer, larger MIB (“A080-92334-0001”on Polar Board silk screen), verify that the Console Activity Zone cable is AK65-00043-0001, Rev A2orlater.Replacecable if it is AK65-00043-0000 or AK65-00043-0001,RevA1.

“Emergencystopdrivetrip”

MIB EStop drive circuitry detects a shortedcondition.

Tether / magnet loose or not installed; Poly-resettable fuse (PTC2) or Q5 on MIB are open; Over current condition on emergency stop relay onmotorcontroller.

Verify tether / magnet are properly replaced /installed.Replace MIB.Replace Motor Controller.

"Console over temperature”

MIB has detected an internal console temperature of over 50degreescelsius.

Console vents may have been blocked byatowel,etc.

This is an informational message and is intended for engineeringonly.

"Network voltage driver trip"

MIB voltage drive circuitry to CSAFE port detected a shortedcondition.

Faulty accessory plugged into the CSAFEport.

Remove CSAFE accessory.

Appendix


168

M051-00K65-A003


“Stopkeyactivated” MIB has decoded aStopkeypress.System aborts workout.

Faulty Activity Zone keypad.

Check proper operation of keypad in diagnostics and replaceifnecessary.

“Unabletoattaintargetspeed”1

Reported if the motor controller was unable to attain the desired user’s speed after a givenamountoftime.

Line voltage low, unit overloaded; too much weight for speed requested.Worn belt and/or deck.

Check belt & deck for signs of excessive wear and replace if necessary.

"Miscellaneous interface communication error"

Typically this is reported if SBC was unable to properly activate the belt and/orinclinemotors.

Communications error with the motor controller.

See“Modulecommunicationerror”

“Workoutinitializationtime-out.Resettingsystem.....”

System was unable to enable the belt and/or incline motors while starting a workout

Communications error with the motor controller.

See“Modulecommunicationerror”

“Pleasereplaceemergency stop switch”

Emergency stop (tether) is replaced, but console still gives thismessage.

Tether / magnet loose or not installed; Poly-resettable fuse (PTC2) or Q5 on MIB are open; Over-current condition on emergency stop relay onmotorcontroller.

Verify tether / magnet are properly replaced /installed.Replace MIB.Replace motor controller.

Appendix


1 Whenuserseesthismessagethebeltspeedwilldecreaseautomatically.Ifuserisalreadyatminimumspeed(i.e.0.5mph)thenworkoutwillenterPausemode.Ifspeedismorethanonemph/kphbelowtargetspeedthenspeedisreducedby½.Ifspeedisclosertotargetwhenan“Unattained…”occursthenspeedisdecrementedbetween0.1to0.3mph/kph.

2 A simple test to determine if console is communicating with the motor controller is to cycle power and listen for beeps from the MIBboard.TheMIB will beep once after it gets power followed by three additional beeps if it can successfullycommunicatewiththemotorcontroller.ThisprocessisdonebeforethemainApplicationontheSBC is upandrunning(i.e.beforeyouseethe“Splash”screenwhichcontainstheword“initializing”onit).

Documents

95T ELEVATION SERIES TREADMILLS - GYMPART.COM...This service manual provides safe and efficient test and service procedures for the 95T Elevation Series treadmills. The service manual