FAULT DISPLAY CODES [2 of 2]
Error
40 - No Lift Motion Detected
Description: Error indicates that the incline (lift)
system on either a treadmill or EFX has been instructed to start moving and no
lift motion has been detected by the lift position monitoring system.
Possible
Causes
1.
The lower PCA lift fuse blown.
2.
The lift motor is physically jammed and unable to move.
3.
The lower PCA is bad.
4.
The lift capacitor is bad.
5.
A lift motor winding is bad.
6.
The upper PCA to lower PCA interconnect cable is bad.
7.
The upper PCA is bad.
Possible
Remedies
1.
Remove power from the unit and remove the lift fuse from the lower PCA. Measure
the fuse with an ohmmeter, the fuse should read approximately 1 ohm or less. If
the ohmmeter reading is significantly high, replace the fuse. If the fuse is
open, please refer to #3 and #4 below before you continue.
2.
Disconnect the lift motor from the lift platform (treadmill) or ramp (EFX). If
the lift tube or lift nut is jammed against the motor housing, rotate the lift
nut or lift tube away from the motor housing. If the lift was jammed, please
refer to #3 below before you continue. Calibrate the lift motor per the
appropriate service manual procedure and reattach the lift motor to the lift
platform or ramp.
3.
The lower PCA can fail in one of two modes. The lift switch could fail in an
operated condition. If this happens the lift will move (either up or down) as
soon as the unit is powered up. The typical result is that the lift will be
physically jammed as described above, it will also probably cause the lift fuse
to blow.. The lift switch may also fail in an open condition. If this happens
the lift will not operate in one direction. If either of these conditions occur
the lower PCA must be replaced.
4.
Some units use external lift capacitors, most have the lift capacitor mounted
inside the lift motor. This section for for use on units with external lift
capacitors. If the lift capacitor is shorted, the lift fuse will blow. The
capacitor may be checked for a short by disconnecting it from the lift motor
and measuring it with an ohmmeter. A good capacitor will read in the millions
of ohms. If the reading insignificantly low, replace the capacitor. Capacitors
also fail in the open condition. If a lift capacitor is open the lift motor
will try to run but will not have normal power. The capacitor may checked by
measuring the A.C voltage across the capacitor. A good capacitor will read A.C.
peak voltage an open capacitor will read A.C RMS voltage.
5.
If a lift motor winding is bad the lift will not operate in one or both
directions depending on the exact fault in the motor. The lift motor winding
may be checked with an ohmmeter. A.C lift motors will have a split winding (3
wires) D.C lift motors will have a single winding. On A.C motors both windings
must be checked. Depending on the lift motor being tested, normal winding
readings could vary anywhere between 1 and 60 ohms. Refer to the appropriate
service manual for the motor being tested.
6.
Substitute a known good interconnect cable to determine if the existing
interconnect cable is bad.
7.
Substitute a known good upper PCA to determine if the existing upper PCA is
bad.
Error
41 - Lift has not responded in Acceptable Time
Description: This error code was present in early
versions of software and is no longer being used. Should you encounter software
with an error 41, troubleshoot it in the same manner as an error 40.
Error
42 - Lift Position Value Out of Range
Description: This error code monitors the physical lift
position via a lift position potentiometer that mechanically tracks the lifts
physical position and sends a D.C. voltage back to the control system that is
converted to an eight bit digital number. This number is then used to represent
the lifts physical position. The software sets upper and lower numerical
limits. If the lift position number is found to be outside of the set limits,
error 42 will be displayed. When troubleshooting an error 42 is important to be
aware of the actual physical position of the lift when the error occurs. If the
lift is physically out of range or jammed you must first determine
why
the lift is physically out of range. When the lift is out of range the error 42
is a secondary symptom and the problem should treated as an error 40 instead of
an error 42.
Possible
Cause
1.
Bad or intermittent connection in the lift motor connector.
2.
The lift motor requires re-calibration.
3.
The lift motor potentiometer is bad.
4.
The lower PCA to upper PCA interconnect cable is bad.
5.
The lower PCA is bad. (This is a rare condition)
6.
The upper PCA is bad. (This is a rare condition)
Possible
Remedies
1.
Intermittent connections can be difficult to locate. If the error 42 conditions
are intermittent a connection is almost certainly the problem. This is
especially true if the error 42 occurs while the lift is within its normal
physical range. Carefully inspect the lift potentiometer connector, repair the
poor connection, if possible. If the intermittent connection cannot be found or
repaired, replace the lift motor. A lift calibration number of 0 or 255
indicates an open or shorted potentiometer connection. This problem could be
anywhere between the lift motor and the upper PCA. It can typically be found
and traced with an ohmmeter.
2.
Refer to the appropriate service manual lift calibration procedure for the unit
being tested. If the lift position number/physical lift position doesn’t
correspond with the service manual, re-calibrate the lift motor.
3.
If the lift calibration number is not 0 or 255 and does not increment when the
lift motor moves, replace the lift motor. A
4.
Substitute a known good interconnect cable to determine if the existing
interconnect cable is bad.
5.
Substitute a known good lower PCA to determine if the existing lower PCA is
bad.
6.
Substitute a known good upper PCA to determine if the existing upper PCA is
bad.
Error
43 - Zero Switch not found
Description: The C944 and several versions of C96X used a
lift position identification system that did not utilize a potentiometer.
Instead,
it utilized a switch that would be physically actuated by the lift when the
lift was in the zero incline position. A revolution sensor counted lifted motor
revolutions to determine subsequent lift positions. In addition two limit
switches where used to remove power from the lift motor if the lift moved
outside of its normal range. When the
unit was powered up the lift would start to hunt for the zero switches. It
would first go up 4% (maximum lowest physical position was -3%) if it did not
find the zero switch or it hit the upper limit switch, it would then go down
until did find the zero switch. When the zero switch was located it would stop,
the system would then know its physical position and be prepared to monitor the
revolution sensor. If during this power up procedure the zero switch was not
found an error 43 would be displayed.
Possible
Causes
1.
The lift position actuator does not physically operate the zero switch.
2.
The lower PCA is bad.
3.
The zero switch is bad.
Possible
Remedies
1.
There are several physical problems related to the lift platform mounting or
the plate the zero switch is mounted on that can cause the actuator knob to
miss the zero switch as it moves past. Repair the lift platform mounting,
repair or replace the lift switch mounting plate as required.
2.
The lower PCA provides a 5 VDC power source for the zero switch. You should
measure 5 VDC across the zero switch when the zero switches activated. If the
reading is significantly low, remove both wires from the zero switch and repeat
the measurement across the wires removed from the zero switch. If the reading
is still significantly low, verify the zero switch wiring. If the wiring is
intact and correctly connected, replace the lower PCA.
3.
Move the lift to position where the zero is switch is not activated and removes
power from the treadmill. Remove both leads from the zero switch and measure
the zero switch with an ohmmeter. The zero switch should read very near 0 ohms.
While measuring the zero switch with the ohmmeter, activate the switch by hand,
the reading should change to infinite (open).
If either of the above readings is significantly incorrect, replace the
zero switch.
Error
44 - Un-commanded Lift Motion
Description: The lift control system has detected that
the lift is in motion without a lift command having been issued. This can
happen in one of two ways: either the lift drive circuit has failed in a turned
on condition or the lift position sensor (lift position potentiometer or
revolution sensor) is sending an erroneous signal to the lift control circuit.
Possible
Causes
1.
Poor or intermittent connection in the lift position sensor.
2.
Bad lift position sensor
3.
Bad lower PCA.
Possible
Remedies
1.
This is the most common cause of an error 44. Verify all wiring and connections
associated with the lift position potentiometer. Repair or replace wiring or
connections as appropriate. Because of the nature of the revolution sensor an
error 44 is rarely associated with it.
2.
Operate the lift in the diagnostics while monitoring the lift position number
being displayed. The the reading is erratic and makes large changes in readings
the lift position potentiometer is probably bad. Replace the lift position
potentiometer or the lift motor if it utilizes an internal potentiometer.
3.
If there is actual lift motion without a manual or program control lift command
having been issued, replace the lower PCA.
Error
45 - Lift Moving in Wrong Direction
Description: The lift control system has detected that
the lift is moving in the opposite direction of the issued lift command.
Possible
Causes
1.
Lift Motor hysterics.
2.
Bad lower PCA
Possible
Remedies
1.
This error would typically happen when the lift was already in motion
(typically downward) when a lift command in the opposite direction (lift up)
was issued. Some motors exhibited a very long turn around time and the lift
motor would still be moving in the original direction (downward) while the
control system was attempting to move the lift in the opposite direction. If
the error 45 conditions is persistent, replace the lift motor.
2.
This is a very rare condition; if the lift moves in the opposite direction of
the issued lift command, replace the lower PCA.
Error
50 - Too Much Brake (Magnet) Current
Description: This error is associated with eddy current
EFX’s. The resistance (brake) control system constantly monitors the amount of
current being demanded by the eddy current magnet. Error 50 indicates that
amount of current being demanded by the eddy current magnet is excessive.
Possible
Causes
1.
The most common cause of this error is shorted or damaged wiring between the
lower PCA and the eddy current magnet.
2.
The eddy current magnet is bad
3.
The lower PCA is bad.
Possible
Remedies
1.
Carefully check the eddy current wiring and connections, ensure that the wires
are not shorted together or shorted to the EFX frame. Repair or replace the
damaged wiring as appropriate.
2.
Remove the wires from the eddy current magnet. With an ohmmeter, measure across
the eddy current magnets terminals. The ohmmeter should read approximately 100
ohms. If the reading is significantly low, replace the eddy current magnet.
Measure between each eddy current magnet terminal and frame ground. Both
readings should be infinite (open). If either reading is significantly low,
replace the eddy current magnet.
3.
If both the eddy current magnet wiring and the eddy current magnet are good (as
tested above), replace the lower PCA.
Error 53 - Can’t Read Target, Can’t Find Home Switch
Description: This error is associated with the 5.17 EFX.
When power is first applied to the 5.17, an arm with permanent magnets moves
from its last position to the zero resistance position. Moving to the zero
resistance position is a two-step process. First it must move forward far
enough to actuate the home switch and the move rearward to a set position (zero
resistance) by reading a
revolution
sensor on the motor driving the moving arm. It detects the actual distance
moved by counting motor revolutions. When in the correct physical positions the
arm stops and the 5.17 is ready for use. If when moving forward the zero switch
is not activated or when moving rearward a response is not seen from the
revolution sensor, an error 53 will be displayed.
Possible
Causes
1.
The F2 fuse is blown.
2.
Intermittent or damaged home switch wiring.
3.
Intermittent or damaged gear motor wiring.
4.
A bad home switch.
5.
A bad gear motor.
6.
A damaged gear motor target.
7.
A bad lower PCA.
Possible
Remedies
1.
Remove power from the 5.17. Remove the F2 fuse from the lower PCA. Measure the
fuse with an ohmmeter. The fuse should measure 1 ohm or less. If the reading is
significantly high, replace the fuse. If the F2 fuse was blown there may have
been a reason that will cause the fuse to blow again such as; damaged gear
motor wiring or a bad gear motor.
Carefully
inspect the home switch wiring for intermittent or damaged wiring or
connections. Replace or repair the wiring or connections as appropriate.
3.
Carefully inspect the gear motor wiring for intermittent or damaged wiring or
connections. Replace or repair the wiring or connections as appropriate.
4.
With the moving arm away from the home switch, remove power from the 5.17.
Remove both wires from the home switch. Check the home switch with an ohmmeter.
It should measure approximately 0 ohms. While monitor the home switch
resistance, activate the home switch by hand; the reading should change to infinite
(open). If either reading is significantly incorrect, replace the home switch.
5.
With power removed from the 5.17, remove both wires from the gear motor.
Measure the gear motor resistance with an ohmmeter; it should read
approximately 9 ohms. If the reading is significantly low or significantly
high, replace the gear motor.
6.
Visually inspect the gear motor target, if it is ripped, torn or badly
scratched, replace the target.
7.
Measure the voltage at the gear motor during the start up sequence, it should
measure approximately 12 V.D.C. The voltage would only be present between the
time the sequence was initiated and the error 53 is displayed.. If the voltage
is significantly low or absent and the F2 fuse is good (see step 1), replace
the lower PCA.
Error
54 - Target Pulses Lost During Operation
Description: This error is associated with the 5.17 EFX.
This error indicates that at some time after the initial start up sequence was
successfully completed, the gear motor was instructed to move and no response
was seen from the motors revolution sensor.
Possible
Causes
1.
The F2 fuse is blown
2.
Damaged or Intermittent gear motor wiring.
3.
Bad gear motor
4.
Damaged gear motor target
5.
Bad lower PCA
Possible
Remedies
1.
Remove
power from the 5.17. Remove the F2 fuse from the lower PCA. Measure the fuse
with an ohmmeter. The fuse should measure 1 ohm or less. If the reading is
significantly high, replace the fuse. If the F2 fuse was blown there may have
been a reason that will cause the fuse to blow again such as; damaged gear
motor wiring or a bad gear motor.
2. Carefully inspect the gear motor wiring for
intermittent or damaged wiring or connections. Replace or repair the wiring or
connections as appropriate.
3.
With power removed from the 5.17, remove both wires from the gear motor.
Measure the gear motor resistance with an ohmmeter; it should read
approximately 9 ohms. If the reading is significantly low or significantly
high, replace the gear motor.
4.
Visually inspect the gear motor target, if it is ripped, torn or badly
scratched, replace the target.
5.
Measure the voltage at the gear motor during the start up sequence, it should
measure approximately 12 V.D.C. The voltage would only be present between the
time the sequence was initiated and an error was displayed.. If the voltage is
significantly low or absent and the F2 fuse is good (see step 1), replace the
lower PCA.
Error
55 - Brake Home Switch Activated Unexpectedly
Description: This error is associated with the 5.17 EFX.
This error indicates that the home switch was activated at a time other than
the initial start up sequence. The home switch is only used to initially
position the moving arm immediately after the 5.17 has been powered up.
Possible
Causes
1.
Damaged or shorted home switch wiring.
2.
Bad lower PCA.
Possible
Remedies
1.
Carefully check the home switch wiring for possible shorts or faults to the
frame. Replace or repair the wiring as appropriate.
2.
If the lower PCA is applying a constant 12 V.D.C. to the gear motor, replace
the lower PCA.
