Treadmill Technical ManualE-TRx E-TR S-TRc S-TRx Power Requirements Product Placement Preventative...

Last updated 03/06/2017 637-4504 Rev. B

Treadmill Technical Manual


Safety Information

Tools

Product Details

E-TRx

E-TR

S-TRc

S-TRx

Power Requirements

Product Placement

Preventative Maintenance

Systems

Power

Display

Drive

Belt & Deck

Elevation

Maintenance Mode

Part Replacement Procedures

Running Belt

Deck / Deck Cushions

Rollers

EMI Filter

Motor Control Board

Drive Motor

Elevation Motor

Console

o LED

o LED Keypad / Display Electronics

o Embedded

o CCB

Troubleshooting


Safety Information

The following pages are intended to educate service technicians on the basic maintenance and

service actions for the StarTrac treadmill. By following the enclosed instructions and

maintenance schedule, you will extend the life of your equipment and help ensure it will withstand

hours of use in your home/facility.

Before working on this equipment, pay attention to the following warnings:

Read and understand the complete Owner's Manual.

Keep Owner's Manual for future reference.

Read and understand all warnings on this machine. If at any time the Warning stickers become loose,

unreadable or dislodged, contact Customer Service for replacement stickers.

Keep children away from this machine. Monitor them closely when near the machine. Parts that move and

appear dangerous to adults can appear safe to children.

Consult a physician before you start an exercise program. Stop exercising if you feel pain or tightness in your

chest, become short of breath, or feel faint. Contact your doctor before you use the machine again. Use the

values calculated or measured by the machine's computer for reference purposes only.

Before each use, examine this machine for loose parts or signs of wear. Do not use if found in this condition.

Pay special attention to the steps. Contact Customer Service for repair information.

Maximum user weight limit: 500lbs. (227kgs). Do not use if you are over this weight.

Do not wear loose clothing or jewelry. This machine contains moving parts.

Set up and operate this machine on a solid, level, horizontal surface.

Do not step off the machine until the belt has fully stopped.

Do not operate this machine outdoors or in moist or wet locations.

Keep at least 20” on each side and 48” from the back of the machine clear for easy egress/ingress. This is the

recommended safe distance for access and passage around and emergency dismounts from the machine.

Keep third parties out of this space when machine is in use.

Do not over exert yourself during exercise. Operate the machine in the manner described in this manual.

When the machine is put in a studio or club environment, it can only be used in areas where access and

control of the machine is managed by approved staff. The degree of management depends on the user's

ability to recognize and prevent danger to third parties during the exercise movement.

To decrease risk of burns, fire, electric shock, or injury to persons:

An appliance must not be left unattended when plugged in. Unplug from outlet when not in operation and

before you put on or remove parts.

Close supervision is necessary when this appliance is used by or near children or disabled persons.

Use this appliance only for its intended use as described in this manual. Do not use attachments that are

not recommended by the manufacturer.

Do not operate this appliance if it has a damaged cord or plug, if it is not working correctly, if it has been

dropped or damaged, or fallen into water. Return the appliance to a service center for examination and

repair.

Keep the cord away from heated surfaces.

Do not drop or put any object into any opening.

Do not use outdoors.

To disconnect, turn all controls to the off position, then remove plug from outlet.


Tools

Qty. Name Model Manufacturer Specifications

1 Multi-meter Various Digital, Continuity

1 Socket Set, SAE Various 1/4" - 5/8"

1 socket Set, Metric Various 4mm - 21mm

1 Socket driver Various

1 Open end wrenches, SAE Various 1/4" - 3/4"

1 Open end wrenches, Metric Various 4mm - 17mm

1 Hex Bit Socket Set, SAE Various 5/64 - 3/8

1 Hex Bit Socket Set, Metric Various 4mm - 14mm

1 Torque Wrench Various

1 Torque Wrench Various

1+ Screwdriver Set, Phillips Various

1+ Screwdriver Set, Flat Various

1 Tape Measure Various

1 Cold Chisel Set Various

1 Ball Pin Hammer Various 10 oz

1 Bearing Puller Various 3-arm 1+ Rubber Mallet Various

1 iPod Apple Video

1 TV Channel Modulator Various Ch.3/4 Output

1 Headphone Standard Various Standard 3.5mm

1 Apple Composite AV Cable Apple

1+ Compression F Connector Wrench

LCCT-SS59/11 DIGICON

25+ Compression F Connectors DIGICON

DS6 DIGICON

1+ Cable Stripper VH596 RCA

1+ Cable Torque Wrench TW207-AH Ripley

2 Coax Seal #104 Coax-Seal

2 FISP - JTAG Programmer JTAG

4D Electronics Ltd. www.4d-electronics.co.nz

1 USB - Flash Drive Various 1 GB

1+ Stretch-wrap Cutter 400021 Highlight 1+ Furniture Dolly Various Rubber top

4 Motorcycle straps, adjustable Various

1+ 15 amp to 20 amp plug, adapter Various

1 Loctite 680 Various

50 zip ties 4”

50 zip ties 8”


E-TRx

15” embedded HD touch screen aligns user’s workout with their entry goals and expectations with sophisticated and intuitive programs and features

Integrated iPod® connectivity with music and video allows users to display personal content

Easily accessible Hot Bar® is located closer to the user with one-finger speed and elevation controls, integrated stop button and contact heart rate grips

Star Trac Coach™ Over 1 million possible workouts ensure a different workout every time taking the ordinary treadmill experience to a new level of engagement never seen before

Soft Trac® triple cell cushioning system provides maximum shock absorption

Centered dual-adjustable personal fans create a more rewarding workout

20% max incline

User weight capacity 500 lbs. (227 kg)

Overall Weight Running Surface Width Length Height 477 lbs 216.4 kg) 60˝ x 21.5˝ (152 x 55 cm) 36˝ (91 cm) 85˝ (215 cm) 63˝ (160 cm)

Features and Specifications: STEP-UP HEIGHT: 10” (25.5 cm) FRAME: Custom aluminum uniframe MOTOR DRIVE: 5 HP AC ELECTRICAL: 110 volt, dedicated NEMA 5-20 cord; 220

volt, dedicated NEMA 6-15 cord (optional)* CERTIFICATION: UL/CSA, CE, FCC, or CISPR SUSPENSION: Soft Trac® triple cell neoprene rubber,

Deck System: Reversible 1” (2.5 cm) composite fiberboard, waxing not required ROLLERS: 3.5” (9 cm) sealed bearings COLORS: Frame: Star Trac Silver, Shrouds: Slate Gray,

Accents: Black INCLINE RANGE: 0 to 20% in 0.5% increments SPEED RANGE: 0.5 to 15mph** (0.8 to 24 km/h**) in 0.1

mph (0.1 km/h) increments HR MONITORING: Polar® Telemetry and Contact Heart

Rate System DISPLAY: 15” embedded touch screen with high

definition TV and four workout views, including Progress View, Track View, Heart Rate View, and Simple View

READOUTS: Dedicated: Speed and incline, time

elapsed, calories, calories/hour, pace (min/mile or km), distance, course profile, heart rate, heart rate tracking, 1/4-mile motivational track, laps completed PROGRAMS: 18 workouts including Dynamic Heart Rate

Control®, Constant Heart Control, Fitness Test (Modified Balke Ware), Firefighter Test (Modified Gerkin Protocol), ARMY Protocol, USMC Protocol, USAF Protocol, NAVY Protocol, three custom workouts and Star Trac Coach™. STANDARD FEATURES: Standard Features: Hot Bar

controls, personal entertainment system, personal cooling fans, wrap-around Aero Bar, dedicated heart rate display, safety lockout control, FitLinxx® certified ENTERTAINMENT: E Series touch screen entertainment

system which includes 15” high definition LCD with touch screen technology, NTSC/ATSC/QAM digital tuner or PAL/SECAM tuner, integrated iPod® connector, USB power port, coaxial cable connector at base WARRANTY: Motor & MCB–5-year parts and labor;

Other parts–2-year parts, 1-year labor; Wear items–1- year parts and labor; Headphone jack, iPod connector, and USB port – 90 day parts, no labor (USA and Canada only)** (Light Commercial warranty for all non-dues paying facilities 3 years parts/labor)


E-TR

Pre-wired for E Series PVS entertainment system

User-friendly console and keypad feature a large service scrolling message window, user-specific workout programs, a dedicated heart rate display, Polar® telemetry and multiple cup and accessory holder


5 HP AC Motor


21.5” (54.6 cm) belt

9” (22.86 cm) step-up height User weight capacity 500 lbs. (227 kg)

Overall Weight Running Surface Width Length Height 575.5 lbs (261.04 kg) 60˝ x 21.5˝ (152 x 54.6 cm) 32˝ (81.3 cm) 81˝ (206 cm) 59.77˝ (151.81 cm)

Features and Specifications: STEP-UP HEIGHT: 9” (22.86 cm) FRAME: Custom powder-coated steel uniframe MOTOR DRIVE: 5 HP AC ELECTRICAL: 110 volt, dedicated NEMA 5-20 cord; 220

volt, dedicated NEMA 6-15 cord (optional) CERTIFICATION: UL/CSA, CE, FCC, or CISPR SUSPENSION: Soft Trac® triple cell neoprene rubber,

Deck System: Reversible 1” (2.5 cm) composite fiberboard, waxing not required ROLLERS: 3” (7.6 cm) sealed bearings COLORS: Frame: Star Trac Silver, Shrouds: Slate Gray,

Accents: Black INCLINE RANGE: 0 to 15% in 0.5% increments SPEED RANGE: 0.5 to 12.5mph (0.8 to 20 km/h) in 0.1


Rate System

STEP-UP HEIGHT: 9” (22.86 cm) FRAME: Custom powder-coated steel uniframe MOTOR DRIVE: 5 HP AC ELECTRICAL: 110 volt, dedicated NEMA 5-20 cord; 220





Rate System


S-TRc




5 HP AC Motor


20” belt

7” step-up height User weight capacity 500 lbs. (227 kg)

Overall Weight Running Surface Width Length Height 533 lbs (241.7 kg) 60˝ x 20˝ (152 x 51 cm) 32˝ (81.3 cm) 81˝ (206 cm) 58˝ (147.3 cm)

Features and Specifications: STEP-UP HEIGHT: 7” (17.8 cm) FRAME: Custom powder-coated steel uniframe MOTOR DRIVE: 5 HP AC ELECTRICAL: 110 volt, dedicated NEMA 5-20 cord; 220





Rate System

DISPLAY: Intuitive, tactile response keypad with LED

technology READOUTS: Large 8-character message window;

Dedicated: Time, distance, incline, speed, heart rate, 1/4-mile motivational track, profile; Scrolling: calories, METs, course profile PROGRAMS: 12 programs including Dynamic Heart

Rate Control®, Constant Heart Rate Control, Quick Start, Burn Calories, Manual, Increase Endurance, Fitness Test (Modified Balke Ware), Firefighter Test (Modified Gerkin Protocol) STANDARD FEATURES: Personal cooling fans,

wraparound Aero Bar, dedicated heart rate display, Entertainment Solutions Ready, Safety Lanyard ENTERTAINMENT: Pre-wired for S Series PVS

entertainment system WARRANTY: Commercial warranty: 2-year parts

warranty, 1-year labor warranty, 5-year parts and labor warranty on the motor and motor control board; Light commercial setting: 3-year warranty on parts and labor, 5-year parts and labor warranty on the motor and motor control board (USA and Canada only)** (Light Commercial warranty for all non-dues paying facilities 3 years parts/labor).


S-TRx




3 HP DC Motor


20” belt

7” step-up height User weight capacity 500 lbs. (227 kg)

Overall Weight Running Surface Width Length Height 514 lbs (233.2 kg) 60˝ x 20˝ (152 x 51 cm) 32˝ (81.3 cm) 81˝ (206 cm) 58˝ (147.3 cm)

Features and Specifications: STEP-UP HEIGHT: 7” (17.8 cm) FRAME: Custom powder-coated steel uniframe MOTOR DRIVE: 3 HP DC ELECTRICAL: 110 volt, dedicated NEMA 5-20 cord; 220





Rate System

DISPLAY: Intuitive, tactile response keypad with LED

technology READOUTS: Large 8-character message window;

Dedicated: Time, distance, incline, speed, heart rate, 1/4-mile motivational track, profile; Scrolling: calories, METs, course profile PROGRAMS: 12 programs including Dynamic Heart

Rate Control®, Constant Heart Rate Control, Quick Start, Burn Calories, Manual, Increase Endurance, Fitness Test (Modified Balke Ware), Firefighter Test (Modified Gerkin Protocol) STANDARD FEATURES: Personal cooling fans,

wraparound Aero Bar, dedicated heart rate display, Entertainment Solutions Ready, Safety Lanyard ENTERTAINMENT: Pre-wired for S Series PVS

entertainment system WARRANTY: Commercial warranty: 2-year parts

warranty, 1-year labor warranty, 5-year parts and labor warranty on the motor and motor control board; Light commercial setting: 3-year warranty on parts and labor, 5-year parts and labor warranty on the motor and motor control board (USA and Canada only)** (Light Commercial warranty for all non-dues paying facilities 3 years parts/labor).


Power Requirements Treadmill Dedicated Circuit Requirement: Star Trac requires a 20 amp dedicated circuit and dedicated neutral for each treadmill installed

and operated. Each treadmill requires an outlet of which line and neutral contacts are wired to

the electrical power distribution box (circuit breaker box) with dedicated wires. Both the line and

neutral wire from an outlet for a treadmill shall be isolated from all other outlet contacts other

than the connection at the electrical power distribution box. The neutral bar of the electrical

power distribution box requires a connection to the earth ground.

Furthermore, there shall be no other electrical device operated off this circuit; just the single

treadmill. The earth ground connection of the outlet may be shared with other outlets’ earth

ground connections through either metal conduit or ground wire.

Each dedicated circuit requires 12 gauge wire for the line and neutral wires for runs less than

100 feet, as measured from the circuit breaker to the termination of the plug (outlet) connecting

to the treadmill. Runs greater than 100 feet require 10 gauge wires, and a run from a circuit

breaker shall not be greater than 200 feet.

Failure to meet these requirements may cause intermittent treadmill shut-down and potential damage to the treadmill’s electronic components, and consequently, void the warranty.


Product Placement Star Trac recommends that treadmills be spaced a minimum of 20.0 inches (0.5 m) apart to

allow safe and easy ingress and egress. More importantly, there must be at least 48 inches

(1.25 m) of free space behind the treadmill.

The E-Series treadmill measures: 85” l by 36.0” w (215.9 x 91.5cm). See the following graph for

proper equipment spacing requirements:


Preventative Maintenance This section provides a list of factory recommended PM requirements. Long-term effects and

cost comparisons usually favor following a regular preventative maintenance schedule over

performing maintenance actions only when the system fails.

Preventative Maintenance Cautions

While maintaining equipment you will want to avoid spraying any liquids directly onto any surface of the unit. Always spray cleaning solutions onto a clean towel first then wipe the unit.

While vacuuming the floor area using an upright vacuum, avoid getting the power cord caught in the beater-brush of the vacuum.

Disconnect the power cord from the wall before vacuuming under the shroud.

Use extreme caution while vacuuming around wires and/or electrical components under the shroud.

Do not attempt to clean the running belt with a mop

Do not apply any cleaners, protectants or solutions onto the running belt (i.e. Armor All,

SlickStuff, belt dressing, etc.)

Maintenance Actions:

Daily Weekly Monthly Yearly Wipe Down all Surfaces X

Wipe Running belt with Dry Cloth X

Elevate Unit and Vacuum underneath X

Check Belt Tracking to assure belt stays centered X

Check Condition of Power Cord X

Inspect and Clean underside of running belt X

Check drive belt tension X

Check Running belt tension, adjusting if needed X

Check all settings and Keypad Performance X

Vacuum under shroud being careful around Electrical Assy

X

Unplug unit and check all power connections including speed sensor

X

Calibrate Elevation & Speed X

Check Belt and Deck Condition and replace if wear found X


Treadmill Systems

Power System The power system supplies AC and DC voltage to different components of the treadmill. There

are two parts of the power system, external power and internal power.

There are two sub-systems:

External

Internal

External

The external power is anything outside of the treadmill that supplies power.

Components:

Breaker Box

Wall Breaker

Power Lines

Dedicated/isolated lines

Neutral Line

Hot Line

Ground Line

Receptacle

Internal Power

The internal power is the components of the treadmill that are involved with power distribution.

Components:

Power Cord

On/Off Switch

Onboard Circuit Breaker

EMI Filter

MCB

Power Supply

Data Cable

Display Electronics


Power Flow Diagrams

1. AC power goes from the

breaker box, through the

circuit breaker and power

lines to the power outlet.

2. AC power continues up

through the power cord,

through the onboard circuit

breaker, on/off switch, and

EMI filter to get to the MCB.

3. The MCB converts the

power to 12.6 volt VDC to

send up the display cable

to power up the display

electronics.

4. The MCB doubles the

incoming voltage (110 volt

systems only) and sends

220 VAC to the power the

drive motor. The MCB also

sends 6 VDC to power the

RPM sensor.

5. The MCB sends VAC to

power the elevation motor.

The power being sent will

depend on the input voltage.

110 VAC treadmills have a

110 volt elevation motor.

220 VAC treadmills have a

220 VAC elevation motor.

The MCB also sends 5 VDC

to the elevation sensor

(potentiometer).

6. The MCB passes along the

input VAC to the power

supply. The power supply

then converts the input

voltage to 12 VDC and

sends it up to the display

electronics to power the

fans (PVS kit or embedded

touch screen).


Display System

The display system controls and commands most of the functions of the treadmill. It is the user

interface and the brain of the treadmill.

There are five sub systems:

1. Treadmill Operation

2. Watch Dog

3. Personal Cooling Fans

4. Heart Rate

5. Hot Bar/Warm Bar

Treadmill Operation

Treadmill operation is those functions and components that the user interacts with while working

out on the treadmill.

Components:

Main Keypad (Display Panel)

Display Electronics

Data Cable

Watch Dog

The watch dog is the circuit/software inside the display electronics that monitors the different

systems in the treadmill. If there are any anomalies, the watch dog triggers any of the various

codes that will show up on the screen.

Components:

Display Electronics

Personal Cooling Fans

This system is used to keep the users cool.

Components:

Display electronics

Fan Keypad

Fans


Heart Rate

The users have 2 types of heart rate to use, contact or Polar. Contact heart rate is used by

grabbing onto to the metal contacts on the hot/warm bar. Polar is a wireless system that

requires the user to wear the Polar chest strap.

Components:

Display Electronics

Contact Heart Rate Board

Contact Heart Rate Cables

Contact Heart Rate Grips

Polar Receiver

Hot /Warm Bar

The Hot/Warm bar is the bar that is right in front of the user that has multiple functions and

components.

Warm Bar Components:

Stop Button

Emergency Stop (lanyard)

Contact Hear Rate Grips

Hot Bar Components:

Stop Button

Emergency Stop (lanyard)

Contact Heart Rate Grips

Speed Control

Elevation Control

Headphone jack (for units with entertainment)


Display System Power Flow

1. The user presses the keypad to select programs, speed, elevation etc. Those keystrokes are received by the display electronics which sends the necessary requests down the data cable to the MCB.

2. The watch dog is a part of the display electronics that monitors the systems of the treadmill and will shut down the system if there are any anomalies.

3. The user presses the fan keypad to turn the fans on/off or change the speeds. The display electronics receives the signals and sends the appropriate VDC to the fans.

4. The user grips the contact heart rate grips. A small amount of voltage is sent through the grips and wires to the contact heart rate board. The contact heart rate board calculates the Beats Per Minute (BPM) and sends this information to the display electronics. If the user is wearing a Polar chest strap, signals from the strap will be received by the Polar receiver. Those signals are sent to the display. The display will display the BPM of the user’s heart.

5. When the user presses the stop button, the circuit opens (confirm that) and the display electronics triggers the treadmill to: (a) pause on the first press, (b) end the program on the second press and (c) give a ‘NO STOP’ code if the key is held for longer than 2 number of seconds. If the lanyard is pulled, the emergency stop circuit opens up and a signal is sent to the MCB to cut power to the drive circuit. The message “EMERGENCY STOP, PRESS STOP TO RESET TREADMILL” will appear on the display electronics.


Drive System

The drive system is what makes the treadmill running belt move as well as sends feedback to

the display for keeping track of speed.

There two sub systems:

Drive Power

Feedback

Drive Power

Drive power is the VAC going to the drive motor to make it turn.

Components:

Display Electronics

Data Cable

MCB

Drive Motor

Feedback

Feedback is what the display uses to make sure the speed is what the user commanded.

Components:

RPM Sensor

MCB

Data Cable

Display Electronics


Drive System Power Flow

1. The user enters what speed they want the treadmill to go by pressing the speed keys or entering the desired speed on the number keypad.

2. The display electronics registers the requests and send information down to the MCB.

3. The MCB sends VAC to turn the drive motor.

4. The drive motor pulley is connected to the headroller..

5. As the drive motor turns the RPM sensor signal is sent to the MCB.

6. The MCB sends the signal back to the display electronics.

7. The display electronics calculates that information to determine the speed of the drive motor. If the drive motor is running too fast/slow, the display will send signals to the MCB to adjust the voltage going to the drive motor until the speed is correct.


Belt & Deck System

The belt and deck system is the main function of the treadmill.


Rollers

Belt and Deck

Rollers

The rollers are used to make the belt rotate. It also applies tension and tracking for the belt.

Components:

Drive Belt

Headroller

Tailroller

Belt and Deck

Belt and deck are two of the wear items in the system. The user runs on the belt and deck.

Components:

Running belt

Deck

1. The drive belt connects the drive motor to the headroller.

2. The tailroller is used for tensioning and tracking of the running belt.

3. The running belt goes around the two rollers and the deck. The deck is the hard surface that the running belt slides on.


Elevation System

The elevation system controls the incline of the treadmill.


Elevation Motor

Elevation Sensor

Elevation Motor

The elevation motor is the muscle that makes the incline go up and down once it has received

signals from the display.

Components:

Display Electronics

Data Cable

MCB

Elevation Motor

Elevation Sensor

The elevation sensor is also known as the elevation potentiometer and is a part of the elevation

motor. It provides incline location feedback to the treadmill console.

Components:

Elevation Motor

MCB

Data Cable

Display Electronics


Elevation System Power Flow

1. The user enters the desired elevation by pressing the elevation keys on the display.

2. The display sends a signal down to the MCB through the data cable.

3. The MCB will send the appropriate amount of AC voltage to the elevation motor to make the incline go up or down. The MCB also sends a constant 5 volts DC to the elevation potentiometer (pot).

4. As the elevation motor turns, the elevation pot’s voltage changes. That voltage is sent back to the MCB.

5. The MCB sends to elevation pot voltage up the data cable and to the display.

6. The display will calculate what the incline number is based on the voltage being received and the min/max values set for the incline to determine the current incline position.


Maintenance Mode

LED Console: To enter Maintenance Mode, press the 0, 2, and OK keys all together at once.

A beep will sound and the console will say Maintenance Mode.

Use the Elevation up/down keys to change between Maintenance Mode options.

Use the Speed up/down keys to edit the options.

Use the OK button to enter, or save.


Embedded Console: To enter the Service Menu, press the Vol +, Ch+, and 3 keys all together at once.

Press the option on the touchscreen, or press the number option you want to select on the keypad.

The embedded console password is 218.

Use the Elevation up/down keys to change between Maintenance Mode options.

Use the Speed up/down keys to edit the options.

Use the OK button to enter, or save.


Part Replacement: Running Belt

Troubleshooting that must be done PRIOR to replacement: 1. DFR code 800 2. Confirm that the running belt logo ( STARTRAC ) is not 75% worn out 3. Confirm that the running belt is not over tensioned 4. Confirm that the running belt does not slip ( use stomp test ) 5. Confirm that the running belt is aligned with the roller 6. Remove drive belt and check for roller noise

Adjustment requirements after replacement:

1. Required running belt installation 2. Required head roller replacement

Testing requirements after replacement: 1. Confirm that the installation test procedure is done

Running Belt Tension: Proper running belt tension and tracking are important to maintain the performance and life of the belt. It is recommended to follow the proper tracking and tensioning procedure whenever running belt or deck is replaced, or as needed.

Tensioning Frequency:

After 1,000 Miles, or 1 Month. Or whichever comes first.

6,000 Miles, or 6 Months


18.000 Miles, or 18 Months


30,000 Miles or 30 Months

Belt Alignment:


Part Replacement: Running Belt

Procedure:

1. Remove the front and side bed covers from the machine.

2. Loosen and remove the two bolts that hold the tail roller onto the machine chassis. Remove the tail roller from between the belt and set to the side.

3. Pull and turn the T-pin idler pulley to remove tension on the drive belt. Caution pinch points.

4. Using a long phillips head screwdriver remove the 4 screws that hold the head roller finger guard in place.

5. Walk the drive belt off of the headroller pulley. Remove belt from small pulley on motor.


6. Loosen and remove the bolt that connects the head roller to the chassis of the machine.

7. Remove the head roller and drive belt from between the running belt and set to the side.

8. Loosen the deck retention rods at the 4 corners of the deck.

9. Remove belt and deck from chassis of machine.

10. Flip deck so that the unused side is face up.

11. Replace new belt. Ensure arrows on the Star Trac logo are oriented in the direction the belt will move.

12. Replace the belt and deck onto the chassis and fasten the 4 corner deck retention rods.


13. Replace head roller through the belt and mount into the chassis of the machine. Ensure drive belt is on the head roller before mounting it.

14. Walk drive belt onto head roller and tail roller pulleys.

15. Tension idler t-pin handle.

16. Replace head roller finger guard onto the chassis of the machine.


17. Replace tail roller through the belt and mount to the chassis of the machine with the two bolts. Tension bolts equally, as they are responsible for overall belt tension as well as tracking.

18. Ensure proper tracking and re-tension belt using stomp test.

Adjustments:

The running belt and its headroller, drive belt, tailroller, and running deck are designed to be

self-centering, slip-free, and smooth-operating without the need for frequent adjustments.

Running belt sideward movement, slipping, or grinding after extended use, or thumping during

initial use, may be corrected by the following procedures:

Belt Tracking:

If the running belt is not centered on the tailroller and is either too far left or right, adjust tracking

using the following steps:

1. Turn the treadmill on. Increase treadmill speed to 3.0 mph (5.0 kph).

2. Adjust tracking by turning the left Allen screws (located at the back sides of the tailroller)

with a 1/4" Allen wrench in 1/4-turn increments. If the running belt is tracking to the left,

turn the screws clock-wise in 1/4 turn increments. If the running belt is tracking to the

right, turn the left screw counter-clockwise in 1/4 turn increments.

3. NOTE: ONLY USE THE LEFT SCREW FOR TRACKING ADJUSTMENT.

4. After the running belt appears to be tracking properly, increase the treadmill speed to

10.0 mph (16.0 kph) and verify that the belt stays centered.

Stomp Test - Slipping-Running Belt:

Remove the motor shroud and operate the treadmill slowly at 1 to 2 mph (2 to 3 kph). While

observing the headroller, walk on the belt and try to slow it down by gently applying pressure

with your feet while holding the handrails. If only the running belt, and not the headroller, slows

down, tighten the running belt by turning both the right and left tailroller adjustment bolts clock

wise 1/4-turn. Repeat this adjustment until the running belt no longer slips; ensuring that you

turn both tailroller bolts an equal number of turns. Re-install the motor shroud. If the headroller

and the running belt both slow down, tighten the drive belt.


Part Replacement: Deck

Troubleshooting that must be done PRIOR to replacement: 1. DFR code 800 2. Confirm that the running belt logo ( STARTRAC ) is not 75% worn out 3. Confirm that the running belt is not over tension 4. Confirm that the running belt does not slip ( use stomp test ) 5. Confirm that the running belt is aligned with the roller 6. Remove drive belt and check for roller noise

Versions / Changes: 1. Wax Removed From Decks

Adjustment requirements after replacement: 2. Required running belt installation 3. Required head roller replacement

Testing requirements after replacement: 1. Running belt tension and tracking 2. Running belt stomp test


Part Replacement: Deck Cushion

Procedure:

1. Remove running belt, deck, and rollers.

2. Remove old deck cushioning rubber. Use a putty knife or scraping tool to remove all adhesive residues from chassis.

3. After removing all the adhesive, use180 grit sandpaper to remove the remaining remnants and to rough up the surface. Note: Clean this area after preparations are complete.

4. Apply epoxy in a zig zag pattern to cleaned metal surface.


5. Lay the cushion on the frame with the larger side on the bottom.

6. Align it and press down firmly on various areas of the deck cushion for 30 seconds. For best results, allow at least 15 minutes for the adhesive to cure before putting the deck back on the frame.

7. Reinstall the rollers, belt, and deck onto the frame. Tip: Use a wet towel to moisten the top of the rubber deck cushion before installing the deck. This stop the deck from sticking to the deck cushion when being installed.


Part Replacement: Rollers

Troubleshooting that must be done PRIOR to replacement: 1. Confirm drive belt has right tension 2. Confirm drive belt is not worn 3. Confirm motor has not been adjusted 4. Remove drive belt from roller and check for roller noise

Versions / changes: 1. Treadmill Roller Crown Change Feb. 2008

Adjustments requirements after placing: 2. Confirm installation procedure

Testing requirements after placing: 3. Confirm drive belt has right tension 4. Confirm stomp test

The care and maintenance of the head and tail rollers are as important as the care and

maintenance of the running belt. Dirt buildup on the rollers can cause noise, rough feelings and

unwanted belt tracking.

Cleaning:

Scrape any dirt and debris build up from the roller using a plastic scraper or an old credit card.

Do not use anything metal or sandpaper, as you will damage the coating on the roller. Vacuum

up any debris from the rollers.

Roller “DO NOT’s”:

• Do not lubricate the roller bearings. They are a sealed type bearing and any lubricant you

attempt to apply, will not penetrate the seal.

• Do not scrape a roller with metal. Use a plastic scraper or a credit card only.

• Do not use sandpaper to clean the rollers


Part Replacement: EMI Filter

Troubleshooting that must be done PRIOR to replacement 1. Check for 120v AC input from wall. 2. Check for 120v AC out from power switch. 3. Check for 120v AC input to EMI filter. 4. Check for 120v AC output from EMI filter. 5. Check for 120v AC input to MCB.

Versions / Changes: 1. Last change was done in Feb/2008.

Programming requirements after replacement: 2. None required.

Testing requirements after replacement: 3. Perform a full function test on the machine.


Part Replacement: EMI Filter

Procedure:

1. Turn unit off, unplug power cord from the wall, and wait until AC LED on the MCB has gone out.

1. Disconnect red and blue leads going from the power switch/breaker into the EMI filter and the red and blue leads from the EMI filter out to the MCB connector.

2. Disconnect the ground wire that connects the EMI filter to the machine chassis

3. Using a phillips head screwdriver, loosen the two screws and disconnect the EMI filter from the machine chassis.

4. Reverse Steps 1 – 3 for installation of

replacement EMI Filter.


Part Replacement

Part Replacement: MCB

Troubleshooting that must be done PRIOR to replacement 1. Check for voltage input to unit. 2. Check AC LED and V-CON LED’s are on. 3. Verify voltage into the EMI filter is 120v AC. 4. Verify 120v AC voltage out of the EMI filter input cable. 5. Verify that the fuse is good on the MCB. 6. Determine if the power connectors have any burn or scorch marks on the MCB. 7. Reseat display (I/O) cable on the MCB & display electronics board 8. Check Display cable out of MCB connected 9. Check MCB LEDs 8 and 11 for status ready Blinking 10. Check that the MCB’s LED 8 for status ready blinking 11. Verify a motor bleeder test must have 19 to 20 mega ohms. 12. Check Last Error List for a DFR 4000 code on the display (LED console).

Versions / Changes: 1. Version 1 MCB’s were updated to Version 2 in Feb/2011.

Programming requirements after replacement: 2. None required.

Testing requirements after replacement: 3. Perform a motor / speed calibration test


Part Replacement: MCB

Procedure: 1. Turn unit off, unplug power cord

from the wall, and wait until AC LED on the MCB has gone out.

2. Remove wiring connectors into MCB for Motor, Speed Sensor, I/O, 12v DC power, Elevation, Power, and Ground wire.

3. Remove 4 phillips head screws that mount the board to the chassis.

4. Reverse Steps 1 – 3 for installation

of replacement MCB.


5. Ensure all wiring connectors are seated fully into the MCB. Check that wires are away from the RPM disc of the motor and are routed properly.

6. Make sure to re-route and zip tie the speed sensor wire around the back of the MCB.


Part Replacement: Drive Motor

Troubleshooting that must be done PRIOR to replacement 1. Check for DFR code 4000 in display 2. Check for voltage input to unit 3. Check AC led & V-CON LED’s on 4. Verify voltage in from the EMI is generating 120v AC 5. Verify that 120v AC voltage coming out from the EMI input cable 6. Perform a motor bleeder test must have 19 to 20 mega ohms. 7. Perform a continuity check on the thermostat wires from the motor

Versions / Changes: 1. Last change was done in Feb/2008

Programming requirements after replacement: 2. Perform a motor / speed calibration

Testing requirements after replacement: 3. Run program on unit


Part Replacement: Drive Motor

Procedure:

1. Remove the top motor shroud and front bumper.

2. Turn unit off, unplug power cord from the wall, and wait until AC LED on the MCB has gone out.

3. Disconnect speed sensor and remove zip ties holding it to the MCB.

4. Disconnect motor wire harness connector from the MCB.


5. Remove the RPM sensor assembly and the RPM disc from the motor. Set aside for use on the replacement motor.

6. Pull and turn the T-pin idler pulley to remove tension on the drive belt. Caution: pinch points.

7. Using a long phillips head screwdriver remove the 4 screws that hold the head roller finger guard in place.


8. Walk the drive belt off of the headroller pulley. Remove belt from small pulley on motor.

9. Loosen the 4 bolts that connect the motor to the chassis and remove the motor and bleeder wire. Lift motor up and take caution not to damage the bolt threads. Caution: the motor is heavy. Do not to damage any of the bolt threads, or wiring connections. Leave the spacer block in place on chassis of machine.

10. Loosen the two set screws that connect the balance wheel to the motor. Using a rubber mallet, remove the balance wheel from the shaft. Remove the key from the motor shaft slot.

11. Mount the key into the keyway and the balance wheel onto the motor shaft. Leave set screws snug, but not tight. These will be adjusted to properly align the motor and head roller pulleys.


12. Place the replacement motor into the chassis of the machine; connect with 4 bolts, including bleeder wire.

13. Using a straight edge, align balance wheel with the head roller pulley, apply blue Loctite to the set screws, and tighten.

14. Walk drive belt back onto motor pulley first and then the head roller pulley. Pull T-pin idler handle to re-tension drive belt.


15. Mount the RPM disc to the motor shaft using blue Loctite on the set screws. Torque set screws and shaft bolt to 60 – 66 Lb-In.

16. Mount the RPM sensor assembly and ensure appropriate gaping (2mm) of speed sensor and RPM disc. Adjust as necessary to ensure proper gap.

17. Re-route the speed sensor wire along the back of the MCB and zip tie into place. Plug the cable harness into the corresponding MCB connector.


18. Re-route the new motor power cable under and behind, or zip tied to the front (as shown) of the elevation motor and plug into MCB.

19. Reconnect dust cover / finger guard.

20. Turn machine on and perform a Speed / Motor Calibration in the Maintenance Mode of the console.

21. Replace all machine shrouds.


Part Replacement: Elevation Motor

Troubleshooting that must be done PRIOR to replacement 1. Check elevation settings on display are set within ranges listed below. 2. Check for elevation errors 3. Check elevation motor wires orange and blue to MCB with meter. 0% elevation reading

should be 9.4 -9.5 k ohms max elevation readings 500-600 k ohms. 4. Press up and down on incline check up /down LEDs on MCB 5. Check for AC output to elevation motor while elevating up or down on display volt meter

reading from 100v AC to 200v AC on RED and BLACK wires 6. E-series elevation motor check potentiometer in the elevation motor measure wires ohm

reading should be range 9.4 -9.5 k ohms at 0% ohm readings should range from 500 – 600 ohms at max elevation

7. Check display cable for any damage

Versions / Changes: 1. Last change was done in Dec. 2016. This change introduced 1.05 Display software, for

8-Series LCD displays, and 1.6 Translator Board software, for E and 8-Series 15” Please note that this new version changed the elevation parameters as outlined below:

Programming requirements after replacement: 2. Perform an elevation / incline calibration

OLD (pre V1.05) Calibration Values:

Model Incline Range Min (zero elevation) Max (full elevation)

E-TRx 0% - 20% 230 38

E-TR 0% - 15% 230 70

S-TRc 0% - 15% 235 - 230 67 – 75

S-TRx 0% - 15% 235 - 230 67 – 75

NEW (post V1.05) Calibration Values:

Model Incline Range Min (zero elevation) Max (full elevation)

E-TRx / 8-TRx 0% - 20% 228 11

E-TR / 8-TR 0% - 15% 228 55

Testing requirements after replacement:

3. Run program on unit.


Part Replacement: Elevation Motor

Procedure:

1. If possible, before replacing the elevation motor, elevate treadmill.

2. Turn Power Off / Unplug from wall

3. Remove the shrouds (both top and front bumper shown in Step 1).

4. Disconnect Elevation Motor wiring harness from MCB and remove ground wire from chassis. Cut any zip ties on the elevation motor, or elevation motor wire harness and remove it from any cable stays on the machine chassis.

5. With a partner, lift front end of machine and place a dumbbell, jack stand, or 12” – 18” 4x4 on metal plate of the machine chassis under power switch/power cable inlet. Or, if space allows, turn the treadmill on its user-left side.


6. On the under-side of the machine, remove cotter pin, pin, and spacer that connect the motor to the lift bar of the machine. Caution: potential pinch points when the elevation frame weldment (lift bar) is removed from the elevation motor.

7. Disconnect elevation motor from chassis and retain plastic cover/grommet for use in the replacement.

8. Remove old elevation motor. Take caution not to damage any of the wiring harnesses upon removal.

9. Install replacement elevation motor onto the chassis making sure the lift screw is all the way in (do this manually by turning).


10. Align lift bar with pin with the elevation shaft connector and insert pin, spacer and connect. Don’t forget spacer.

11. With a helper, remove the jack, or 4x4 holding the unit up and return unit to the ground.

12. Using a level ensure treadmill is level and adjust leveling feet as needed. Use as the base when running an elevation calibration.

13. Route Elevation motor wires away from the RPM disc of the Drive motor. Connect wiring harness to MCB connection and seat fully. Ensure ground wire from Elevation motor to machine chassis is connected.


14. Verify potentiometer reading is 9.4 – 9.6 Ohms, blue and orange wire of elevation MCB connector, when the treadmill is at zero elevation.

15. Plug unit in, power on and perform an elevation / incline calibration in the Maintenance Mode of the console.

16. Re-zip tie elevation motor wiring to machine chassis and reconnect shrouds.


Part Replacement: LED Display

Troubleshooting that must be done PRIOR to replacement 1. Check for DFR code on MCB 2. Check for EE error 3. Check AC led on MCB 4. Check V-CON led on MCB 5. Verify voltage input to MCB 120 volts AC from EMI 6. Verify the display (I/O) cable is connected from MCB to Display. 7. Check for damage on the display cable 8. Check voltage across C79 and ground 12 volts DC


Programming requirements after replacement: 2. Set appropriate machine maintenance mode, verify all other settings 3. Perform motor calibration 4. Perform elevation calibration

Testing requirements after replacement: 1. Perform a keypad test 2. Perform HR test


Part Replacement: LED Display

Procedure:

1. Using a phillips head screwdriver disconnect upper and lower rear covers from the console.

2. Disconnect the I/O Ribbon cable and the DC Power Cable.

3. Remove all the applicable electrical connections from the back of display electronics board.


4. From the back of the display, connect the grounding wire to the frame using a washer & phillips head screw.

5. Disconnect 6 screws that connect the console to the machine chassis.

6. Prepare new display for mounting.


7. Identify all the applicable electrical connections to the back of display electronics board.

8. Connect the E-Stop cable (g) to the J25 connector and connect the rail stop cable (f) to the J5 connector on the display board.

9. Connect the Hot Bar cable (i) to the display board.

10. Connect the Contact Heart Rate cable (c) to the display board.


11. Connect the I/O ribbon cable (e) to the display board and ensure it is seated fully.

12. Reconnect new console to the machine chassis.

13. Ensure ground wire is reattached.

14. Replace rear console covers. Turn machine on and run Heart Rate and Keypad Test procedures in Maintenance Mode.


Part Replacement: LED Console Keypad / Display Electronics

Troubleshooting that must be done PRIOR to replacement: 1. Perform a keypad test 2. Check for ribbon cable damage 3. Check ribbon cable is connected to all pins on display board


Programming requirements after replacement: 2. None required

Testing requirements after replacement: 3. Perform a keypad test


Part Replacement: LED Console Keypad / Display Electronics

Procedure:

1. Remove console from chassis.

2. Disconnect 3 screws that connect the overlay to the plastic console housing.

3. Remove 5 sheet metal screws that hold the Display Electronics onto the metal brace of the console housing.

4. Disconnect fan keypad, personal cooling fan wire harnesses, CSAFE, and hot bar connections to the Display Electronics.


5. Remove the overlay and Display Electronics from the plastic console housing, making sure to unhook the 2 clips at the base of the keypad overlay.

6. Remove the keypad overlay from the Display Electronics by removing the 5 extension posts and screw.

7. Disconnect main keypad ribbon cable.

8. Fasten new keypad overlay to the Display Electronics with the 5 post extensions and screw.


9. Reconnect the keypad overlay and Display Electronics to the console housing. Note: ensure to align tabs at base of keypad to the corresponding holes in the console housing.

10. Reconnect wires back onto the Display Electronics.

11. Remount console onto chassis.


Part Replacement – Embedded Display

Troubleshooting that must be done PRIOR to replacement 1. Confirm power from FCB or MCB ver2 12v DC to CPU 2. Confirm power from the CPU 12v DC to CCB input 3. Confirm Power from Translator to FITCPU 12v DC 4. Confirm all setting and Model setting are correct 5. Confirm TV channel scan 6. Confirm touch screen calibration 7. Confirm software Version 8. Confirm touch screen error code

Versions / Changes:

Dates Sold Software Details / Differences

1st Generation 2008 - 2010 GUI 1.XX - 2.27 Either has no USB port for coaching stick or the coaching USB port is on the mother board. TV Tuner mounted to motherboard of CPU.

2nd Generation 2010 - 2014 GUI 3.XX – 4.XX The coaching port is a cable that sticks out and the tuner card is mounting on the mother board (ref doc 637-1422). TV Tuner mounted to motherboard of CPU.

3rd Generation 2014 - Present GUI 5.XX External USB TV Tuner card mounted outside the CPU sheet metal.

Programming requirements after replacement: 1. Perform Motor calibration 2. Perform elevation calibration 3. Perform touch screen calibration 4. Perform channel scan

Testing requirements after replacement: 1. Verify all work out programs work 2. Verify that all channels are clear 3. Verify there is audio coming from the audio jack at the display housing 4. Verify that iPod menu/video will display on the screen 5. Verify touch screen response



Procedure:


Part Replacement: CCB

Troubleshooting that must be done PRIOR to replacement: 1. Check CCB keypad for power lit LED (If no RED led is on follow CCB replacement # 22 2. Check the power for 12v DC input (under 11 volts DC replace power FCB or wire ) 3. Check power input to PVS 12v DC. (Check for burn marks on cable/connectors) 4. Check for 12v DC output from CCB (if not found replace CCB board.) 5. Reseat all cable/plug connections. 6. Check all cable/plug connections for burn marks.

Version/Changes:

Programming requirements after replacement: 1. Perform channel scan 2. Delete any channels the facility does not want

Testing requirements after replacement: 1. Confirm iPod menu comes on 2. Confirm you can access the PVS programming mode


Part Replacement: CCB


Troubleshooting

DFR Codes:

The MCB monitors various temperatures, currents and voltages coming in. When the

MCB senses an anomaly it will shut down and identify a Drive Fault Record (DRF) code.

Under normal operation circumstances, LEDs 1 – 3 blink in a staggered pattern sequence. When the machine is in an error state, LEDs 1 – 3 blink together in a repetitive pattern, pause, and then blink in a repetitive pattern again. The number of blinks can be counted and their meaning can be referenced in the flow charts below.


Troubleshooting

No Power to the Display

NO POWER TO DISPLAY

SOLUTIONS:

_________A1_______

Tripped Wall Breaker

or Bad Wall Circuit

_________A2_______

Replace Line Cord

_________A3_______

Replace On Off

Breaker

Note: Make sure the

line cord cables are

making a good

connection to the on

off breaker. Also make

sure the on off breaker

is turned to the of

position.

_________A4_______

Replace EMI Filter

Turn treadmill power on

Locate AC LED on the MCB

Is the AC LED off?

Verify all AC power wires are

making good connection

Yes

Measure wall output voltage

Measure EMI filter AC input voltage

Measure line cord output voltage

Was the wall output

voltage adequate?

Yes

Measure EMI output AC voltage

Was the

line cord output voltage

adequate?

A1

No

No

Yes

Was the

EMI filter input voltage

adequate?

Yes

A3

No

Was the

EMI filter output voltage

adequate?

A2

No

A4

No

Yes

Page 2

(A)

Start

Page 2

(B)


No Power To The Display

A

Measure MCB input

AC voltage

SOLUTIONS:

_________A5_______

AC MCB Input Cable

_________A2_______

Replace MCB

_________B1_______

Replace MCB

_________B2_______

Input component or

wire causing direct

short to display

electronics

Note: Plug one cable in

at a time into display

electronics to determine

the component or wire

that needs to be

replaced.

_________B3_______

Replace Display

Electronics

_________B4_______

Replace I/O Cable

Note: If problem still

exist after replacing the

I/O cable, replace display

electronics.

NO POWER TO DISPLAY

Was the

MCB input AC voltage

adequate?

A5

No

A6

Yes

B

Locate V-Con LED on the MCB

End

Is the

V-Con LED lit?No

Unplug the I/O cable

(Display Cable)

Yes

Is the

V-Con LED lit?

Disassemble back display

housing

Again check V-Con LED

No

Yes

Measure display input DC

voltage across positive side of

C79 and display ground

Voltage should be

approximately 12 volts

Was the display input

DC voltage adequate?

B1

Open display panel to expose

display electronic

Leaving only the I/O cable

plugged in disassemble all other

wires from display electronics

Is the

V-Con LED lit?

Yes

B2

B3

No

End

Re-connect the I/O cable

Back into the MCB

B3

Yes

B4

No


Error Code - Check Speed Systems

CHECK SPEED SYSTEM / CHECK MOTOR SYSTEM (AC MOTOR)

Start

Press 0, 2, and start

keys simultaneously

Screen will display

“Maintenance Mode”

Screen will display

“Press list error to view

last error list”

Press “Incline – or +“

key until display reads

“Last Error List”

Press “OK” key

Press “Speed – or +“


“Last DFR (5)xxxxxxxx”

Does

DFR (5) register

any # greater

that zero?

Yes

Press “5” key

Does the

Last Code (5) read

Check MO or

Check SP?

No

Yes

Does the

Last Code (4) read

Check MO or

Check SP?

No




Yes

Press # 4 key

Does

DFR (4) register

all zero?

Press # 3 key

No

Yes

Does the

Last Code (3) read

Check MO or

Check SP?

No




Yes

Does

DFR (3) register

any # greater

that zero?

Yes

Press # 2 key

No

No

Does the

Last Code (2) read

Check MO or

Check SP?




Yes

Does

DFR (2) register

all zero?

Press # 1 key

Yes

Does the

Last Code (1) read

Check MO or

Check SP?

No




Yes

Does

DFR (1) register

any # greater

that zero?

Call for

tech

support

Yes

No

No

Refer to

DFR #

flowchart

Refer to

DFR #

flowchart

Refer to

DFR #

flowchart

Refer to

DFR #

flowchart

Refer to

DFR #

flowchart

Refer to

DFR #

flowchart


Turn the tread AC power off.

Measure ohms between TM

ground and drive motor bracket.

Measurement should read

approximately 19 mega ohms.

Did the

measurement read an

open circuit?

Yes

Start

Make sure multimeter ohm

setting is greater than 20

Mega ohms.

Measure ohms directly

on bleeder resistor.

Does the

Circuit measurement

read open?

B1

Yes

Measure continuity between TM

ground and drive motor sensor

bracket screw.

No

No

Measure ohms on brake

resistor

Does the

Circuit measurement

read closed?

YesB2

No

Disconnect brake resistor wires

from MCB

Make sure multimeter ohm

setting is greater than 1K ohms.

Does the

Circuit measurement

read open?

Measurement should read

approximately 19 mega ohms.

B3

Yes

First addition of AC drive

motor system had a floating

motor bracket

Does this

unit have the old style

motor bracket?

No

Are the

spacers mounted

properly into the

bracket?

Yes

B4

No

B5

Yes

B4

No

Solution:

B1____Replace Bleeder

Resistor

B2____Isolate drive motor

from ground.

Note: Check motor

bracket gaskets,

sensor bracket

gasket, or anything

else related that is

causing the drive

motor to have

continuity with

ground.

B3____Replace brake

resistor

B4____Replace MCB

B5____Isolate bracket bolts

for the motor

bracket.

Note: Reattach

spacers through the

motor bracket and

re-tighten nuts.

End

DFR Code = 10000

Brake Gate Drive Fault / 17 Blink

Possible Causes:

(1) Faulty MCB.

(2) Bad or missing bleeder resister.

(3) Drive motor not isolated.

DFR Code = 100000

Output Peak Over Current / 21 Blink

Possible Causes:(1) Bad or missing bleeder resister.

(2) Bad brake resister.


DFR Code = 1000000

DC Link Bus Over Voltage / 25 Blinks

Possible Causes:

(1) Faulty MCB.

(2) Bad or missing bleeder resister.


DFR CODE FLOWCHART: DEFINITIONS / MCB LED BlinksDFR Flowchart For #: 1000000, 100000, and 10000


Solution:

C1____If the unit came up

with check speed or

check motor system

refer back to the

correct DFR number

listed on A1.

C2____Replace Drive

Motor

Note: Verify the

probes of the

multimeter are

making a good

connection with the

thermostat wires

labeled 5 and 6 on

honest connector.

Only take reference

to the drive motor

honest connector,

not the drive motor

wires they may not

coincide with each

other.

C3____Replace Drive

Motor

Note: Verify the

probes of the

multimeter are

making a good

connection with the

thermostat wires

labeled 5 and 6 and

Phase wires labeled

1, 2, and 3 on

honest connector.

Only take reference

to the drive motor

honest connector,

not the drive motor

wires they may not

coincide with each

other.

C4____

Replace MCB

Start

Recycle the tread AC power by turning

it off and back on

Run TM belt by

pressing quick start key

Does the

running belt have

movement?

Did the

TM error out with

a 4000 DFR

code?

Yes

No

Yes

No

Does the

circuit measurement

read closed?

YesC2

No

Measure continuity on thermostat

and phase wire on drive motor

Plug one probe into any thermostat

wire (5 or 6) and the other probe into

any of the phase wires (1, 2 or 3)

Does the

circuit measurement

read open?

Yes C3

No

Did the relay

switch on MCB

activate?

Yes

Measure continuity on drive motor

thermostat wires (pin 5 and 6)

Verify the drive motor, sensor, and display

cable wires are not damaged and making a

good connection with MCB.

C1

C4

End

DFR Code = 4000

Over Temp on Motor or Drive / 15 Blink

Possible Causes:

(1) Open thermostat wires on drive motor.

(2) Drive motor over heating.

(3) Faulty MCB.

DFR CODE FLOWCHART: DEFINITIONS / MCB LED BlinksDFR Flowchart For #: 4000


Solution:

__ D1_______

Replace Speed

Sensor

__ D2_______

Connect sensor wire

and retest

Note: Make sure

there’s no objects or

moveable parts that

may cause damage

to the wire.

__ D3________

Clean between

speed sensor and

disk to make sure

there is nothing

obstructing the

signal. Also make

sure the gap is

approximately 16th of

an inch difference.

__ D4________

Go back to last error

list and look for other

DFR codes different

than 1000

Note: Possible there

is another DFR in the

system due to sensor

failure will not cause

the unit not to run in

test mode.

__ D5________

Replace Speed

Sensor and if unit still

fails replace MCB

__ D6________

Unit is operable and

can be used again

Start


Check speed senor for

damaged or disconnected wire

Do the wire appear to

be in good condition?

Was the

Wire making a good connection

with the MCB?

YesD1

No

D2

No

Yes

D3

No

Was there

clearance and proper gaping between

the sensor and disk?

Yes

Engage motor test mode

Increase PWM to 100

Check for dirt build up between

the sensor and disk and proper

gaping.

Was there any belt movement?

Was there a sensor reading

in motor test mode

YesD4

D1

No

No

Calibrate running belt and retest

the unit in regular users mode

Yes

Does the 1000 DFR

code re-occur?

D6

D5

Yes

No

End

DFR Code = 1000Faulty Speed Sensor / 13 Blinks

Possible Causes:

(1) Sensor disconnected.

(2) Faulty speed sensor.

(3) Faulty MCB.



Solution:

__ E1_______

Clean the underneath

side of the running

belt and re-test

Note: If the problem

continues replace the

running belt.

__ E2_______

Replace MCB

Note: Make sure

there’s no objects or

moveable parts that

may cause damage

to the wire.

_________________

_________________

Solution:

__ F1________

Replace MCB

Note: If AC LED is

on and get this error,

replace the MCB.

__ F2________

Reconnect display

cable and re-test

Note: If AC LED is

not on check the I/O

interface cable and

connection. A speed

command with the

relay off will cause

this error.

__ F3________

Replace I/O Interface

cable (Display cable)

__ F4________

Replace I/O Interface

cable (Display cable)

and if the error still

occurs replace the

MCB

Start

Recycle the tread AC power

by turning it off and back on


Incline the unit to max

elevation

Stand at the highest point of

the incline and push body

weight back

Does

the running belt slide

smoothly across

deck?

Yes

No

E1

Decline unit back to zero

percent in test mode.

Increase the speed to 2 MPH

and attempt to push the

belt back faster that the

commanded speed.

Does the

running belt hold strong to it’s

commanded speed?

E1

E2

No

Start



Check AC LED on MCB to

see if it’s lit.

Does the AC LED off?

F1Yes

No

Check I/O cable (display

cable) at the display and

MCB for bad connection

Was the I/O cable

(display cable) making a

good connection?

F2

No

Check I/O cable (display

cable) pinched or damaged

wires

Yes

Was the I/O cable

(display cable) pinched or

damagd?

F3

F4

No

Yes

End End

DFR Code = 800Phase Over Current / 12 Blinks

Possible Causes:

(1) Worn running belt.

(2) Dirty running belt

(3) Faulty MCB.

DFR Code = 400Illegal Speed Command / 11 Blinks

Possible Causes:

(1) Pinched or damaged display cable.

(2) Bad wire connection to drive system

(3) Faulty MCB.

DFR CODE FLOWCHART: DEFINITIONS / MCB LED BlinksDFR Flowchart For #: 800, and 400


Solution:

__ G1_______

Consult with

electrician to fix AC

input rail voltage.

Note: The AC rail

voltage with a load

should never drop

greater that 5 volts

deferential comparing

it with no load. There

are many equations

to measure for low

rail voltage.

Example: If you take

a person that weighs

200 Lbs at the speed

of 5 MPH, and the

voltage drops greater

that 5 Vac. The wall

voltage is not

adequate and will

cause intermittent

200 DFR codes.

__ G2_______

Replace EMI Filter

__ G3_______

Replace MCB

Start


Measure AC voltage out of the

wall circuit.

Was the AC voltage within

the specs listed above?

The AC voltage should be

approximately:

95 to 120 for 110v unit

The AC voltage should be

approximately:

185 to 250 for 220v unit

G1

No

Check Ac output voltage

coming out of the EMI filter

Was the AC voltage within

the specs listed above?

G2

No

Yes

Engage maintenance mode

(0, 2, start simultaneously)

Yes


(#8 after engaging

maintenance mode)

Increase the speed to 5 MPH

or greater.

Measure AC input voltage with

a load

Was the voltage greater

Than 5 volt deferential?

The input AC voltage should

be less that 5 volt deferential

from the original AC voltage

that was taken with out a load

G1

G3

No

Yes

End

DFR Code = 200DC Link Bus Under Voltage / 10 Blinks

Possible Causes:

(1) Low AC voltage from wall.

(2) Low AC voltage from EMI filter.

(3) Faulty MCB.



Start



Solution:

__ H1_______

Replace MCB

__ H2_______

Replace I/O cable

__ H3_______

Reinsert the phase

wires into the honest

connector.

Note: If the wire

continues to make a

bad connection

replace drive motor.

There is a relay on the MCB

that will activate when turning

the AC power on when unit is

in operable condition.

Did the

display beep with

out the relay switch

activating?

Check I/O cable (display cable)

for pinched or damaged wires.

Yes

H1

No

Was the I/O cable

in good condition?

Check the phase wires on the

drive motor for good

connection in the motor honest

connector or damaged wire.

Yes

Was there a damaged

wire or bad connection on phase

wires to honest connector?

H2

No

H3

H1

Yes

No

End

DFR Code = 40Phase A Circuit Open / 7 Blinks

DFR Code = 20Phase B Circuit Open / 6 Blinks

DFR Code = 10Phase C Circuit Open / 5 Blinks

Possible Causes:

(1) Bad wire connection on drive motor.

(2) Open phase wire in drive motor.

(3) Faulty MCB.

DFR CODE FLOWCHART: DEFINITIONS / MCB LED BlinksDFR Flowchart For #: 40, 20, and 10


DFR Code = 2000Heat Sink Over Temp / 14 Blinks

DFR Code = 100Critical DC Link Bus Over Voltage (MAX

_VDC2) / 9 Blinks

DFR Code = 80DC Link Bus Over Voltage (MAX _VDC1) /

8 Blinks

DFR Code = 8Phase A Current Sensor / 4 Blinks

DFR Code = 4Phase A Current Sensor / 3 Blinks

DFR Code = 21.65 Vdc Ref. Status / 2 Blink

DFR Code = 12.5 Vdc Ref. Status / 1 Blink

DFR Code = 800000Phase C High (Gate Drive Fault) / 24 Blink

DFR Code = 400000Phase B High (Gate Drive Fault) / 23 Blink

DFR Code = 200000Phase A High (Gate Drive Fault) / 22 Blink

DFR Code = 80000Phase C Low (Gate Drive Fault) / 20 Blink

DFR Code = 40000Phase B Low (Gate Drive Fault) / 19 Blink

DFR Code = 20000Phase A Low (Gate Drive Fault) / 18 Blink

___________________________________

___________________________________

Possible Causes:(1) Faulty MCB.

Solution:

__ I1_______

Replace MCB

__ I2_______

Verify the drive

motor, sensor, and

display cable wires

are not damaged and

making a good

connection with

MCB, and re-test.

Note: If all drive

system wires are

making a good

connection replace

MCB.

__ I3_______

If different DFR error

come up refer back

to the DFR flowchart

of the error that’s

coming up.

Start



A relay switch should click on

the MCB

Does the relay switch

click on the MCB?

I1

I2Yes

No

End

Did the

display beep with

out the relay switch

activating?

Yes

Verify the drive motor, sensor,

and display cable wires are not

damaged and making a good

connection with MCB, and re-

test.

Yes

I1

Does the unit error out

with the same DFR code?

Yes

I3

No

DFR CODE FLOWCHART: DEFINITIONS / MCB LED BlinksDFR Flowchart For #: 2000, 100, 80, 8, 4, 2, 1, 800000, 400000, 200000, 40000, and 20000


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Treadmill Technical ManualE-TRx E-TR S-TRc S-TRx Power Requirements Product Placement Preventative...

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