Need help with a failed controller for a treadmill.

[gears47]

I have attached a report of what happens and what I have done so far to no avail. Full details in uploaded file and pics. File uploaded, having problems uploading pics, will try again later.
regards Gears47

 

[bertus]

Hello,

The pictures are likely to large.
Resize the pictures to about 300 kB.

Bertus

 

[gears47]

Thanks, have reduced size of photos. uploading them now.

 

[Bluejets]

You may have to speak to someone on how to upload photos acceptable to size regs but still visible detail.
As they are, repoduction is blurry there is not anything identifiable and way too small.

 

[gears47]

I've tried again with the pics, hope they are okay this time. Uploading now.

 

[Cirkit]

What were the part numbers of the original rectifier and IGBT?

Do you have an ESR/component tester? You can buy a fairly cheap one and worth having.

 

[Bluejets]

2 x for that....I bought one of these....saves a lot of time and frigging around.

Rechargable in to the bargain, all leads supplied.
Was about $23.00 last year but as with many things since the virus hit....gone up mostly due to postage fees.
Still, $30.00 not bad for what you get.

https://www.ebay.com.au/itm/Transis...655584?hash=item3426869ce0:g:u90AAOSwDYNd7ja-

 

[gears47]

What were the part numbers of the original rectifier and IGBT?

Do you have an ESR/component tester? You can buy a fairly cheap one and worth having.

I don't have a ESR tester and the attachment contains what info I got off original parts.
regards gears47. 9am, 23/5/20

 

[gears47]

2 x for that....I bought one of these....saves a lot of time and frigging around.

Rechargable in to the bargain, all leads supplied.
Was about $23.00 last year but as with many things since the virus hit....gone up mostly due to postage fees.
Still, $30.00 not bad for what you get.

https://www.ebay.com.au/itm/Transis...655584?hash=item3426869ce0:g:u90AAOSwDYNd7ja-

Thanks for the info. regards gears47

 

[Cirkit]

I don't have a ESR tester and the attachment contains what info I got off original parts.
regards gears47. 9am, 23/5/20

OK, so you replaced the parts like for like.

If you place your meter across the sensor contacts and manually rotate the fly wheel, do you register any change in reading?

It would be worth investing in an ESR tester if you can. You can buy cheaper ones that do not have a built-in rechargeable battery.

 

[Bluejets]

Looked for a user manual but no luck so far.

What I did notice from your photo of the panel when powered is there is no number shown on the incline section.
Wondered if there needs input there from an incline sensor for the motor to initiate run.
Most I have seen will run a tiny bit and then check the speed sensor for movement and if none then stop, however your unit is not moving at all.
Note the motor drive voltage is more than likely PWM so may not show what you expect to see on a digital multimeter.

 

[gears47]

OK, so you replaced the parts like for like.

If you place your meter across the sensor contacts and manually rotate the fly wheel, do you register any change in reading?

It would be worth investing in an ESR tester if you can. You can buy cheaper ones that do not have a built-in rechargeable battery.

I have ordered an ESR tester, should have it next week. I measured the voltage across the 2 pins on the sensor lead, had motor running using 20vdc supply. Had multimeter set on 200mv and it showed 00.1, 00.2 vdc but mostly 00.0. Have uploaded photo of flywheel and sensor.

 

[gears47]

Looked for a user manual but no luck so far.

What I did notice from your photo of the panel when powered is there is no number shown on the incline section.
Wondered if there needs input there from an incline sensor for the motor to initiate run.
Most I have seen will run a tiny bit and then check the speed sensor for movement and if none then stop, however your unit is not moving at all.
Note the motor drive voltage is more than likely PWM so may not show what you expect to see on a digital multimeter.

Checked, there is no sensor for the incline, it is a manual incline unit.
Thanks, Gears47. 5:02pm, Sunday 24/05/2020

 

[Bluejets]

What about with the sensor disconnected from the board , set the meter on low ohm and roll the pulley over by hand.
Only having 2 wires seems to infer it may be simply a reed switch.

Is there a magnet imbedded in the pulley anywhere in its peripheral in line with the sensor?

 

[gears47]

What about with the sensor disconnected from the board , set the meter on low ohm and roll the pulley over by hand.
Only having 2 wires seems to infer it may be simply a reed switch.

Is there a magnet imbedded in the pulley anywhere in its peripheral in line with the sensor?

I will check that tomorrow. I think it is only used as a distance counter.

 

[gears47]

I removed the controller from the treadmill, removed the heat sink mounting bracket and took several pics of the board and components, this might help.

 

[Bluejets]

One would assume the pwm signal would have to come from the control panel given the operator would need to control the speed.

Nothing between there and the power board left unconnected in any way..?

 

[gears47]

Checked reed switch and magnet on fly wheel. No magnetism on magnet. Removed reed switch and checked operation on bench with magnet, Switch operated. Photo's attached. I have checked the control panel and could not find any disconnections. There is only the 5 core cable from the controller and control panel. Have checked each core for continuity and all is fine. I will have to try to replace magnet on flywheel. I'm not sure where to go from here.

 

[Bluejets]

The number of cables from the controller to the power board could contain many possible forms of communications.
Having just 5 cables is no indication of what information can be sent, in or out.

Bit confused here...your first photo shows the drive pulley with what appears to be a magnet but you say it contains no magnetism...??

One could say fair enough, maybe just a proximity sensor but most sensors I am aware of (except the reed switch) require 3 cables, yours is just 2.
3 wire sensors usually 5V pos and neg and a signal out.

Reason I am asking is, I have seen videos on some treadmills and they show a pulse from a sensor feeding to the main power board required to ramp up the motor speed.

Have seen also where they simulate this by bridging a couple of input terminals (on and off rapidly) on the power board for on-bench testing.

 

[Minder]

Most of the T.M.s I have come across have the track speed sensor that comes into the main board but is then sent up to the console where the speed is compared to the programmed speed and then a corrected signal is sent back down to the main board speed controller.
M.