Monday 15 February 2016

Defective treadmill. It turns on but stops after a while.

The treadmill turns on but stops after 3/5 seconds, with an acoustic signal and/or an error code displayed. After restarting it, the same thing happens. It seems that the treadmill controller detects something abnormal, therefore it stops as a safety measure. You should immediately check the speed sensor, which is often the cause of this anomaly. This sensor checks the engine or the belt speed. The controller get the information that the engine is powered, but it doesn’t spin. Or it’s powered, but running belt does not turn.
In our case the belt and the motor spin regularly, but the speed sensor doesn't sends signals because it has failed. If the sensor is magnetic, sometimes it is too far from the pulley and does not detect it. Magnetic sensor should be within 2/3 mm from the pulley. If the sensor is optical, make sure that you have not accumulated dirt on the optical emitter/receiver.
Other problems? Check out our blog!!

Sunday 14 February 2016

Treadmill, what to do if the tool stops working

If you are going to do your daily exercise and suddenly your treadmill stops working, you need to check a few things.
Check that the power led is on (it means power arrives into the treadmill). If you can, check that LEDs on motor controller light up in normal mode.
Check all plugs and connections.
Check if the thermal protection is activated (in this case after an hour of waiting / cooling off the treadmill should resume operation).
If the treadmill stops working between 3 and 10 seconds, it means that there are problems with the speed sensor.
If you use between 5-15 minutes and then it stops, check the lubrication between the belt and the platform.
If you feel a burning smell, there are engine overheating problems (this often depends on maintenance, deck or running belt).
If it works and suddenly stops, check the brushes and motor.
For further information, read the articles on our blog.

A troubleshooting to solve some problems on your treadmill

When you make one step on the belt stops or feels sticky.
Remove the engine cover and see if the slip depends on walking belt or motor belt.
If it's the walking belt, adjust the tightening screws according to the instructions on our blog to avoid overtightening.
If it is the motor belt, adjust the screws or nuts regulation according to the instructions on our blog to avoid overtightening.

If the treadmill during use stops or the thermal protection skips.
Check the status of the platform in its central part, ensure that it is not worn or damaged. Check also the lubrication.
Check the status of the belt. Remember that running belts lasts from 3 to 4 years for home use and do not exceed 2 years in case of intensive use (gyms). Check the tips on our blog.
Solution: change the walking belt.

If the treadmill doesn’t start.
Solution: check all plugs, sockets and wiring. Check the fuses (they are intact and not burned).

You hear a noise like pat (tac-tac) from front or rear roller.
replace the bearings.

The LCD does not read the numbers or appear in half.
Make sure the batteries are in good condition.

Other problems?
Check out our blog!

Treadmill-motor-alternating current (AC)

The professional treadmills, used in gyms, are nowadays usually equipped with AC motors, instead of DC motors. DC motors have a large maintenance (changing the brushes, high wear), while maintenance for AC motors is almost nothing and the duration is up to 10 times longer.
In addition to the much higher duration of AC motors, even the controllers used with AC motors last much more. They consist of an inverter that is normally equipped with protection systems operated by a controlling chip and this allows a much greater functional life.

The Inverter can be programmed with over 100 parameters including, for example: curve of acceleration or deceleration, load capacity (minimum and maximum), minimum and maximum speed, breaking, time variation of torque. Since the inverters are used a lot in the industrial sector, the branded ones (such as Toshiba) have high degrees of reliability, and often the manufacturer guarantees them for a long period (5 years for Toshiba).

The AC mechanics is more secure. You can transform any home use treadmill using top-grade components to an AC treadmill, thanks to the retrofit kit provided by Parts For Treadmill.

The importance of change the belt in due course

All the belts have a lifespan and when the engines overheat for the effort this is almost always due to the high coefficient of friction between belt and base.
Does the belt stop or doesn't seem to have the strength to carry the person using the treadmill? Do you notice an excessive consumption (high amperage)?
This is a warning signal that the belt or the deck are in bad shape and need to be replaced urgently.
If you don't change the belt, the motor brushes wear out faster (for DC motors) and you risk compromising your controller (both for DC and AC motors). The smell coming out from motor that sometimes smells like "burnt paint" indicates that the windings are overheating and protective resin is likely to melt. If we do not control and settle belt and deck, sooner or later it will happen the same thing even with a new motor. Belt manufacturers indicate a useful lifespan of two or three years. In practice, for domestic use a standard belt lasts 3-4 years, a quality one up to 5/6 years. In the gym lifespan does not exceed more than 2 years.
It is important for treadmill owners to understand what they must replace regularly, therefore establishing in advance the expenses and the amortisation of their investment.
A preventive maintenance pan for treadmills: things to do at least every two months for commercial use (gyms)
Basic cleaning (dust and impurities) with suitable, NOT aggressive, cleansing agent.
Vacuum the engine compartment (NO water, use a vacuum cleaner and do not touch directly the electronic components).
Motor control (check brushes if DC motor).
Check the drive belt and its tension
Inspection of the controller (connectors).
Tilt motor control (functional tests and cleaning/lubrication of screw only).
Cleaning and lubrication of the deck.
Belt monitoring: upper and lower side inspection, cleaning, lubrication with spray lubricant for treadmills, tension and alignment/centering.
Checking/cleaning the rollers and the drive system.
Where necessary: calibration of the speed.
Amperage testing with no load and with load.
Final functional test with no load and with load.

Friday 12 February 2016

...if the motor of the treadmill warms up

If the motor heats up, usually that’s due to a running belt fault. All service engineers should be aware of this!

Moreover, it is obvious that if a customer melts or breaks a motor, he installs a replacement and this heats again -> something brings an excessive load to the engine.

Signs of overheating of the old motor are visible

    1. if you open the old motor and notice blown resin (plastic) on the armature,
    2. if the old motor is demagnetised,
    3. if some of the windings are open circuit, or went into short circuit.

If so, double check motor load (i.e. running belt friction factor), to avoid further breakages.

SPECIAL TIP: in 90% of cases, replacing the engine, and pay more attention on maintenance and operation is sufficient to solve the problem and use the equipment again for years. However please check motor temperature during (every 10 minutes) and after the first trial workouts, to prevent problems and discussions with the customer or vendor (which hardly will accept back an overheated engine).

What to do if the temperature goes up…
First you have to look at the mechanical/electrical side:
1) are pulleys aligned? Does the drive belt run perfectly aligned? Do the rollers spin regularly or are they blocked?

2) is the running deck smooth and straight? It is not enough to look with naked eye, sometimes putting a metal rod bar on the table you can notice a central depression of even 1 cm

3) how old the belt is? If you replaced it, did you install a quality running belt with low friction factor?

4) are walking belt and drive belt properly tightened? Or are overtightened as a result of an improper adjustment? Are they old (more than 4 years for home use or 2 years for commercial)?

5 ) if there’s too much lubricant on belt and rollers that will increase friction factor (opposite effect). What kind of lubricant is used? We recommend silicone spray. That doesn’t leave many residues and is easy to put on. Alternatively, you can use vaseline, being very careful not to exceed, to avoid the opposite effect. If the customer used other types of grease/oil, with petroleum derivate, that may have increased friction factor and the belt must be replaced with a new one.

6) remember to clean before lubrification, to avoid the lubricant to mix up with dust/sand.

7) only for treadmills which require calibration: is the speed shown on the display similar to the actual speed of the belt, with a tolerance of +/-10%? If not, calibrate.

The characteristics of the user
1) an engine with 8 cm in diameter or less, is designed for maximum 80 Kg who walks at a minimum speed of 5 km/h for max. 20 minutes.

2) weighs the user more than 80 kg? You need a motor by at least 10 cm in diameter

3) is the user around 100 kg? You need a motor Turdan by 12 cm or an AC motor

A brief summary
If a car loses traction on the road, there might be many reasons; no doubt the main factor is the quality of the tires. Old or smooth tires will have a catastrophic effect.

Likewise, if your treadmill has problems and the engine warms it’s usually running belt problem. The running belt determines the most important friction factor with the deck. Numerous field and laboratory tests have shown that replacing the running belt can safely REDUCE the electric consumption. So a new running belt with low friction not only solves the problem of overheating, but also reduces the energy bill of the customer and prevent damages to the engine electronic controller.

This also applies to the belts of the gyms, in the long run a worn belt could damage the inverter with damages that may be beyond 1000 €.

After changing the walking belt (and eventually the drive belt) there are a few things you can do to improve the treadmill:

1) mount an external fan to cool the engine. This is useful especially for those who have to walk slowly. In that condition in fact the fans on the engines have no effect because they rotate at the same speed of the motor.

2) install a bigger engine (and the external fan). This is an appropriate solution especially if the user is a bit heavier than it should or walk slowly. It can be a long term solution.

3) whenever possible, monitor over time the temperature of the engine.

Saturday 6 February 2016

Frequently asked questions on the Treadmill

1. The console shows only "zeroes".

Check the correct positioning of the safety key. If the console has batteries, replace them.

2. The belt stops when I walk on the treadmill.
If the belt starts again when you step off, check the belt tightening. The belt should pop up to 3-4 cm. If the tension is correct, run the treadmill without no one above it. If it keeps its speed, the belt is consumed or the board is not well lubricated. Check the instructions on our blog for maintenance. Note that you may need to replace the belt (especially if it is older than 4 years). If the belt does not maintain a constant speed, contact a service engineer, because the problem may be in the motor or in the controller (see other articles on our blog)

3. How can I adjust the belt?
Follow the instructions on our blog for the tightening and the centering of the belt. Be careful not to overtighten the belt. This can lead to expensive damages in the electronic parts. Plug in the power cord, insert the safety key and walk on the treadmill for a few minutes. Repeat until the belt is centered. If you are not an expert, start doing very small adjustments.

4. How can I loosen or tighten the belt?
Even in this case, take care not to overtighten. If you have to tighten much the belt to avoid it slipping, it means that you need to replace it. Follow the directions on our blog to properly adjust the belt tension.

5. How can I calibrate the speed and/or the incline of treadmill?
To calibrate the speed and/or incline, see the instructions under the lid of the engine hood or in our blog. Be sure to unplug the machine when working inside the engine compartment. High voltage is present!

6. There is no reading pulse/heart rate monitor (chest belt).

If you use a chest belt, make sure that the strap is under the clothes (and not above), in direct contact with the skin, in the pectoral area.

Note: If the heart rate monitor does not function when positioned as described, try moving it slightly below or above your chest.
Make sure the sensor logo is facing forwards.

Use saline solution (for example that of contact lenses) to moisten the two electrodes on the sensor unit. If the heart rate is not shown, moisten the electrodes again. Position yourself at the center of the belt to display your heart rate.

The heart rate monitor is designed to work with people who have normal heart rhythms. Some heart rate detection problems can be caused by medical disorders as premature ventricular contractions (pvcs), tachycardia, and arrhythmia.

Operation of the heart rate monitor can be affected by electromagnetic interference caused by electric lines, mobile phones, microwaves or other sources. If you suspect that electromagnetic interference can cause a problem, try moving the treadmill.

If the heart rate monitor still doesn't work correctly, before resorting to the assistance, another person should use the treadmill.

7. There is no reading of the frequency/handpulse.

Hand Grip Pulse Sensor/EKG:
clean the metal contacts with a damp cloth.

Make sure that the palm of the hand is tight around the top and bottom plates of the sensor. If necessary, moisten the palms of your hands.

If suddenly no pulse appears on the console for a long time, the console software might be blocked and must be reset. To reset the console:

stop the machine and remove the plug from the wall, leaving the safety key inserted.

Wait at least 30 seconds.

Connect the power cord, for some models a reset signal appears on the console.

Remove the safety key to clear the alarm, then reinsert the key.

Recheck. If the impulse is still not working properly, before resorting to the assistance, another person should try using the treadmill.

8. Demo mode of the console
When in Demo mode, the console lights up. This mode becomes active only when the treadmill is plugged in, the main on/off switch is switched on and the safety key is not inserted in the console. The Demo mode has been added to some brands to attract attention on the treadmill while it is on display in the shop. The demo mode can be deactivated at any time.

Method # 1 to switch from Demo mode to actual function:
press and hold the STOP button while inserting the safety key, to enter user information.

Watch the calories. When the Demo mode is active, the letter D will appear.

Press the SPEED button DOWN to turn on/off mode.

Once the mode is set, remove the safety key.

Method # 2 to toggle Demo mode:
press and hold the STOP button for about five seconds.

Remember to properly connect the safety key to the treadmill.

9. Does the treadmill need a planned maintenance?
First, regularly check the tension on the belt. You must be able to lift the running belt 5-6 cm from the platform toward the center. You should also carry out regular cleaning and lubrication. Follow the instructions provided in the manual or see our blog for more information.

10. Other faults.
Failure to read the speed sensor.

Magnetic sensor: unplug the treadmill and remove the motor cover. The sensor is located on the frame near the front roller pulley. There's a magnet glued on the front roller pulley. When adjusting the sensor, make sure it is pointed directly at the magnet. Move the sensor so that it passes to 2/3 mm far from the magnet. Also, check that the wire is not damaged and is connected to the controller.

In case of no-reading, purchase a replacement sensor.

Optical sensor: unplug the treadmill and remove the motor cover. Optic disc (encoder) and sensor are located at the end of the motor or on the right side of the front roller. Optic disc rotates between two optical sensors. The disk must rotate freely without touching the sensor roughly in the middle of the two sensors. The sensor can be moved by loosening the adjusting bolt.

In case of no-reading, purchase a replacement sensor.

In case of other faults, check out our blog for more information.

How to conserve your treadmill?

Exposed to dust, drops of sweat and bacteria, the treadmill must be maintained regularly. Ongoing maintenance of equipment optimizes performance and longevity. It is not easy to carry a treadmill from the store when you buy it, because it's heavy and bulky. That is why we offer a variety of services for repair and maintenance. But, if you simply follow the below maintenance steps regularly, your equipment will operate well for a long time.

Why taking care of your treadmill?

The treadmill is accessible to external agents such as dust. It can build up in the engine compartment. That may block the cooling fans, and expose the engine or the electronics to overheating and thus reduce the duration. So, clean the running belt and vacuum the motor housing regularly. You also have to clean the environment near the equipment to prevent the accumulation of dust. In addition, as the treadmill involves all the muscles of the body, it is obvious that you sweat during exercise. The humidity generated from the drops of sweat does rust metal parts. Just spray a little quantity of 100% special silicon lubricant spray Silic One on metal parts to create a thin protective layer. Sweat will slip away and the metal parts will be protected.

Where to put the device to facilitate cleaning?

Before cleaning, make sure the unit is placed on a flat surface. If the floor has some flaws, compensate them by choosing an appropriate level of adjustment of the feet. This is also better for the walking belt and the engine of the treadmill. To simplify the matter, place a mat under the equipment to collect the dirt coming out of the cleaning job.

Clean the treadmill parts

Take a cloth moistened with water to clean the different pieces of hardware. To minimize friction between the belt and the wooden deck, reduce engine wear and prolong the life of the tread, it is essential to lubricate the running deck. When necessary adjust running belt, following the directions on our blog. This simple operation is important for optimal functioning of the equipment. Some models are pre- lubricated, but the treatment will be effective only for a short period, at most in the first year of use. Later it is therefore necessary to carry out the lubrication. Silicon based lubricants are recommended for effective maintenance of the equipment.

Small gestures to remember

Prevent premature wear of the walking belt, making sure it is straight and centered. To take better care of the treadmill, you should wear suitable shoes. They must be clean so that they don’t bring on the running belt any sand or gravel, which could damage it. The user may carry on some maintenance operations. By doing the necessary preventive care, you do not need to call a technician. However, for a complete evaluation of the treadmill, consider calling a qualified engineer, especially for products intensively used in gyms.

Follow the instructions of the user manual for the treadmill

After receiving the treadmill, be sure to read the instruction manual that came with it. The most important thing is that all the equipment must be powered by a single-phase 220 V grounded socket. Often there isn’t any specific statement regarding the duration of use of the treadmill. However, before another workout session, you must leave the treadmill rest for at least 2 hours if you used continuously for about 45 minutes. This applies to all equipment with direct current (DC). You can use AC motors treadmills much more without any risk of damage.

Monitor the tightening and lubrication of the walking belt

If the walking belt of the tread is still new, we recommend that you carefully monitor its centering and tension for a few days. After that, you need to clean, lubricate and regularly check the walking belt. In the event that it isn't enough tighten, you can adjust by turning two bolts. However, if it is too tight, turn these two bolts opposite. Follow the instructions on the blog and avoid the risk of overtighten the walking belt. This could in fact bring problems to the treadmill.

If the belt is too old, it’s better to replace it to safeguard the electronic parts from premature wear.

The walking belt of the treadmill slips or skips

If the treadmill is in trouble, such as slips or skips, you don't always need to call a technician if you have a bit of dexterity. So we can save one or more calls to the technician. We try to follow these steps:
1.) Remove the motor cover paying attention: electronic parts inside are exposed which must not be touched with bare hands.
2.) Set the rate at about 2 mph, stand on the side rails. Then, with one foot, step on the tape to make him stop. Keep firmly handrail to avoid falling.
3.) If everything stops including engine, there is no problem.
4.) If the front roller keeps turning but the tape stops, this means that either the tape is too loose, or is worn and should be replaced. Internal textile canvas catches normally the drive roller when tightened correctly, even if it is lubricated. When the bottom of the belt is worn, it's too smooth and hasn't got sufficient elasticity/grip to grasp the front drive roller. Do not overtighten the running belt. If the running belt is old, replace it. An old overtightened belt can lead to premature failure of the controller and the engine itself, with much higher replacement costs than the belt itself.
5.) If the front roller stops when you get off the treadmill, but the pulley on the roller still turns partially, the front roller needs to be replaced or you have to better fix roller pulley on roller.
6.) If the belt and the pulley of the front roller stop, but the engine still turns, even partially, the drive belt needs to be tensioned or needs to be replaced. In this case, avoid extra-tension, if the belt is old and/or worn, it must be replaced.
treadmill belt slipping

treadmill belt slipping

Wednesday 3 February 2016

Turdan Greenmaster installation




Installing treadmill motors with special motor fixing bands

Every time it is possible, installing the motor with special motor fixing bands instead of screws allows to obtain several advantages:

1) You get a perfect alignment between belt and pulley of the motor.

2) It avoids the use of excessively long screws, which my interfere with the motor armature.
3) You can tension easily the drive belt. Release (unscrew) the fixing bands which tighten and put the belt in place. Then tighten (screw) the fixing bands to tighten the drive belt.