Error 25
Motor Controller Hardware Error
Applies to
TRM 800.v2
Issue Symptoms
This error monitors the functionality of the MC. If the software detects a defect in the MC the treadmill will stop working and Error 25 will be displayed.
Troubleshooting steps
Attempt to clear the error. It is does not clear, cycle power to the cycle three times. If the error persists, replace the MC.
Motor Controller Hardware Error
Applies to
TRM 800.v2
Issue Symptoms
This error monitors the functionality of the MC. If the software detects a defect in the MC the treadmill will stop working and Error 25 will be displayed.
Troubleshooting steps
Attempt to clear the error. It is does not clear, cycle power to the cycle three times. If the error persists, replace the MC.
Error 27, 28, 29
Drive Motor Current Overloading
Applies to
Treadmills
Overview
Characteristics of treadmill overloading are:
# Most frequent cause of treadmill shutting down.
# Overloading is most often caused by excess deck/belt friction, but can be made worse by line voltage conditions.
# Happens more often with heavier runners, but never walkers.
# In high user clubs (10 hours or more of use per day), the decks/belts will wear out much faster than at other locations, sometimes in months rather than years.
# Often accompanied by an error code:
# Error 27 (motor current too high)
# Error 28 (average input current too high, or motor controller overheated)
# Error 29 (instantaneous input current too high)
Drive Motor Current Overloading
Applies to
Treadmills
Overview
Characteristics of treadmill overloading are:
# Most frequent cause of treadmill shutting down.
# Overloading is most often caused by excess deck/belt friction, but can be made worse by line voltage conditions.
# Happens more often with heavier runners, but never walkers.
# In high user clubs (10 hours or more of use per day), the decks/belts will wear out much faster than at other locations, sometimes in months rather than years.
# Often accompanied by an error code:
# Error 27 (motor current too high)
# Error 28 (average input current too high, or motor controller overheated)
# Error 29 (instantaneous input current too high)
Error 27
Issue Symptoms for Error 27
The motor controller monitors the amount of current being delivered to the drive motor. The software sets a maximum amount of allowable drive motor current. This error indicates that maximum drive motor current has been reached. The most likely cause of this is a badly worn running belt/deck. Less likely but possible is a faulty drive motor causing high current demand.
Troubleshooting steps
1. Check the belt rating for TRM800.v2 treads. If below 2 replace the bed and belt.
2. For older treadmills, a clamp-on AC ammeter must be used to determine the amount of A.C input current being drawn by the treadmill under no load and loaded conditions. The current readings can be used to determine the condition of the running belt and/or running bed. Replace the running belt and/or running bed as required. Remember, many running beds are double sided and the bed can be flipped over rather than being replaced.
3. A known good drive motor must be substituted for the existing drive motor.
Issue Symptoms for Error 27
The motor controller monitors the amount of current being delivered to the drive motor. The software sets a maximum amount of allowable drive motor current. This error indicates that maximum drive motor current has been reached. The most likely cause of this is a badly worn running belt/deck. Less likely but possible is a faulty drive motor causing high current demand.
Troubleshooting steps
1. Check the belt rating for TRM800.v2 treads. If below 2 replace the bed and belt.
2. For older treadmills, a clamp-on AC ammeter must be used to determine the amount of A.C input current being drawn by the treadmill under no load and loaded conditions. The current readings can be used to determine the condition of the running belt and/or running bed. Replace the running belt and/or running bed as required. Remember, many running beds are double sided and the bed can be flipped over rather than being replaced.
3. A known good drive motor must be substituted for the existing drive motor.
Error 28
Electronics Temperature Too High Issue Symptoms for Error 28
Treadmill motor controllers monitor the temperature of the motor controller output switching device. Typically, these motor controllers use a fan to force cool the output device’s heat sink. This error indicates that the heat sink temperature has exceeded maximum. The most common cause of this is a clogged cooling fan or heat-sink. Lesser causes include an inoperative cooling fan, a defective lower PCA or a faulty drive motor.
Troubleshooting steps
1. Check the cooling fan mounted on the lower PCA to ensure that the fan is not clogged with dust.
2. Thoroughly clean the fan and ensure that it spins freely.
3. As with Error 27, check the belt rating or current, and replace bed and belt as needed.
4. Replace the lower board.
5. Replace the motor.
Electronics Temperature Too High Issue Symptoms for Error 28
Treadmill motor controllers monitor the temperature of the motor controller output switching device. Typically, these motor controllers use a fan to force cool the output device’s heat sink. This error indicates that the heat sink temperature has exceeded maximum. The most common cause of this is a clogged cooling fan or heat-sink. Lesser causes include an inoperative cooling fan, a defective lower PCA or a faulty drive motor.
Troubleshooting steps
1. Check the cooling fan mounted on the lower PCA to ensure that the fan is not clogged with dust.
2. Thoroughly clean the fan and ensure that it spins freely.
3. As with Error 27, check the belt rating or current, and replace bed and belt as needed.
4. Replace the lower board.
5. Replace the motor.
Error 30, 31, 32, 33
Communication Errors
Applies to
All products
Issue Symptoms
Errors 30 through 33 all indicate the loss of communications or erratic communications between the microprocessors in the upper PCA and the lower PCA. The troubleshooting procedures for all of them are essentially the same.
# Error 30 is defined as upper PCA is active, the lower PCA is not communicating
# Error 31 is defined as faulty data received from lower PCA (extremely rare)
# Error 32 is defined as lower PCA is active, the upper PCA is not communicating
# Error 33 is defined as faulty data received from upper PCA (extremely rare)
The main reason for a general communication error is a faulty interconnect cable, either it is not connected securely, or it has become damaged. Error 30 can be caused by an overloaded or shorted +3.3VDC or +5VDC on the lower PCA, which can be caused by an external component plugged into the lower PCA. Error 32 is often caused right after service or installation, when the interconnect cable is unplugged from the upper PCA while the lower PCA is powered. It is also caused when the cable is plugged into the CSAFE port on the upper PCA. Less likely but possible is a defective upper or lower PCA.
Troubleshooting steps
1. Substitute a known good interconnect cable between the upper and lower PCAs to determine if the interconnect cable is defective.
2. Verify the interconnect cable is securely connected into the proper connectors on both PCA’s. The cable should lock, if the locking tab on the connector is broken replace the cable.
3. Unplug all the components from the upper and lower PCA's except the data cable and the AC power going to the lower PCA. If the unit does not show an error, plug in components one at a time, cycling power on after each new component is plugged in. If a communication error is newly displayed, the last component plugged in is the cause of the error.
4. Substitute a known good lower PCA to determine if the lower PCA is defective.
5. Substitute a known good upper PCA to determine if the upper PCA is defective.
Communication Errors
Applies to
All products
Issue Symptoms
Errors 30 through 33 all indicate the loss of communications or erratic communications between the microprocessors in the upper PCA and the lower PCA. The troubleshooting procedures for all of them are essentially the same.
# Error 30 is defined as upper PCA is active, the lower PCA is not communicating
# Error 31 is defined as faulty data received from lower PCA (extremely rare)
# Error 32 is defined as lower PCA is active, the upper PCA is not communicating
# Error 33 is defined as faulty data received from upper PCA (extremely rare)
The main reason for a general communication error is a faulty interconnect cable, either it is not connected securely, or it has become damaged. Error 30 can be caused by an overloaded or shorted +3.3VDC or +5VDC on the lower PCA, which can be caused by an external component plugged into the lower PCA. Error 32 is often caused right after service or installation, when the interconnect cable is unplugged from the upper PCA while the lower PCA is powered. It is also caused when the cable is plugged into the CSAFE port on the upper PCA. Less likely but possible is a defective upper or lower PCA.
Troubleshooting steps
1. Substitute a known good interconnect cable between the upper and lower PCAs to determine if the interconnect cable is defective.
2. Verify the interconnect cable is securely connected into the proper connectors on both PCA’s. The cable should lock, if the locking tab on the connector is broken replace the cable.
3. Unplug all the components from the upper and lower PCA's except the data cable and the AC power going to the lower PCA. If the unit does not show an error, plug in components one at a time, cycling power on after each new component is plugged in. If a communication error is newly displayed, the last component plugged in is the cause of the error.
4. Substitute a known good lower PCA to determine if the lower PCA is defective.
5. Substitute a known good upper PCA to determine if the upper PCA is defective.
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