HUR PREMIUM 5 Series Instruction Manual

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HUR INSTALLATION AND MAINTENANCE
Ab HUR Oy
Patamäentie 4
67100 Kokkola, Finland
Tel. +358 - (0)6 –832 5500
www.hur.fi

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CONTENT
HUR INSTALLATION AND MAINTENANCE .....................................................................................................1
1 HUR PRODUCTS ...............................................................................................................................................3
2 REQUIRED TOOLS ............................................................................................................................................4
3 RECEIVING HUR DELIVERY ...............................................................................................................................5
4 LAYOUT............................................................................................................................................................6
5 INSTALLATION..................................................................................................................................................7
5.1 INSTALLING COMPRESSOR........................................................................................................................7
5.2 INSTALLING AND USING HUR PNEUMATIC CONTROL UNIT .....................................................................8
5.2.1 INSTALLING CONTROL UNIT ..............................................................................................................8
5.2.2 USING CONTROL UNIT.......................................................................................................................9
5.3 INSTALLING MAIN PRESSURE CIRCUIT......................................................................................................9
5.4 INSTALLATION CHANNELS AND TUBES...................................................................................................12
5.5 FLOORING FOR TUBES AND WIRES.........................................................................................................13
5.6 COMPLETING THE INSTALLATION...........................................................................................................15
6 MAINTENANCE AND TROUBLESHOOTING ................................................................................................... 16
6.1 ROUTINE MAINTENANCE TIMETABLE.....................................................................................................16
6.2 DISCONNECTING MACHINE FROM PRESSURE CIRCUIT ..........................................................................17
6.3 LUBRICATING AND ADJUSTING ROLLERS................................................................................................17
6.4 LUBRICATING PISTON RODS ...................................................................................................................18
6.5 CHECKING FOR LEAKAGE ........................................................................................................................19
6.6 ADJUSTING INNER LEVER ARMS .............................................................................................................21
6.7 TOUCH SCREEN MAINTENANCE..............................................................................................................22
6.7.1 GENERAL SAFETY PRECAUTIONS .....................................................................................................22
6.7.2 ANTI-STATIC PRECAUTIONS.............................................................................................................22
6.8 FCM (SmartCard) TROUBLESHOOTING...................................................................................................23
6.9 FCM2 (SmartTouch) TROUBLESHOOTING...............................................................................................25
6.10 FCM RELATED NOTES............................................................................................................................29
7 NETWORKING ............................................................................................................................................... 30
7.1 NETWORK TROUBLESHOOTING..............................................................................................................31
8 HUR WARRANTY TERMS............................................................................................................................... 33

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1 HUR PRODUCTS
1. PREMIUM LINE
HUR´s most developed range, offering many features that enhance safety and facilitate rehabilitation, for
example, range limiters, additional supports and specially designed equipment for wheelchair users. Model
numbers 5xxx, 9xxx
2. ACTIVE LINE
Single and dual function models with pneumatic resistance and minimal adjustment points. Model numbers
3xxx.
3. MULTIFUNCTION
Multi-purpose equipment which combine separate essential HUR equipment into one. Model numbers 8xxx
4 RESEARCH LINE
Delivered complete with computer and test/ analyse software. Research Line users are top-athlete, university
or any other use with high demands. These machines include lots of hi-tech electronics. Model numbers start
with number 7, for example 7530.
5 HUR-SOFTWARE
HUR software family consists of wide range of testing and analysing programs.
6 SPECIAL TEST DEVICES
This category includes electronic devices like Performance Recorder, Balance- and Force Platforms.

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2 REQUIRED TOOLS
For installation, service and repair of HUR products some basic tools and accessories are required. Service
technician should always have these items when visiting HUR customers. Tools listed here should fit in all
small size tool bags or carrying cases. The list includes only the most important tools. Additional items might
be necessary, depending on application.
NOTE!
In case of air travelling, don’t try to bring tools inside the cabin. Spray bottles (aerosols) are completely
forbidden items on-board.
Basic tools for HUR service technician:
Wrenches: 8, 10, 11, 12, 13, 14, 16, 17, 19 and 21 mm spanners.
Sockets with similar sizes for use with ½” ratchet also recommended.
Hex keys: Multi tool with sizes 1.5–10 mm recommended.
Long type 10 mm Hex key to be used with ½” ratchet required for adjusting inner lever arms
½” ratchet wrench
Torque wrench: With ½” adaptor. 110 Nm of capacity required.
Screwdrivers: Assortment of small and normal sized regular and Phillips heads.
Tube cutters: Camozzi PNZ-12 recommended.
Knife: Mat cutting type recommended.
Hammer
Rubber hammer
Universal pliers
Cutters
Basic accessories recommended:
Lubricant: Teflon based spray / white Vaseline / silicone free (Festo LUB-AL2) for low
friction cylinders
Cleaning solvent
Paper: For cleaning hands and parts
Thread adhesive Loctite or equivalent
2-sided tape 3M recommended
Cable ties: Various sizes
SmartTouch specific accessories recommended:
Network switch
Network CAT 5/6 cable
Network RJ45 - RJ45 connector (Female-to-Female) for extending network reach
Service technician should also carry some tubing and basic pneumatic components like valves and
connectors.
It’s better to have 5 extra parts instead of 1 missing!

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3 RECEIVING HUR DELIVERY
All the packages leave HUR factory in perfect shape. When receiving your HUR delivery, first thing
is to visually check the packages for any damages. Transportation damages should be documented
and reported to sender and company responsible for transportation before signing the delivery
documents.
STORAGE CONDITIONS AND TRANSPORTING
HUR machines should be stored in dry conditions and protected from weather, concerning all transport
stages and terminals.
The package should not be opened until at the final location to prevent scratches and other damages to the
machine
Condensing humidity should be taken into account when the equipment is transferred to the destination
from storage and the temperature change between the places is remarkable. It is recommendable to open
the packages and let the equipment stand about 6 hours.
When installing stored touch screens, kiosk, software etc. always make sure they are up to date concerning
software version, language and compatibility. Also inspect and estimate factors which might cause problems
on site (for example attachment/mechanism). A Check-up done forehand is an easy way to ensure successful
installation.
Removing product from the package:
-Cut the straps used to hold cardboard package together
-Remove top section of the package.
NOTE! The top cover has the written information of content of the package attached.
-Remove the box part by lifting it over the machine
-Remove additional packing material and plastic bag covering the product
-Cut the straps used to attach product to the pallet
Check the packing list to ensure that you have received all the items listed.
NOTE!
HUR cardboard package is completely recyclable. Follow local laws and regulations on disposal.

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4 LAYOUT
Visual appearance is the first impression that customer gets when coming inside the gym.
After that things get even more critical. If the layout is messy or it is difficult and confusing to go around the
gym, customer will complain. In worst case, they will not come back.
Therefore planning the layout is very important. Even if you have a pre-designed layout you don’t have to
use it as the law. Don’t assume that the first layout that you make is the best one. Think about options.
Luckily, moving HUR machines around is easy
You can use following list as a guideline:
1. Is there enough room around the machines?
Moving around the gym
Accessing machines
Older peoples view
Wheelchair users view
2. Is there enough room for each machine to be operated?
Whole range of movement
Walking by the machine if it is in use
3. Does the layout meet customer requirements?
Effective space usage
Grouping machines by muscle groups
4. Is the gym visually comfortable?
Straight lines are not always the best
Using layout to guide users around the gym
5. Compressor
Place in a cool, dry place
Avoid direct sunlight and heater pipes
Do not install compressor in near of water sources. It is an electronic device!
6. Pneumatic tubing
Tubing under floor / inside trunking
Keep distances short, estimate the need for circular tubing
7. Is there enough electric/network sockets available for all devices?
FCM / ST / Kiosk / Other devices
Plan how to position network switches and/or use long enough network cables

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5 INSTALLATION
Before starting the installation, make sure you have all the accessories and tools required. Check
also that correct installation kit is within delivered items if it is listed in delivery note.
Check the layout one more time. It is recommended to get customer approval for the layout before
installation is started.
Each installation is different and characteristics vary, this manual gives a basic guideline based on our
knowledge and experience,
NOTE!
Always make sure that each machine is connected with suitable power supply.
If compressor or any other electronic device has been stored or transported near or below 0 °C (32 °F), let it
warm up in room temperature for at least half an hour before switching power ON.
5.1 INSTALLING COMPRESSOR
Always read compressor user manual before starting the installation. If you notice any differences on
compressor related issues between the compressor user manual and HUR service manual, use information
written in compressor manufacturer’s manual.
Removing compressor from package:
1. Check package for damages
2. Open the package from the top
3. Remove packing material from top of compressor
4. Remove all additional items (documents, oil etc.) packed within the package
NOTE! Make sure that these items are forwarded to customer
5. Lift the compressor unit from the package (ask someone to help you, compressor is a heavy item)
Preparing compressor for use:
1. Remove all the transportation related parts
a. Cut the cable tie used to pack power cable
b. Remove plugs from motor air intakes and install air filters in place
2. Check oil level, add if necessary
3. Check that the power cable has a correct plug
4. Set the power switch to OFF-position
Compressor is now ready to be placed in its final position. Refer to compressor user manual for selecting the
place. Also make sure that compressor is not in walkways. It’s good to place the compressor so that power
switch, oil level checkpoints and water separator tank can be reached easily.

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5.2 INSTALLING AND USING HUR PNEUMATIC CONTROL UNIT
Compressors without automatic drain system are delivered with HUR Pneumatic Control Unit that includes
a circuit shutoff valve, an additional water separator and a drain bottle.
5.2.1 INSTALLING CONTROL UNIT
It is recommended that distance from compressor output to control unit input is at least 1 meter. Control
unit should also be assembled, if possible, so that input of the control unit is located higher than output of
the compressor. Always install control unit so that the water separator can points towards to the floor.
NOTE! Arrows indicate air flow direction. Connect tube from compressor Output to control
unit Input. Connect the main pressure circuit tube to control unit Output.

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5.2.2 USING CONTROL UNIT
Circuit shutoff valve
Red switch operates as a shutoff valve that is used to drain the main pressure circuit and close the air
supply from compressor to main pressure circuit. This eliminates the possibility of compressor
overheating due disconnected tube (for cleaning etc.).
Drain bottle
Water separator removes condensed water from pressurized air. Water is collected to separator cup
which is drained automatically when water level reaches certain point. From the separator cup water
is directed to drain bottle with tube.
When drain bottle water level reaches ½ - ¾ full, it should be emptied.
Do not remove the tube from water separator. If you want to remove the bottle and the cap from
the system for emptying, disconnect the tube from the bottle cap connector.
5.3 INSTALLING MAIN PRESSURE CIRCUIT
The main pressure circuit delivers pressurised air from compressor to all of the machines. In case of multiple
compressors to be used in the gym, connect one compressor to one pressure circuit.
Start routing the main pressure circuit from the compressor. Make sure to leave extra length for being able
to move compressor for service and cleaning purposes.
In case any tubing is to be routed through walls etc., drill and clean holes before routing the tubes. This is to
keep all the dirt out of the tubes.
If tube is to be routed through the wall etc., cover the tube end with tape or equivalent. Make sure that no
scratches or bends are made on tubing when routing.
NOTE! Any scratches and bends will cause pressure leakage. Damaged tube should be replaced
immediately.
T-connector with reducer fitting is required for each machine. Placing the connection points depend on
selected installation type. Simplest (analog installations), main pressure tubing can be attached to baseboard
or routed using plastic channels/trunking (see chapter 5.4)

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When routing over floor, machine connections can be done underneath. In this case, it is very important to
check the clearance to moving parts underneath the machine.
Make sure that all the cuts made for pneumatic tubing are straight. Use only special tube cutters developed
for the work (see `Required tools´ on p. 4). Bad quality cuts will result leaking.
All the connectors are `push-in´ type. For connecting simply push the tube inside the connector. For
disconnecting, push the locking ring of the connector and pull the tube out.
Pushing tube to connector Disconnecting tube
Cut a 6mm tube for each unit. This tube is for connecting the machine to main pressure circuit. Make sure
to leave extra length for being able to tilt the machine for cleaning and service purposes without causing
tension on the 6mm tube. Connect the 6mm tubes to reducers on the T-connectors, but not yet to machine
inputs.
Before connecting machine air tubes, check that the shutoff valve switch on water separator is switched in
closed-position. Switch the compressor on and observe the compressor output pressure gauge. When
gauge reads 2-3 bar, open the shutoff valve switch for few seconds.
Connect the 6mm tubing to machine input. If connections are made underneath the machine, disconnect
the bulkhead connector from machine frame and connect it underneath the machine.
It is recommended that you use as large overall diameter tubing for main pressure circuit as possible. This
ensures faster response time when adjusting machine pressures. (Picture A)

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When there are more than 4 machines connected to pressure circuit, it´s recommended either route the
pressure line after last machine straight back to main line after compressor, or “double tube” the line back
to compressor. (Picture B) This ensures adequate response to pressure adjustment for each machine.
Picture A Picture B

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5.4 INSTALLATION CHANNELS AND TUBES
When installing on floor level, certain channels (trunking) can be used to cover all the tubing and wiring.
Trunking itself, besides planning it, has significant effect on appearance, functionality, accessibility and
customer satisfaction. Make sure you (are able to) purchase suitable channels, parts and accessories for the
installation.

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5.5 FLOORING FOR TUBES AND WIRES
HUR machines usually weigh less than 100 kg, so capacity of the flooring is not a problem. Pressure and
electric connections can be integrated in the flooring material (as shown below). Pictures 5 and 6 show the
pressure and electrics hidden under the floor. After the connections are made under the floor, each
machine has its own inlet (picture 7, a hole made before installing the floor material). Before connecting
machines, there should be extra length on connections for turning the machine afterwards (=cleaning or
service).
Picture 3 Picture 4
Picture 5

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Surface for the machines is easy to install even on existing floor. With suitable under material, the channels
for tubing and wires can be built underneath (picture 7). Inlets are then made, before installing the
laminate and the tube and wires are placed ready for the machine (picture 8). After this, the channel for
tubing and wires is attached in front of baseboard (picture 9) and the connections made ready.
Picture 7 Picture 8
Picture 9

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5.6 COMPLETING THE INSTALLATION
When a machine is connected to pressure circuit, make sure it is stable and steady and all the
rubber feet are in contact to the floor. If necessary, washers can be installed between machine
frame and the rubber feet.
Turn the compressor ON.
Listen for any sounds indicating leakage.
Observe output pressure gauge on the compressor. (See compressor manual)
The gauge indicates pressure of the main pressure circuit. This pressure should not exceed 9,9 bar.
Output pressure is adjusted with pressure regulator located near the output connector. If pressure
exceeds 9,9 bar, adjust the regulator.
Wait until the compressor stops.
Check the output pressure gauge. Adjust the pressure to maximum of 9,9 bar, if necessary.
Test machines for proper operation.
Make sure to test complete movement range.
Test all the adjustments like pressure and range limiters for proper and smooth operation.
NOTE! If a Pre-1995 HUR machine is connected to circuit, the output pressure must be
limited to 8 bar. Old type valves are rated for lower maximum pressure and immediate
failure will result if pressure is not limited.
NOTE! Installation operative is responsible for correct compressor settings.
If everything is OK after all the tests, the installation is to be confirmed by customer representative.
It is recommended that basic training for machine use and maintenance is done with installation.
NOTE! Make sure to clean up before leaving site. The target is that when you leave, users can
start exercising.

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6 MAINTENANCE AND TROUBLESHOOTING
Proper service and maintenance is important for keeping any product in use for long and trouble-free time.
For HUR-machines the list of maintenance and service procedures is reasonable and actually very short
compared to many of the more complicated units in the market.
The following chart includes all the necessary routine maintenance procedures with HUR recommended
timetable. Note that some of the routine maintenance procedures are required for validating warranty.
6.1 ROUTINE MAINTENANCE TIMETABLE
MAINTENANCE PROCEDURE
ADDITIONAL INFORMATION
EVERY DAY
Wipe upholstery using soft cloth.
Normal daily routine for overall hygiene.
EVERY WEEK
Wipe upholstery using soft cloth damped
with mild detergent and water.
Check Water Extractor tank from
Compressor (if equipped) or from HUR
Pneumatic Control Unit.
Check Oil level of Compressor motor(s).
Do not use too much water.
Drain if ½ full or above.
Add oil if necessary. See compressor manual
for details.
EVERY MONTH
Tilt machines and clean floor surface
underneath. Helping hand is
recommended for tilting machine.
Wipe or use vacuum cleaner. Be careful not
to cause too much tension on tubes/ electric
wiring when tilting machine. Avoid hitting
components installed underneath machine.
EVERY 6 MONTHS
ROUTINE SERVICE
Checking overall condition of machines.
Cleaning and lubricating cylinder rods.
Lubricating and adjusting rollers.
Checking compressor.
See compressor manual for recommendations of compressor related maintenance and service.

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6.2 DISCONNECTING MACHINE FROM PRESSURE CIRCUIT
For some services or repairs it is necessary to remove machine from pressure circuit. This must not be done
before pneumatic system is depressurized.
1. Switch the compressor OFF and close the main output valve if available. Never use pressure
regulator adjustment for closing main output airflow. (See compressor manual)
2. Remove pressure from pneumatic system. Easiest way to do this is to use Shutoff valve on HUR
Pneumatic Control Unit. If that is not available, press and hold + and –valve buttons
simultaneously. This allows air to flow through machines pneumatic system. Hold buttons down
until machine pressure gauge reading is near zero.
3. Disconnect the pressure tube from machine pressure input connector
6.3 LUBRICATING AND ADJUSTING ROLLERS
To ensure silent operation it is recommended to lubricate and adjust (if necessary) rollers every 6 months.
Basic lubrication of rollers:
1. Remove roller end plug carefully
2. Apply lubricant to both ends of the roller
3. Test for proper operation
4. Install roller end plug, replace if broken

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If rollers need to be adjusted or replaced:
1. Remove roller end plug carefully
2. Remove roller bolt and washer
3. Remove roller assembly
NOTE! Cover upholsteries before removing roller
4. Remove conical washer
5. Wipe roller axle and roller end cap contact surfaces clean
6. Lubricate contact surfaces of axle and end caps
Lubricating complete axle surface is not necessary
7. Install new conical washer
8. Install roller assembly
9. Install roller bolt and washer
NOTE! Make sure that the smooth surface of the washer is against the roller end cap
10. Use Loctite Green or equivalent for bolt threads
11. Tighten the bolt until rotating roller has a slight resistance
12. Check for proper operation
13. Install end plug, replace if broken
NOTE!! Do not force plug in with hammer etc. This will alter roller adjustment and additional
tightening might be necessary
6.4 LUBRICATING PISTON RODS
To maximize cylinders lifetime and to ensure silent and smooth operation it is recommended to lubricate
piston rods every 6 months.
NOTE! This procedure is required for keeping warranty validated.
Locate the cylinders of the machine and move the outer
lever so that the piston rod of the cylinder is fully
extended.

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Apply Vaseline to the piston rod using fingertips.
NOTE! Use white Vaseline that has no chemicals.
(Festo LUB-AL2 for low friction cylinders recommended)
Contract and extend the piston rod a few times by moving
the outer lever arm back and forth.
When tilting the machine, avoid causing tension on
pressure tubing or electric wirings.
6.5 CHECKING FOR LEAKAGE
There will always be a little escaping air through the system that will not affect the way the machines work.
However, excessive air leakage will not allow the machines to work at their full potential. There are few
reasons why leakage may occur, such as fittings becoming loose, dry piston rod seals, corroding connectors
and valve leakage.
Wipe the piston rod using a soft dry cloth to clean away
any dust accumulated.

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Testing for leakage:
1. Set machine pressure to 50-70% of maximum level
a. Adjust the pressure higher than your test pressure and set the correct pressure using minus
valve
2. No visible pressure losses should occur in 5 minutes
a. Do not use the machine that is on a pressure test
Dual Function units should be tested for both exercise directions.
In case of a pressure drop the leakage point should be located.
1. Listen for hissing noises from the machine.
2. Connectors can be tested by spraying soap water on them
a. Do not soak the machine!
b. Bubbles indicate leakage
In case of Dual Function unit dropping pressure on only other exercise direction:
-Check switch valve connectors
-Check OR-valve connectors
-Check 5/2-valve connectors
-Check cylinder for leaking through
1. Remove non-pressure side tube
2. Test leakage by spraying soap water on the connector that the tube was disconnected
from.
Rotate connector so that opening is downwards for keeping water of getting inside
the cylinder
3. Bubbles indicate cylinder leaking through
Leakage in following components or connectors cause continuous leakage no matter of switch valve
position:
-Pressure adjustment valves
-Pressure gauge
-Pressure tank (on pressurised side only)
In case of leakage in tube connection, try to reconnect the tube first. Connections are sometimes loosened
for miscellaneous reasons (tension on tubing etc.)
Damaged part that causes leakage should be replaced immediately.
Leakage can increase compressor runtime. This may cause excessive wear or even overheating related
damage.