FAULT DIAGNOSIS
HORIZON FITNESS TREADMILL
Diagnosis Process
The following steps are provided
as routine checkpoints when diagnosing problems on a Horizon Fitness treadmill.
If followed correctly, these checkpoints should help diagnos the majority of problems that may be encountered.
1. Proper supplying
power to treadmill.
# Make sure the treadmill is not on an extension cord or surge protector. Extension cords and surge protectors create energy loss, which prevents proper voltage from being supplied to the treadmill.
# Make sure the treadmill is on a dedicated circuit. Horizon Fitness recommends a 0 amp dedicated circuit, but a 15 amp dedicated circuit may be sufficient.
#Make sure that proper voltage is being supplied from the wall outlet.
# Make sure the treadmill is not on an extension cord or surge protector. Extension cords and surge protectors create energy loss, which prevents proper voltage from being supplied to the treadmill.
# Make sure the treadmill is on a dedicated circuit. Horizon Fitness recommends a 0 amp dedicated circuit, but a 15 amp dedicated circuit may be sufficient.
#Make sure that proper voltage is being supplied from the wall outlet.
Hazardous voltages will be tested
in the following procedure. Exercise
extreme caution when performing these procedures. Do not connect or disconnect any wiring, connectors, or other
components with the power applied to the treadmill.
#Disconnect the treadmill power
cord from the wall outlet. Using an AC voltmeter, verify that the proper AC voltage is present at the wall outlet.
Nominal 10 volts AC may vary between approximately 105 volts AC and 135 volts
AC. If the AC voltage is missing or
incorrect, check the AC service or consult an electrician.
2. Proper Wiring
# Verify that all wires are secure and attached in the correct position.
# Verify that there aren’t any pinches or cuts in any of the wires, especially the console cable connecting from the motor control board to the upper board. Replace any wires that are pinched or cut.
# Verify that all wires are secure and attached in the correct position.
# Verify that there aren’t any pinches or cuts in any of the wires, especially the console cable connecting from the motor control board to the upper board. Replace any wires that are pinched or cut.
3. Proper Motor
Function
# Verify that the treadmill is properly lubricated and drive motor is operating at the proper amperage rating. To verify the current draw, place a clamp meter around the red motor wire. If a clamp meter is not available, an additional wire harness can be produced to measure amperage with a standard voltmeter.
# Verify that the treadmill is properly lubricated and drive motor is operating at the proper amperage rating. To verify the current draw, place a clamp meter around the red motor wire. If a clamp meter is not available, an additional wire harness can be produced to measure amperage with a standard voltmeter.
# Remove the brush covers on the
drive motor and inspect the brushes and the motor commutator for any uneven wear. If the surface of the
motor brush is pitted, rough, has burn marks, or the commutator has a black residue on it, replace the motor
brush and stone the motor commutator.
4. Proper Speed Calibration
# To ensure proper belt speed and proper calibration use engineering mode to verify that machine is running in MPH not KM (all models) and that the correct roller diameter is set
4. Proper Speed Calibration
# To ensure proper belt speed and proper calibration use engineering mode to verify that machine is running in MPH not KM (all models) and that the correct roller diameter is set
# Auto-calibrate the machine from
engineering mode if the belt speed is erratic or the belt speed does not correspond to what is displayed on the
console.
5. Voltage
Checkpoints/Diagnostic LED’s
# Verify that the motor control board is functioning properly by referencing the Diagnostic LED’s located on the lower control board.
# Verify that proper voltage is being transferred through the console cable.
# Verify that the motor control board is functioning properly by referencing the Diagnostic LED’s located on the lower control board.
# Verify that proper voltage is being transferred through the console cable.
If the techniques described in
the five-step diagnostic process did not resolve the problem, reference the symptoms in the table of contents and review
other possible causes in the troubleshooting section.
Console Cable Voltage
Chart (DC Volts)
Console Cable Voltage
Check
To check the voltage of a
specific function (i.e. elevation, motor control, etc), place the negative lead
of your
multi-meter on pin B3, B4 or B5, and
place the positive lead on the desired pin. Follow the voltage chart above for the correct voltages.
Wire colors are subject to change.
Motor/AC Wire Voltage
Check
Spin motor flywheel to produce
voltage
AC Wire Voltage Check
Lower Board LED
Diagnosis
LED 1: Transfer indicators - When the power switch is
turned on, LED 1 lights up, meaning that power is supplied to the lower board.
This LED should remain on while operating the drive motor and elevation motor.
If
the LED’s are not lit, check the AC
service from the wall outlet.
LED 2 & 3: Motor indicator - The LED 3 will come on if the motor starts to run. The motor control board will begin detecting the status of the motor and if everything is OK then LED will turn on in 1 or seconds.
LED 4 & 5: Incline Motor Indicator - When the upper board is commanding the incline motor to move UP or DOWN, the LED’s go on. LED 4 is for the UP function, and LED 5 is for the DOWN function.
LED 2 & 3: Motor indicator - The LED 3 will come on if the motor starts to run. The motor control board will begin detecting the status of the motor and if everything is OK then LED will turn on in 1 or seconds.
LED 4 & 5: Incline Motor Indicator - When the upper board is commanding the incline motor to move UP or DOWN, the LED’s go on. LED 4 is for the UP function, and LED 5 is for the DOWN function.
LED 1: DC Voltage Indicator - When the power switch is
turned on, LED 1 dimly lights up. If the belt begins to run LED1 will remain. Power is stored in the
board, do not touch.
LED 2 & 3: Motor indicator - The LED 3 will come on if the motor starts to run. The motor control board will begin detecting the status of the motor and if everything is OK then LED will turn on in 1 or seconds.
LED 4 & 5: Incline Motor Indicator - When the upper board is commanding the incline motor to move UP or DOWN, the LED’s go on. LED 4 is for the UP function, and LED 5 is for the DOWN function.
LED 2 & 3: Motor indicator - The LED 3 will come on if the motor starts to run. The motor control board will begin detecting the status of the motor and if everything is OK then LED will turn on in 1 or seconds.
LED 4 & 5: Incline Motor Indicator - When the upper board is commanding the incline motor to move UP or DOWN, the LED’s go on. LED 4 is for the UP function, and LED 5 is for the DOWN function.
