Troubleshooting MCB Issues – Version 2 AC MCBs Trac/STARTRAC... · Customer Services Bulletin STAR TRAC FITNESS 1 of 2 637-1393 Rev: A MCB Transformer Issue (PN: 715-3880 & 715-3881)

Troubleshooting

STAR TRAC FITNESS 1 of 1 637-1394 Rev: A

MCB Issues – Version 2 AC MCBs

All Treadmills with Version 2 AC MCBs There are some critical actions that should take place when using the version 2 MCB. These actions will eliminate unnecessary random errors that occur on the treadmills. Below is a list of the failure modes, and the supporting documentation to resolve the issues.

Display Type LED Embedded Failure Mode Support Documentation (Document Number)

X Check Speed System 637-1391 X Check Motor System 637-1391 X X 100,000 DFR (21 Blinks) 637-1391, 637-1392 X X 1,000,000 DFR (25 Blinks) 637-1364, 637-1391, 637-1392 X Error Code 40 637-1327, 637-1391

X X Treadmill won’t calibrate 637-1327, 637-1364, 637-1391 X X MCB won’t power up. 637-1393 X X Speed Fluctuation 637-1327, 637-1391 X X Treadmill will reset 637-1364, 637-1393

Doc Num Title

637-1327 AC Drive Motor Rumbling/ RPM Sensor Gap 637-1364 Version 2 AC MCB: Calibration Issues 637-1391 110 Volt MCB Jumpers on MCB: 715-3881 637-1392 Loose Components on the MCB 637-1393 MCB Transformer Issue (715-3880 & 715-3881)

Troubleshooting

STAR TRAC FITNESS 1 of 1 637-1327 Rev: B

AC Drive Motor Rumbling / RPM Sensor Gap

Treadmills with an AC Drive Motor If an AC drive motor is making a rumbling sound and has a jerky motion, check the gap between the RPM sensor and the tach wheel. The gap must be at least 2mm. When the gap between the sensor and the tach wheel is less than 2mm, it may give the symptoms of a faulty drive motor.

Note: It is important to rotate the flywheel one complete revolution to ensure that the gap remains fairly consistent.

Customer Services Bulletin


Version 2 AC MCB: Calibration Issues

E Series Treadmills Star Trac Customer Service has received a few reports of E Series treadmills with the following issues:

• Will not perform auto calibration • Shortly after starting a program, the treadmill will reset. • DFR Code 1,000,000 (25 blinks on the MCB LED)

Upon investigation, it has been found that the ferrite on the power cable for the MCB is positioned too close to the magnetic RPM sensor (Fig. 1). This causes interference on the RPM signals going to the display which cause the symptoms listed above.

Fig. 1



To resolve this issue, use a tie wrap (zip tie) to fasten the ferrite to the elevation motor cable (Fig. 2). This will ensure there is proper distance between the ferrite and the RPM sensor.

Fig. 2

Also the routing of the RPM sensor cable may cause intermittent issues if the cable is run near the power cable of the

MCB. To ensure that this interference is avoided, route the cable as show below (Fig. 3). You may need up to 4 tie wraps.



110 Volt MCB Jumpers on MCB: 715-3881

E Series Treadmills

Warning: The following procedures require the power to be on. Take extreme caution when working around live electrical components.

This document covers the first production batch of 110V MCBs (PN: 715-3881). These MCBs were put into production in mid-August 2010 (TREx1008-xxxxxx) and continued in production through January 2011 (TREx-xxxxxx). The potential problem with these MCBs is that 2 ground jumpers are missing on some units within this batch. Figures 1, 2 & 3 will show the actual location of the ground jumpers. If you experience any of the following issues:

• “Check Speed System” on LED treadmills

• “Check Motor System” on LED treadmills

• “Error Code 40” on Embedded treadmills

• Difficulties calibrating speed

• Fluctuations in speed

• DFR codes: 100,000 (21 blinks on MCB) or 1,000,000 (25 blinks on MCB) First, refer to document 637-1364 and ensure that the RPM sensor cable and MCB power cable are properly routed to avoid sensor interference. If the routing of those 2 cables are correct and one or more of the above listed issues still persists then look at the MCB and check to see if the 2 jumpers are present (as shown in figures 1, 2 & 3). If the jumpers are not present on the MCB, then this is likely the cause of your issue and the MCB must be replaced. We have experience a very low percentage of failure due to this issue. The majority of MCBs in the field without these jumpers will perform correctly and normally for the life of the product. This affects only 110V MCBs with PN: 715-3881. It does NOT affect 220V MCBs with PN: 715-3880. These have the ground jumpers incorporated into the board (not visible from the outside).



Fig. 1



Fig. 2

Fig. 3



Loose Components on Version 2 MCBs

PN: 715-3881 & 715-3880 At Star Trac, we are continually testing the components that go into our products. One such test discovered that the some components on the version 2 MCB could shake loose over time. These components are:

• RT1 • RT2 • MOV1

Warning: Do not touch the MCB with the power on. Take extreme caution when working around live electrical components.

When one of these components becomes loose, the connection between one of the legs and the MCB is bad and the board signals a DFR code. There are two possible codes that can appear:

• 100,000 (21 blinks) • 1,000,000 (25 blinks)

Once one of these components has become loose or the connection on one leg is broken, the MCB must be replaced. To ensure that this issue does not occur in the future, our manufacturer has applied mechanical reinforcements to each of these areas. The new MCB you receive will have these reinforcements in place.



MCB Transformer Issue (PN: 715-3880 & 715-3881)

E Series Treadmills and S-TRc

Warning: Take extreme caution when working around live electrical components.

The following MCBs: (PN: 715-3880 220V & PN: 715-3881 110V) underwent several re-works. The following should explain the re-work that has been done to the transformer. The symptom you might see if there is an issue with the transformer is a complete power down of the treadmill. The reason is a slightly out of specification transformer used from the manufacturer of the MCB. The solution is to replace the MCB. The timeline of MCBs that are affected are from August until November of 2010. Note: The failure occurs early in the life of the product. Chances are, if the MCB has not failed in the first few days, it will not fail in the future.

Fig. 1



110V MCB (PN: 715-3881) 1. NOTHING written on the transformer (yellow middle section) indicates a MCB that did NOT undergo a rework of

the transformer. 2. WITH something written on the yellow middle section of the transformer (normally an ‘OK’) indicates a MCB that

underwent the first rework of the transformer (Fig. 1). 3. A ‘V’ or ‘check sign’ on it will indicate the MCB also underwent the second rework with added ground jumpers

(see document 637-1391 for details, 110V MCBs only) AND cut off outer pins of the DC power supply port (Fig. 2, connector number JP3 on the board) AND glued on components (Fig. 3 and see document number 637-1392).

220V MCB (PN: 715-3880) 1. NOTHING written on the transformer (yellow middle section) indicates a MCB that did NOT undergo a rework of

the transformer. 2. WITH something written on the yellow middle section of the transformer (normally an ‘OK’) indicates a MCB that

underwent the first rework of the transformer (Fig. 1). 3. A ‘V’ or ‘check sign’ on it will indicate the MCB underwent the second rework with cut off outer pins of the DC

power supply port (Fig. 2, connector number JP3 on the board) AND glued on components (Fig. 3 and see document number 637-1392).

Fig. 2

Fig. 3

Troubleshooting MCB Issues – Version 2 AC MCBs Trac/STARTRAC... · Customer Services Bulletin STAR TRAC FITNESS 1 of 2 637-1393 Rev: A MCB Transformer Issue (PN: 715-3880 & 715-3881)

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