Service Manual - Nasan Medical
ST WIN
Service Manual
Nasan Medical Electronics Pvt.Ltd
© All Rights Reserved
Rev 7, Dated 21-3-2016
1
TABLE OF CONTENTS
1.
2.
3.
4.
5.
INDEX
PROCEDURES LIST
SYSTEM DIAGRAMS AND CONNECTIONS
SYSTEM CONFIGURATION
PROBLEMS,SOLUTIONS AND MATERIAL REQUIRED TO
SOLVE THE CALL
6. APPENDIX
A. TREADSTAR TABLE
B. USE OF CLAMP METER
C. 15 PIN SIGNAL DETAILS
D. TOOLKIT
E. BASIC PATIENT PREPARATION
F. IMPORTANT NOTE
G. EARTHING
H. STANDARD PROCEDURES
I. PRECAUTIONS
7. SERVICING OF TREADMILL CONTROLLER AND BODY LEVEL USED
WITH HIGH FREQUENCY DRIVE
Rev 7, Dated 21-3-2016
2
1. INDEX
Nature of Problem
Elevation Related
Page No
6 to 11.
Speed Related
11 to 17.
Software Related
18 to 20.
Miscellaneous
20 to 21.
Procedures List
27 to 38.
2. PROCEDURES LIST.
NO
PROCEDURE LIST
PAGE
NO.
1.
Independent testing of the treadmill
27
2.
Changing of 10 K10 turn pot.
27
3.
Changing of AC motor.
29
4.
Changing of Dc motor.
30
5.
Changing of AC card+ DC drive Assembly to ACDC
30
drive combined.
6.
Changing of actuator.
32
7.
Changing of rollers.
33
8.
Changing of Rack and pinion.
34
9.
Changing of magnet.
34
10.
Changing of limit switch
34
11.
Changing of Conveyer belt.
34
12.
Standard calibration procedure.
35
Rev 7, Dated 21-3-2016
3
3) SYSTEM DIAGRAMS:
230V AC
MAINS
STWIN
AMPR
TREADMIL
L & COMPR
TREADMILL
PC
TO
PATIENT
Fig 1. BLOCK DIA OF ST-WIN SYSTEM
LED INDICATION
FOR SPEED AND
ELEVATION
9-PIN
SERIALPORT
CONNECTOR
GOING TOWARDS
PC
FUSE 2A
POWER CORD
COMING FROM
AC MAINS
ON OFF
SWITCH
15 PIN
CONNECTOR
GOING TO
TREADMILL
(TPC cable)
Fig 2. AMPLIFIER CONNECTIONS
Rev 7, Dated 21-3-2016
4
4) MINIMUM SYSTEM CONFIGURATION
Minimum Requirement of PC for ST-Win system
1. Motherboard: Recommended
MAKE: D-Link/ASUS/INTEL/HIS
CHIPSET: Intel/VIA
SPEED: FSB, 400 MHz and onwards
2. CPU: Recommended
MAKE: Intel P-4, Speed 2.4 GHz, 400FSB
3. RAM: Recommended
Make: Symtronics/Hyundai/Transcend.
Size: 128 MB
Speed: 266 MHz
4. Serial Ports (RS-232): One working free serial port for ST-Win
amplifier.
5. VGA card: 64 bit, 2 MB memory PCI VGA card or onboard.
6. Monitor: 14” color monitor or onboard.
7. SMPS: Recommended
Make: Priya/Mercury/Intex.
Capacity: 300 Watt.
8. Hard disk: Recommended
Make: Seagate
Size: Barracuda 40 Gb 7200 RPM or onwards.
9. Display Settings: Resolution-1024*768
Font-Small font.
Color-16 bit hi color.
10. Key Board: PS/2 with 101 keys.
11. Mouse: PS/2.
12. Operating System: Windows 98/2000/XP/Win 7
13. Stabilizer: 3.5 KVA Servos (For treadmill only).
14. CD ROM: Recommended
Make: LG/Samsung/Sony/ASUS.
Type: Speed 52X
15. Printer: Recommended
Type: HP Laser Jet 1000/HP Laser Jet 1010 of USB port
HP Laser Jet 6L Gold/Pro.
16. Independent earthing connection.
Rev 7, Dated 21-3-2016
5
5) PROBLEMS, SOLUTIONS AND MATERIAL REQUIRED TO SOLVE THE CALL.
PROBLM
PROBLEM
PAGE
NO
NO
1.
Speed Related.
1. Speed reduction in second stage and onwards
2. No speed(conveyor belt is not moving at all)
3. Speed and elevation not as per protocol through software
4. Speed goes on increasing when we switch on the
TM(Uncontrolled speed)
5. Fuse blows as speed goes on increasing.
6. Jerk in speed/Speed reduces as patient walks on treadmill
7. Elevation is correct but speed incorrect in protocol
2.
3.
4.
Elevation Related.
1. No elevation
2. Treadmill runs smoothly for 1st couple of stages, after that
it elevates randomly.
3. Treadmill stuck/elevates to its top position
4. On/Off switch(mcb) of treadmill trips down
5. Treadmill elevates properly upto 1st stage only and no
further elevation
6. Treadmill elevates/de-elevates slightly
7. No medians and no heart-rate.
8. While coming down treadmill not stopping.
9. Slow speed and slight elevation before 1st stage.
Software Related.
1. PC getting hanged while running software.
2. Communication error.
3. Noise in ECG when patient walks on treadmill or even if he
stands on treadmill.
4. Error of DAO setup or error as ‘STWIN 98 mdb’ file not
found.
5. Error as ‘STWIN 98-mdb’ file missing. When we install
DAO Setup for ST Win 3.74 from CD ROM, it works fine. But
when we remove the CD, then an error as ‘.mdb’ file missing
comes.
6. Lead 1 is coming inverted
7. Spikes during the test due to which HR is more than actual
value.
Miscellaneous.
1. Treadmill non-functional again and again.
2. 10K-10-turn pot getting burned.
3. ST-Win amplifier fuse blowing.
4. Base line wandering while test is going on.
5. Noise observed on lead V6
6. Spike in ECG
Rev 7, Dated 21-3-2016
6
6
8
9
9
10
10
11
11
12
12
13
14
14
16
17
17
18
18
19
19
19
19
20
20
21
21
21
22
22
1) SPEED RELATED.
NOTE: - Always connect Clamp meter before servicing the treadmill through live
wire of AC/DC card/High frequency drive and then check current is in range.
Problem
1.
Speed reduction in second stage and onwards
Background:
In calculating speed of treadmill, we are adhering to the following
principles:
1. We use a pmdc motor, which is required to drive the treadmill with
high speed. To drive the motor and subsequently the treadmill at
different appropriate speed we use dc drive (Refer fig 3 top view).
2. Any medical equipment must be precise, and it should have
continuous feedback. A closed feedback is maintained by following
method:
a. At the side of dc motor our treadmill has a heavy
wheel, which is called as flywheel. There is a
magnet
embedded
on
this
flywheel.
At
approximately 5 mm from the flywheel, a sensor is
located (Refer fig 4).
b. Each time the flywheel rotates one cycle the sensor
detects it and the LED on AC/DC card flashes. If the
LED is not flashing on every rotation of flywheel
then correct speed will not be detected.
c. Even if the sensor is too near to the flywheel then it
will not detect the speed properly.
(Note: It is essential that the sensor should be between 5 mm
to 7 mm from flywheel and the (d41) LED should flash when treadmill
is running.)
Possible cause:
Generally this happens when the sensor whose function is to sense the
flywheel revolution, is very close to flywheel (Refer fig 3).The solution to
this is that the distance between the flywheel and the sensor should be
between 5mm and 7mm.
Check points/Solution:
1. Check weather sensor connection is loose
2. Interchange sensor connections wires from 2 pin relimate connector
3. If still problem persists, change ACDC drive
4. If still problem persists change ST Win amplifier.
Material
Req.
Sensor coil, silicon oil (200ml).
Rev 7, Dated 21-3-2016
7
SPEED
SENSOR
FLYWHE
EL
DC MOTOR
FRONT
ROLLER
AC MOTOR
CONDENSOR
GEAR BOX
AC/DC
COMBINE
D CARD
Fig. 3 TOP VIEW
Rev 7, Dated 21-3-2016
8
MAGNET IS
EMBEDDED IN
THE FLYWHEEL
SPEED SENSOR
DC
MOTOR
Fig 4. SPEED SENSOR
Problem
2.
No Speed (Conveyor belt is not moving at all)
Check Points/Solution
1. Run test treadmill program (Refer procedure 12) and click
appropriate buttons for speed increase and decrease.
2. Observe the speed increase/ decrease LEDs on back panel of the
STWIN amplifier (Refer fig 2).If LEDs are glowing, then the
problem lies in TPC cable or in treadmill.
3. But if the LEDs are not glowing then the problem lies with
STWIN amplifier or calibration factors are incorrect.
4. Check TPC cable continuity, if needed cut both ends and resolder
the cable (Refer fig 13 for Cable Details).
5. If belt is not moving while testing the treadmill independently
then the problem probably lies on the treadmill side. First check
whether the speed indication feedback LED (Fig 9) is glowing on
AC/DC drive.
6. If it is not glowing, then ensure that 230-volt ac is reaching ac
mains connector on AC/DC card. If 230 volt is present and still
no speed, then change ac/dc drive.
7. The last step is to change the dc motor. But before changing do
the following cold test.
8. Cold test for dc motor:
a. Remove 3-pin top of treadmill from mains supply.
b. Remove all the two wires of dc motor.
c. Ensure that there is no continuity between treadmill body and
all connectors of dc motor.
d. In case of pmdc motor, ensure that the armature resistance is
nearly equal to 2-3 ohms.
Material
Req.
ST win amplifier,AC/DC combined card, silicon oil(200ml).
Rev 7, Dated 21-3-2016
9
Problem
3.
Solution
Material
Req.
Problem
4.
Material
Req.
Speed and elevation not as per protocol through software
1. If conveyor belt is too tight then also this problem occurs. In
that case loosen the belt accordingly and put silicon oil (50100ml)under belt
2. Earth voltage should be less that 5V
3. Check continuity of TPC and serial port cable and re-solder if
needed (Refer fig 13 for Cable Details).
4. Check voltage setting of 10k 10 turn pot setting and speed
sensor alignment.
5. Calibrate the treadmill for speed and elevation.
6. Confirm that treadmill and PC, both are connected to one and
the same phase only. Always give power from one and the same
extension board to treadmill.
7. Though the treadmill and PC both are connected on the same
phase, there might be difference in earth to neutral voltage, so
short the both earth points with 24/36 wire externally.
8. Reload the software.
9. If still problem persists, change STWIN amplifier.
ST Win amplifier, silicon oil (200ml).
Speed goes on increasing when we switch on the treadmill
(Uncontrolled speed)
Possible cause:
1. When the stress test is started and the program goes into the
first stage, the treadmill should reach a speed of 2.7 km/hr
gradually.
2. But if the speed goes on increasing continuously more than
2.7km/hr (uncontrolled), it means that the feedback path is not
getting completed.
Solution:
1) For this do following steps one by one till the problem gets solved.
a) Check sensor connector is properly connected. Ensure that it is
not loose also.
b) Check continuity of treadmill to STWIN amplifier cable, if needed
re-solder the same.
c) Remove the speed sensor wires & ensure that resistance of
speed sensor is nearly equal to 14 ohms.
d) Check the position of magnet on flywheel and ensure that
magnet is present on flywheel.
e) Ensure that the (d 41) LED on AC/DC drive is blinking.
2) If points 1/2/3 as mentioned above are correct and still this LED is
not blinking, change the AC/DC drive.
(1) This problem also occurs due to failure of IC 324 or IC
374 and LM339 on PCB 141.
Sensor coil, AC/DC drive, silicon oil (200ml).
Rev 7, Dated 21-3-2016
10
Problem
5.
Fuse blows as speed goes on increasing.
Background:
1. In our treadmill, the magnetic ring acts as a speed sensor (Refer
fig 5). Our software takes feedback from treadmill to know the
actual speed.
a. If the actual speed is more than required by protocol, the
software sends signal to treadmill so as to reduce the
speed.
b. If the actual speed is less than the required by protocol,
the software sends signal to treadmill so as to increase
the speed (attain the required speed).
Possible Cause:
If the speed sensor is broken or not at appropriate position the
feedback will be zero and the PC will consider that the actual speed is
zero. Hence the PC will keep on increasing the speed of treadmill
resulting in large current drawn by ac/dc drive. This cumulative action
will result in blowing of the fuse.
Check that current limit in each stage is normal, If there is a problem in
ac/dc drive then it will take large current then normal in that case
blowing of the fuse may occur.
Solution:
Change the broken speed sensor or magnet if needed.
Material
Req.
Problem
6.
Fuse, sensor coil, magnet, and ACDC drive, silicon oil (200ml).
Jerk in speed/Speed reduces as patient walks on treadmill.
Possible causes:
1. No silicon oil below conveyor belt.
2. AC/DC drive unable to provide sufficient current to dc motor.
3. Interference of DC choke radiation with speed sensor feedback.
(Wrong increased speed feedback to PC).
4. Conveyor belt might be loose.
Solution:
1. Add silicon oil (50-100ml)below the belt from both sides.
2. Here, run test treadmill software, increase the speed up to 10
km/hr in steps of 1 km/hr. And ask a person to walk on
treadmill. Here the actual speed is reducing; adjust
compensation trim pot (p1) slightly so that sufficient current is
supplied to dc motor (Refer Fig 9).
3. After trying above two points, if still speed reduces as patient
walks on treadmill, interchange the two wires connected to
choke.
Material
Req.
Silicon oil (200ml), sensor coil/ACDC drive.
Rev 7, Dated 21-3-2016
11
Problem
7.
Elevation is correct but speed incorrect in protocol
Possible causes:
1. Treadmill and STWIN amplifier not connected on one and the
same phase.
2. Treadmill connected on UPS supply.(It should be on stabilizer)
Solution:
1. Note down (i) Earth to neutral voltage, (ii). Earth to line voltage,
for treadmill, PC and stwin amplifier by removing the 3-pin
power cord (Refer fig 11).
2. If the treadmill, computer, amplifier are connected on
one and the same phase, you should get the same voltage
measurements at all 3 points.
3. If these voltages are different at all 3 points, there is a
possibility that all the three equipments are not connected on
one and the same phase.
4. Another possibility is that all three equipments are not
connected on one and the same earthing.
5. Remove the treadmill from UPS supply and connect directly on
mains 230-volt ac supply.
6. Hence whenever you face such problem, first of all always check
the above said voltages even though all mains supply
connections are the same as done previously.
7. You can also refer the solution for problem no 3,4
Material
Req.
Sensor coil, TPC cable, ST-Win amplifier, silicon oil (200ml).
2) ELEVATION RELATED.
Problem
1.
No Elevation
Background:
1. In our treadmill the function of elevation is performed with the
help of ac/dc drive and ac motor.
2. To make treadmill understand when and to what degree it
should elevate, signals are given by the PC through our
software.
3. A feedback mechanism is established so that the protocol and
actual elevation match.
Causes:
1. Whenever there is no elevation then there is a problem in either
the AC/DC drive or ac motor, which elevates the treadmill.
2. The problem lies in the feedback mechanism.
3. The feedback mechanism consists of 10 k 10 turn pot, AC/DC
card and TPC cable.
4. If the treadmill does not elevate, then ac motor may be jammed
due to long inactive period of 2-3 months.
Solution:
1. Switch off treadmill, open the top cover, rotate shaft of the ac
motor manually by hand. In this way elevate the treadmill
nearly up to 3rd stage elevation.
Warning: Do not put any sort of oil at the shaft of ac motor to
make it free. This will burn the windings of the ac motor.
2. Whenever there is a no elevation do the following steps:
1) Run test treadmill program (Refer procedure 12) and
click appropriate buttons for speed increase and
decrease.
2) Observe the LED on the back panel of STWIN amplifier
3) If corresponding LEDs are glowing then do the next step.
But if the LED is not glowing then the problem lies with
STWIN amplifier or the calibration factors might be
Rev 7, Dated 21-3-2016
12
wrong.
4) Disconnect the treadmill to STWIN amplifier cable and
short pin 1 & 7 of the 15-pin d type connector (the place
from where you have disconnected the cable on treadmill
side) and check whether the treadmill is elevating.
5) If the treadmill is elevating then the problem most likely
lies on STWIN amplifier side.
This problem occurs due to
a. Low voltage below 180v
b. Due to shortage of limit switch pins
c. Failure of condenser(capacitor)
d. 10k pot settings got disturbed
Material
Req.
Problem
2.
Material
Req.
Problem
3.
10 k 10 turn pot, STWIN amplifier, silicon oil (200ml).
Treadmill runs smoothly for first couple of stages, after that it
elevates randomly.
Background:
1. The 10 k 10 turn pot acts like sensor for elevation feedback.
2. On the shaft of the pot a plastic wheel is mounted. This wheel is
engaged with plastic ring having teeth, which is mounted on pinion
(metallic rod to which pot is engaged).
3. As the treadmill elevates up or down, the pinion rotates
accordingly. This results in rotation of pot.
4. Depending on this rotation of the pot, the feedback voltage
changes.
Possible Cause:
If the engagement between pot and pinion gets misaligned, the pot
will not rotate properly and the feedback will not be proper. This will
result in wrong elevation or random elevation.
Solution:
Change 10 k pot if existing pot is not getting set. (Refer procedure
2, Changing of 10 K 10 turn pot, page- 26).
10 k 10 turn pot. In amplifier, problem rise due to failure of IC 324 on
2K 20156, silicon oil (200ml).
Treadmill stuck /elevates to its top position
1. Check treadmill manually by removing TPC cable.
2. Check treadmill manually from 15 pin connector on ac/dc drive. If
working, fine. If not working then remove AC motor’s connections
from acdc card and put in extension board to check AC motor.
3. Connections: Grey+BlackDOWN
Grey+RedUP
Warning: Do not put red and black simultaneously it will physically
burn the ac motor.
If motor is working then change AC/DC drive.
Possible cause: STWIN amplifier not working.
Solution:
1. Change the STWIN amplifier;
2. Recalibrate the treadmill check the treadmill through test
treadmill option.
3. If still problem persists, isolate the treadmill from PC and test
the same independently for elevation as given in procedure
‘Independent testing of treadmill’. (Procedure 1,page-26**)
4. If the problem still persists, replace AC/DC card.
Material
Req.
AC/DC Drive, AC motor, silicon oil (200ml).
Rev 7, Dated 21-3-2016
13
Problem
4.
On/Off switch (mcb) of treadmill trips down
Possible cause:
Due to sudden large spike or high voltage, ac/dc drive may be shortcircuited.
Solution:
1. Isolate the treadmill from PC by removing treadmill to STWIN
amplifier cable. Switch on treadmill.
2. If still mcb trips, change AC/DC drive.
Material
Req.
AC/DC Drive, silicon oil (200ml).
AC MOTOR
CONNECTION
10 K 10
TURN
POT
TO
EMERGEN
CY STOP
SWITCH
CHOKE
FROM AC
MAINS
MCB
TO TPC CABLE
Fig 6. FRONT PANEL CONNECTIO
Problem
5.
Treadmill elevates properly up to 1st stage only and no further
elevation.
Possible cause:
Treadmill not calibrated.
Solution:
Calibrate the treadmill as per user manual.
10k 10 turn pot setting might get disturbed or it is faulty.
Material
Req.
10k 10 turn pot along with 33 t gear wheel, silicon oil (200ml).
Rev 7, Dated 21-3-2016
14
Problem
6.
Treadmill elevates /de-elevates slightly
Possible causes:
1. AC/DC card not working.
2. Capacitor 33uf/440 volt becomes leaky/faulty.
3. Ac motor may be faulty.
Material
Req.
Solutions:
1. Switch off treadmill; remove TPC cable from treadmill end.
2. Remove back cover of treadmill.
a. Switch ON the treadmill; short pin no. 1 & 7 of 15- pin d
type connector.
b. Here if the treadmill does not elevate up and the relay on
the ac/dc card is also not making any clicking/audible
noise, the ac/dc card is faulty and needs to be replaced.
c. The same is also applicable for de-elevation. Short pin
no. 1 & 8 of 15- pin d type connector.
d. Here if the treadmill does not come down and the relay
on the ac/dc card is also not making any clicking/audible
noise, the ac/dc card is faulty and needs to be replaced.
3. In continuation to above test, if the relay on the ac/dc card is
making any clicking /audible noise, and the elevation/deelevation is taking place by a very small amount, then the
33uf/440 volt capacitor need to be replaced.
4. So change the capacitor by a new one. This capacitor is to be
changed directly. It cannot be tested on multimeter or on 230volt ac supply alone. Check Input voltage to ACDC it should not
be less than 180 v.
5. If treadmill is elevating and de-elevating properly independently
from 15 pin d type female connector, but elevating or deelevating slightly in test treadmill or calibration program, then
STWIN amplifier needs to be replaced. First of all check 10k 10
turn pot setting.
6. Even after changing the capacitor, the elevation /de-elevation
does not takes place, the ac motor need to be checked.
7. For this, switch off the treadmill; remove mains 230-v supply to
treadmill. Mark the connection details of three wires according to
their position. (Color-coding cannot be mentioned because out of
three wires, 2 wires are green. And if these wires are
interchanged, instead of elevation, de-elevation will take place.
Here if treadmill is already at ground level, further de-elevation
will not take place and you will get confused) Isolate the three
wires coming from ac motor. Measure the resistance between all
pairs of these 3 wires. You should get resistance around 28
ohms. If you get zero resistance or infinite resistance, ac motor
is faulty and needs to be replaced.
How to check AC motor independently:
1. Remove three wires coming from AC motor to ACDC drive
2. Put grey wire in neutral and red wire on live for elevation up
3. Put grey wire in neutral and black wire on live for elevation down
Warning: Do not put red and black wire at a time, it will burn
motor.
AC/DC drive, capacitor, ac motor, 10k pot, silicon oil (200ml).
Rev 7, Dated 21-3-2016
15
FROM SPEED
SENSOR
AC MOTOR
NORMALLY
SHORTED. Like fig
on page 26.
AC MAINS
DC
MOTOR
LOWER
LIMIT
SWITCH
UPPER
LIMIT
SWITCH
15 PIN
CONNEC
TOR
FROM
TPC
CABLE
FROM
10 K
POT
Fig. 7 AC/DC COMBINED CARD CONNECTION
Problem
7.
Material
Req.
No medians and no heart rate.
Background:
1. In stress test, sometimes it happens that patient is connected to
stress test, and all the leads are displayed properly but there are
no medians.
2. In our stress test, heart rate is counted depending upon the
number of R waves appearing in QRS detect lead.
3. If this QRS detection lead has very low amplitude of R wave
(less than 0.4cm), then heart rate cannot be calculated.
Cause:
If heart rate is not calculated, then the medians will also be not
displayed.
Solution:
1. Change the QRS detection lead from menu option so that the Q
detection lead is with tall R wave.
2. Amplify the QRS detection lead.
3. Increase the gain. After doing any one of above three options,
wait till the heart rate settles to correct value. Once the heart rate
settles, click relearn button buttons 3 to 4 times so that the medians
get updated correctly.
Software CD.
Rev 7, Dated 21-3-2016
16
Problem
8.
Material
Req.
Problem
9.
While coming down treadmill not stopping
Possible Cause:
Bottom limit switch might be loose. Because of this, when the treadmill
elevates it goes up but while coming down it does not stop. The bottom
switch does not operate; it must not be getting pressed. It might be out
of its original position, because of this 11t sprocket can get damaged
(Note: While fitting limit switch use plain and spring washer
from top side of the bolt and from bottom side use plain washer
spring washer and nut).
Solution:
1. Check the bottom limit switch position whether in alignment with
the treadmill.
2. Make the limit switch tight if it is loose.
Plain washer, spring washer, bolt nut for limit switch.
Slow speed and slight elevation before 1st stage.
Possible causes: 1. PC configuration less than P-III 550 MHz.
2. Treadmill not calibrated for speed and elevation.
3. Treadmill and amplifier, both not connected on one and the
same phase.
4. Problem in amplifier.
Solution:
1. If PC configuration is less than P-III 550 MHz such as Celeron,
this problem will occur. Hence always use PC configuration,
which is higher than P-III 550 MHz.
2. During speed calibration, at last stage, the computer tells us to
press any key when treadmill speed reaches to zero. Here if you
press any key before the speed reaches to zero, this slow speed
will occur in supine, standing, and hyperventilation stages.
Hence during speed calibration always wait till the speed
becomes zero in last stage.
3. If treadmill and amplifier, both are not connected on one and
the same phase, this problem may occur. Hence always ensure
that the treadmill and the amplifier, both are on same phase and
both should be connected on one electrical extension board.
4. If after checking all above possibilities, if still problem exists,
change the amplifier and re-calibrate treadmill for speed and
elevation.
Rev 7, Dated 21-3-2016
17
3) SOFTWARE RELATED.
Problem
PC or ECG getting hanged while running software
1.
Possible causes:
Following software are running at the background
1. Web shot wall papers
2. Quick Heal Antivirus with auto-protect On
3. Screen Saver
The sampling frequency of ST-WIN is 250 samples/seconds i.e.
samples are read after every 4 millisecond. Software has to perform
many tasks in 4 milliseconds, like reading data of 12 channels through
serial port, Display data in different format on screen, apply algorithms,
store data on hard disk, print online automatic reports and many more.
If applications other than ST-WIN like as listed above are running in the
background, they interrupt processing of ST-WIN Software and
problems like System Hanging, Traces Becoming Slow, Improper
Traces, Spikes on QRS Complex start coming. Such types of problems
may be seen with other softwares like Neurowin / Necropsy and Omni
watch. These softwares can be seen in the right side of the Task Bar,
near time display.
Solution:
For disabling these softwares, right click on the icon and select
disable.
1. Remove unnecessary files in startup
click on start-run type MSCONFIG-startup tab
2. Then restart PC
Material
Req.
Problem
2.
Material
Req.
Problem
3.
Remove unnecessary files in startup.
Start: 1. RUN.
2.
MS CONFIGURE
STARTUP and restart PC.( Software can be hanged due to
3.
wrong reset procedure)
Communication Error
Possible Cause:
1) Serial port connection open or short check continuity or resolder if needed
2) COM port not working.
3) COM port interface in the amplifier not working.
Solution:
1) Check connection and reconnect
2) Try by changing the Com port.
3) Replace MAX 232 IC and connect serial port cable to amplifier and
check for communication.
MAX 232 IC, IC 374(u34)/STWIN amplifier.
Noise in ECG when patient walks on treadmill
stands on treadmill
Possible Cause:
1. Treadmill is not grounded to earth properly.
Solution:
1.Check the first green wire from DC motor body
black box of ACDC card
2.Check whether the second green wire from DC
connected with earth wire of mains into ACDC drive
3.Check the earth wire from mains is connected to
refer fig 12 for better idea of earthing).
Material
Req.
Rev 7, Dated 21-3-2016
18
or even if he
is connected to
motor body
is
chassis. (Please
Problem
4.
Solution
Material
Req.
Problem
5.
Solution
Material
Req.
Problem
6.
Solution
Error of DAO setup or error as ‘STWIN 98-mdb ‘file not found.
For the softwares after version 3.74, we have observed that the old
DAO Setup is not sufficient. So we have developed new DAO setup
which is already been supplied with ST-Win Software. Install new DAO
setup wherever there is new installation or up- gradation.
Software CD.
Error as ‘STWIN 98-mdb’ file missing. When we install DAO Setup
for St-Win 3.74 from CD ROM, it works fine. But when we remove
the CD, then an error as ‘.mdb’ file missing comes.
While installing DAO Setup, it is taking the source path as default path.
That’s why when we install DAO Setup from CD ROM and remove the CD; it
can’t find required files from CD ROM.
For installing DAO Setup and NASAN Software, you are requested to
follow the steps as,
1.
Install NASAN software from CD.
2.
Copy DAO setup from CD to C:\progrm files\nasanstwin.
3.
Install DAO setup from this folder.
Install other utilities from CD. St-Win 3.74 and onwards is developed on
“.net” platform which needs different DAO setup. This DAO setup is
provided with St-Win 3.74. To install this, one has to just double click on
DAO.exe.The above written procedure is also to be followed for new DAO
setup.
Software CD.
lead I is coming inverted
There are two ways in which lead I may come inverted,
1) Lead I is derived from Lead II and Lead III (Lead II – Lead III). So
whenever lead II is coming as straight line then Lead I come
inverted. In such case we have to change the amplifier.
2) Doctors are comparing our Stress Test reports with BPL’s or others’
stand alone ECG machines. In stand-alone system, electrodes are
placed on limbs whereas in stress test we place electrodes on chest.
There is significant distance between chest and limbs, which causes
increase in resistance offered to signals. Hence there is strong
chance of getting difference between morphology of Stand-alone
systems and morphology of Stress test.
Material
Req.
Problem
7.
Spikes during the test due to which HR is more than actual
value.
Possible cause:
1) Earthing may not be proper (Refer fig 12).
2) Hard-disk may be less than 72000 rpm.
3) Sound drivers not installed properly or not
compatible with the system.
Solution:
1) Check whether earthing is proper or not.
2) Remove unwanted s/w like WEBSHOTS etc.
3) Disable unnecessary startup files.
Procedure for disabling.
• Go to START menu and click on RUN icon.
• Type ‘MSCONFIG’ and click startup menu bar.
• Select unwanted items and apply.
4) Install the sound drivers properly and use compatible
drivers
Mat Req.
Rev 7, Dated 21-3-2016
19
4) MISCELLANEOUS
Problem
1.
Treadmill becomes non-functional again and again.
Possible Cause:
1. No Servo make voltage stabilizer is used for treadmill even
though the supply voltage is fluctuating.
2. Voltage Stabilizer is not stabilizing the voltage.
3. Type of Stabilizer is other than Servo.
4. There might be leakage current.
5. Problems due to slower configuration.
Solution:
1. Use 3.5 KVA Servo Stabilizer for treadmill.
2. Ensure that in spite of changes in supply voltage at mains, the
output voltage is stable. For this, change the analog meter
switch of stabilizer to INPUT mode, Connect digital voltmeter
(D.M.M.) to output of the stabilizer. Now you are observing input
voltage to stabilizer and output voltage of the stabilizer. Here
the out put voltage displayed on D.M.M. should not vary by
more than 2-3 volts even though the input voltage changes by
more than 10-20 volts.
3. If this output voltage to treadmill is also varying with changes in
supply voltage, the stabilizer needs to be repaired immediately.
4. There are different types of voltage stabilizers used for voltage
stabilization. One is the On-OFF type of stabilizer. Here
depending upon the input voltage range, the relay inside the
stabilizer operates to stabilize the output voltage. But this relay
operation generates a spike at the output. This spike creates a
problem to DC motor speed control circuit and hence the
treadmill stops working. Another type of stabilizer is SERVO
STABILIZER. This stabilizer has built-in servo- motor, which
rotates continuously with change in supply voltage. The shaft of
this motor selects the appropriate winding of the VARIAC so as
to stabilize the output voltage at 230 volts. Hence there are no
spikes in the output voltage of the stabilizer.
5. This SERVO type is recommended for treadmill.
Material
Req.
Problem
2.
Solution
Material
Req.
10K 10-turn pot getting burned.
10K pot setting procedure is given below,
1) Remove the 15-pin TPC cable from Treadmill end.
2) Bring the treadmill down to ground level by shorting the pin no. 1 &
pin no. 8.
3) Unpack the gear assembly of 10K 10 turn pot.
4) Rotate the pot & set it to get voltage across brown & black wires as
950 mv To 960 mv.
5) Fix the gear assembly in achieved condition.
6) It will set the lower limit.
7) Make treadmill UP and DOWN 2-3 times to check 10 pot gear
assembly.
8) Pack the AC/DC Drive & top cover of Treadmill.
9) Calibrate Grade through software.
10) The upper limit will be set by software.
Check whether it is working properly or not
10K 10-turn pot.
Rev 7, Dated 21-3-2016
20
Problem
3.
Solution
Material
Req.
Problem
4.
Solution
Material
Req.
ST Win Amplifier fuses blowing off.
1. If the SMPS fuse has blown OFF, change the TOP 224Y IC.(Please
carry soldering gun).
IC –TOP 224Y.
Base line wandering while test are going on.
1. Checks the DSP IC.If not working properly change it.
2. If the unit has DIP IC, then change that IC.
IC’s-DSP.
Problem
5.
Solution
Material
Req.
Noise observed on lead V6
Problem
6.
Solution
Material
Req.
Spike in ECG
Change 1 battery from set of battery
Battery
Use branded SMPS for PC
Intex make SMPS
Fig 8A.Limit switch clip at its original
position.
Rev 7, Dated 21-3-2016
21
Fig 8B.limit switch not at its
Position
Fig 9.WIRING DIAGRAM OF AMPLIFIER
Rev 7, Dated 21-3-2016
22
6) Appendix
A. Treadstar Table
St
ag
e
Speed
Grade
(Kmph)
Rota
tions
1
2.7
10
14
2
4
12
21
3
5.5
14
28
4
6.8
16
34
5
8.1
18
40
6
8.9
20
44
7
9.7
22
48
DC Motor
Current(A)
Voltage Across
DC Motor(V)
Noise
Level
Speed
feedback
Voltage
Grade
Feedback
Voltage
w/o
load
Load
With w/o
(db)
V DC
(approx)
V DC
(approx)
0.5
1.3
0.5
1.4
0.5
1.5
0.5
1.5
0.5
1.6
0.5
1.6
0.5
1.7
with
load
to
2A to 3.0
21.8
23.7
66
0.21
1.18
to
1.5A to 3.0
31.6
34.5
66
0.32
1.36
to
1.5A to 3.5
47.7
44.5
66
0.44
1.53
to
2A to 3.5
50.8
53.5
66
0.54
1.71
to
2A to 4 A
60.8
62.4
66
0.71
1.91
to
2A to 4 A
65.7
68.3
66
0.71
2.1
to
2A to 4.5
71.7
75.6
66
0.79
2.3
B. Ac current limit to be checked with Clamp meter (See fig.1 for how to
connect clamp meter)
Stage
Speed
Grade
Rotations
(Kmph)
Current sensed by Clamp meter (A)
W/o load
With load
1
2.7
10
14
0.2A-0.5 A
0.8A to 1.5A
2
4
12
21
0.3A-0.8 A
0.8A to 2.5A
3
5.5
14
28
0.3A-1A
1A to 3 A
4
6.8
16
34
0.5A-1.2A
1A to 3.5A
5
8.1
18
40
0.5 to 1.5 A
1.5A to 3.5A
6
8.9
20
44
0.5A to 1.7A
2A to 4A
7
9.7
22
48
0.5A to 1.8A
2A to 4.5A
NOTE:-With load current can vary somewhat.
Rev 7, Dated 21-3-2016
23
B) Use of Clamp meter for measurement of AC current:Clamp meter is used to monitor the AC current taken by AC-DC card/High frequency
Drive.
Connecting Clamp meter to measure AC current:1) Put the Clamp meter rotary switch in AC current measuring side at range of
200A (~)
2) Pass “Jaws” of Clamp meter through the live wire which is connected to “L” of ACDC card/high frequency drive by pressing the knob as shown in fig.
3) When treadmill start and current passes through the live wire of treadmill, Clamp
meter sense the current and same is shown on its digital display as shown in below
fig.
Knob
Fig10. Clamp meter connected with high frequency drive to measure AC
current.
C. 15 pin connector signal details
1.+5 VDC
2. NC
3. NC
4. Ground
5. Speed Feedback
6. Grade Feedback
7. Grade increment
8. Grade Decrease
Rev 7, Dated 21-3-2016
9. Speed Increase
10. Speed Decrease
11. NC
12. NC
13. NC
14. NC
15. NC
24
D.Toolkit.
SR NO
1
NAME
CLAMP METER.
SR NO
14
NAME
FUSE
SCREWS :M 3*10,
M3*15
STRAPPER.
WASHERS
:FIBER
WASHER 3 mm.
NUTS :- M3
10K 10 TURN POT WITH
WHEEL.
CSK& CHESEHAED
SPEED SENSOR.
FEVIBOND.
FEVICWIK.
PIECE
OF
WIRE
:
GREEN,BLACK,RED 14/36 3
FEET EACH
INSULATING TAPE
SLEEVE
2
3
SCREW DRIVER SET.
PLIERS (NOSE PLIER).
15
16
4
5
SOLDER GUN /METAL.
BIG PLIER.
17
18
6
7
8
9
10
S/W FLOPPIES/ CD'S OF ALL PRODUCTS.
CUTTER.
SPANNER SET & ALLEN KEYS.
BIG SCREW DRIVER / TWEEZER.
SILICON OIL.
19
20
21
22
23
11
12
13
MULTIMETER & ITS RODS.
DISPOSABLE ELECTRODES (10 IN No.).
FUSE WIRE: - 5A, 15A.
Spares
24
25
26
1
10 K 10 turn pot
5
2
3
HDD,FDD & flat cable
Software CD,floppy
6
7
4
IC 7805,7905,7812,7912,324,339
8
All types of connectors,9
pin m/f,15 pin m/f
Loose STPC & 12 PC lead
set
Serial port cable
Loose
ultistrand
wires,
insulated tape
5
6
7
8
PRICE LIST of all spares
and consumables
Servicing manual
Pirangut factory address
Mobile phone no list
Documents
1
2
3
4
SERVICE REPORT /AMC COPIES
DC OF MATERIAL.
CASH MEMO.
Pending payment status in that area
Rev 7, Dated 21-3-2016
25
D. Patient Preparation
PRE - JELLED
DISPOSABLE
ELECTRODE
Fig 10.
•
•
•
•
•
•
•
Electrode Site
Shaving of electrode site is compulsory irrespective of man/women(if electrode
site is hairy)
Wipe skin with spirit/alcohol
Wait till skin completely dry
Peel off the backing from pre jelled disposable electrode. the jelly pad should
remain intact along with the electrode
Place electrode one by one on selected sites as sown in figure. Press the
electrodes from inside to outside covering entire electrode area
Take care that jelled pad is in firm contact with the skin surface. Place patient
lead on each electrode as per the color(the electrode has male notch while the
lead has female type notch, insert the lead onto electrode)
Apply Medical adhesive tape(dressing tape/bandage tape) across the
electrode.(From loop of patient cable and apply medical adhesive tape if
necessary)
E. Important Notes for servicing
1. While fitting limit switch use plain washer and spring washer from top side of
the bolt and from bottom side use plain washer, spring washer and nut.
2. Whenever you work with ADC/DC card. Make sure that all screws are fitted
properly, Always use CHHD(round head) screws of M3 by 15.Also use plain and
spring washers(fiber) for proper fitting.
F. Earthing
1. ENSURE THAT THE AC MAINS HAS VOLTAGE RANGE IN BETWEEN 230 V
AC+/- 10%; IF THE VOLTAGE FLUCTUATES THEN USE STABILISER TO
MAINTAIN THE VOLTAGE.
2. ENSURE THAT SUPPLY FOR TREADMILL, PC AND AMPLIFIER IS TAKEN
FROM ONE AND SAME ELECTRICAL EXTENSION BOARD.
3. ENSURE THAT SEPARATE EARTHING IS PROVIDED AND VOLTAGE
BETWEEN EARTH AND NEUTRAL IS LESS THAN 5 VOLTS, IF NOT FOUND
SO, INFORM THE DOCTOR IMMEDIATELY TO GO FOR SEPARATE
EARTHING.
Rev 7, Dated 21-3-2016
26
G. Procedures
Procedure
1.
Steps
Material
Req.
Procedure
2.
Steps
Independent testing of the treadmill
1. Switch off the treadmill.
2. Isolate treadmill from pc (remove treadmill to STWIN
amplifier cable at treadmill end).
3. Take a small piece of insulated wire (7-8 cm long) with its
conducting ends open.
4. Switch on treadmill.
5. At rear side of treadmill, near on/off switch (mcb), a 15-pin d
type female connector is located. At this 15-pin d type female
connector, short pin 1 and pin 9 and check that speed
increases linearly. If by shorting pin 1 and 9 does not result in
speed increase, then on ac card also there is one 15-pin
connector. Short pin no 1 and 9 and get the speed increase.
Do not increase the speed more than 7km/hr approx.
(this speed will be reached within 5-6 seconds after
shorting pin 1 & 9).
6. Now short pin 1 and pin 10.check that speed reduces to zero
linearly. If by shorting pin 1 and 10 does not result in speed
decrease, then on ac card there is one 15 pin connector, short
pin no 1 and 10 and get the speed decrease.
7. Short pin 1 and pin 7 and check that treadmill elevates up
linearly. After reaching top position, it will stop automatically
due to limit switch. If by shorting pin 1 and 7 does not result
in elevation up, then on ac card connector short pin no 1 and
7 and get the elevation up.
8. Short pin 1 and pin 8 and check that treadmill moves down
linearly. After reaching bottom position (ground level), it will
stop automatically due to limit switch operation. If by shorting
pin 1 and 8 does not result in elevation down, then on ac card
connector short pin no 1 and 8 and get the elevation down.
9. Switch off the treadmill.
small piece of insulated wire (7-8 cm long)
Changing of the 10K 10 turn pot (for elevation)
Ensure that the resistance of new pot (potentiometer) is continuous
and variable with the help of multimeter.
1. Open back panel and top cover of treadmill.(Refer fig
2. Ensure that the treadmill is at ground level. (Front portion and
the back portion of the treadmill should be at equal height of
about 190 mm.).
3. Adjust this level by referring to point no.06 and 07given on
page no 01.
4. Loosen the metal part on which 10 k pot is mounted.
5. Loosen the 10 k 10 turn pot.
6. Stick the plastic wheel on the shaft of pot (new pot) with
feviquick.
7. Replace the pot keeping the original connections same.
a. (Refer to diagram).
8. i.e. Solder black wire to pin no 1.
a. Solder brown wire to pin no 2.
b. Solder red wire to pin no 3.
9. If the connections are interchanged, the pot will burn
physically.
10. Switch on the treadmill.
Rev 7, Dated 21-3-2016
27
11. Adjust the pot such that you get 950 milli-volts between black
and brown wires at con 6 connector of AC/DC card. This
connector is located at left hand bottom corner of AC/DC card.
Measure this voltage with the help of digital multi-meter on dc
voltage range.
12. Fix and tighten the pot properly.
13. Fix the metallic part on which pot is mounted.
14. Again ensure that the voltage between a1 and a2 is 950mvdc
(tolerance of +/-4 mill volt is acceptable).
15. Ensure that the elevation up and down takes place smoothly
and ensure teeth of both gears are engaged with each other
properly.
16. Switch OFF the treadmill.
17. Fix the back panel again to its original position with screws.
Material
Req.
10K 10 turn pot(along with 3 pin relimate connector and 33 gear
wheel), multimeter
44 T
SPROCKETS
10 K 10
TURN
POT
Fig 11: 10 K 10 Turn Pot.
Rev 7, Dated 21-3-2016
28
Procedure
3.
Steps
Material
Req.
Procedure for changing AC motor
1. First elevate the treadmill up. It should be at 300 mm from
ground level. if ac motor is not working at all you will have to
follow step no 2
2. if it is not possible, lift up the treadmill and put a small stool
under the treadmill at front side for supporting purpose so that
both racks will become free.
3. switch of the treadmill and remove the 3 pin top from ac mains
4. remove the TPC cable from treadmill
5. Remove the link in the chain; it can be half or full link. if you find
it difficult to remove the chain and fit again you may take help 9of
cycle mechanic or motorcycle mechanic.
6. take out the chain from 11T sprocket this sprocket is fitted on the
shaft on AC motor
7. remove the wires of the AC motor from the condenser
8. remove the Allen bolts of AC motor
9. take out the ac motor
10. Mount the gear motor with 4 nos nylon spacers of 12 mm height
by M8 by 40 mm Allen bolt, nut along with plain and spring
washers for Delco motor(make)
OR
Mount the gear motor with 4 nos,nylon spacers of 2 mm height
by m 12 by 50mm hex bolt along with plain and spring washers for
VISHWAS motor(make)
11. Loose the Allen grub screw of 44t sprocket. This sprocket is fitted
on the pinion of the treadmill.
12. Align both the sprockets (11T & 44T ) such that both are in
one line if there is a mismatch between two sprockets, the
chain will come out from wheel and the treadmill will fall
down from the top position, this may create an accident
13. Fit the chain on both sprockets with the help of half link or full
link.
14. Do not tight the Allen grub screw of the 44t sprockets it should be
loose.
15. Solder wires of ac motor with wires of the condenser
16. elevate the treadmill up and down two three times
17. now check both sprockets aligned properly in the straight lines
18. now tight the Allen grub screw of 44t sprockets if you forget to
tighten this screw the treadmill will fall down from the top position
19. Check if noise is coming during elevation.
20. If noise coming from the chain then, check the chain tension if it
is loose then put washers between spacers and bolt of ac motor at
back side of motor
21. Checks the Allen grub screws of both sprockets are tight.
22. take out the support stool from the treadmill
Spanner of size 16/17,allen key of 10mm,2.5 mm,3.0mm,6mm,half link
full link chain small piece of chain (1 ft) wires of 14/36 red grey ,black,
black
Rev 7, Dated 21-3-2016
29
Procedure
4.
Steps
Procedure for changing DC motor.
1. Remove 3 pin top from mains and 15 pin TPC cable.
2. Remove top cover of treadmill/handles.
3. Remove all connections from DC motor.
4. Do not disturb settings of adjuster bolts.
5. Remove timer bell from Dc motor
6. Put DC motor on chassis
7. Fix the timer belt into motor.
8. Adjust the holes of Dc motor and chassis.
9. Insert M10-bolts & fix the nut accordingly(Do not tight nut bolts)
10. Do the wiring of Dc motor but do not plug-in 3 pin top to mains.
11. Set the timer belts properly(check its tension, it should either
too loose or too tight)
12. Tight all four M 10 bolts
13. Check whether magnet is present on flywheel.
14. Connect the sensor along with flywheel.
15. Adjust sensor in such a way that there should be a gap
between sensor and magnet from 5mm to 7mm.
16. Plug in 3 pin top check treadmill by shorting pin 1 & 9.
Material
Req.
Procedure
5.
Steps
Changing of AC Card + DC Drive Assembly to ACDC Drive
Combined.
1. Switch Off the Machine and remove the 3 pin plug.
2. Open back cover of Compact Treadmill.
3. Remove all connections from AC Card and DC Drive.
4. Remove AC Card and DC Drive from Bakelite sheet including
transformer.
5. Keep limit switches and speed sensor as they are.
6. Remove Bakelite sheet from its position.
7. Mark Top & Bottom sides of Bakelite before removing.
8. Place ACDC Drive on Bakelite Sheet Centrally and mark the four
corners of ACDC drive box on Bakelite.
9. After marking, make drill with M6 Drill bit markings (total 4
drills).
10. Insert M5X30 mm screw from back side of Bakelite with plane
washer.
11. Fit this screw from front side using M 5 spring washer then M 5
plane washer then M 5 nut.
12. Put ACDC drive box on Bakelite. See matching of Box holes with
fitted screws.
13. Remove box & fit Bakelite to its original position.
14. Insert base grommet on all 4 screws (M5 X 30 mm).
15. Mount ACDC drive on 4 screws (M5 X 30 mm) & fit it with M5
plane washer, M5 spring washer & M5 nut (as in pt.11).
16. Remove top cover of ACDC drive box.
17. Bring out two earthing connections from DC Motor (Rotomag or
Thyron). Connect one to AC mains socket (CON 10) on ACDC
drive & other to ACDC drives corner mounting screw with
earthing clip.
18. Fit armature wires coming from DC Motor in A+ and A- pins of
connector CON 15 on ACDC drive.
19. If there is Thyron DC Motor then solder “GMKDSP 3/2” green 2
pin connector at CON 15.Fit field wiring of DC Motor in ‘F+’ and
‘F-of connector CON 15. Make sure that diode D-24 (4148) is
connected on ACDC drive (for Thyron Only).
20. Solder two wires coming from speed sensor to 2 pin Relimate
connector (female) and insert it on ACDC drive at CON 8.
Rev 7, Dated 21-3-2016
30
21. Fit wires coming from limit switches in CON5 and CON 7.
22. Fit wires coming from AC Motor in connector CON 11 as
[B|R|G].
23. Short 2 Pin MCB connector CON 13 with wire.
24. Remove old emergency switch wiring.
25. Make 10.5 mm hole on the side cover of Treadmill in line with
15 pin D type connector leaving 50 mm distance from top cover.
26. Open the Emergency Stop Box. If it is metallic, use new plastic
EMG Box.
27. Take new 3 Core AC Mains cable. Cut the Yellow/Green wire as
we won’t require it.
28. Insert Red wire at one end of Red colored connector of EMG
switch and Black wire to another end of same connector. Other
end of cable should be inserted in CON 12 of ACDC Drive.
29. Care should be taken while looping mains wire. It should not be
loose as it may collide with Rack.
30. Mains Wiring: Bring Red wire of Mains to one end of MCB switch
fitted on Treadmill and from other end on MCB bring out 2.5
sq.mm red wire, loop it at sides of ACDC Drive and connect to
LIVE (L) point of AC Mains connector CON 10. Bring black wire
from 3 core AC Mains cable looped at side of ACDC Drive and
connect to NEUTRAL (N) point of CON 10. Connect Yellow/Green
wire to Earthing Fitting screw of ACDC Drive Box (M5 X 30)
using earthing clip.
31. Connect 15 Pin D type Male Connector on other side of cable
which goes to 15 Pin D Type Female Connector fitted on side of
Treadmill (where TPC is to be inserted). Do connections pin to
pin for both connectors (pin1 & pin4 to pin11) as per diag.
32. Solder 3 pin Relimate female connector to 10K pot as per circuit
diagram and insert it on connector CON 6 as [Bl|Br|R].
33. Turn ON the Treadmill.
34. Increase treadmill speed manually by shorting Pin1 & Pin9. If
belt rotates in opposite direction, reduce speed by shorting Pin1
& Pin10 of 15 pin D type connector for TPC cable.
35. Interchange A+ & A- connections at CON 15 and Check treadmill
response again.
36. Check treadmill grade by shorting Pin1 & Pin7 to increase and
Pin1 & Pin8 to decrease.
37. Fit top cover of ACDC Drive.
38. Fit the Treadmill cover and check with Software.
Rev 7, Dated 21-3-2016
31
MATERIAL LIST REQ. TO SOLVE A CALL
No
1
Material
2 Pin Green Connector for Field wiring. (in case of thyron
motor only)
Quantity
1
2
2 Pin White Relimate (Female) Connector. (for sensor
connection)
1
3
3 Pin White Relimate (Female) Connector. (for 10 k turn
pot connection)
1
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Diode 4148 (in case of thyron motor only)
Screw M5 X 30 mm
Nut M 5
M5 Plane washer
M5 Spring washer
base grommet
10 mm wire grommet
3 core Mains wire (non shielded)
2.5 sq. mm Red wire
2.5 sq. mm yellow wire(for earthing)
14*36 black wire
14*36 red wire
14*36 grey wire
Binding sleeve
18
19
20
21
22
23
24
25
26
27
28
29
Heat sync able Sleeve 6 mm
Heat sync able Sleeve 3 mm & 1 mm
Heat syncable Sleeve 2.5 mm
Brass lugs
Silver lugs
Cable tie with pads
Supporting mounting plates (25*5) flat
Screws M5*50
12 core cable
15 pin d-type connector –female
15 pin d-type connector –male
ACDC drive combined
1
4
10
8
8
6
2
5 meters
3 meters
1 meter
1 meter
1 meter
1 meter
As
per
requirement
1 meter
1 meter
1 meter
10
6
15 sets
2 nos
6 nos
3 feet
1
1
1
Procedure
6.
Steps
Changing of Actuator.
1. Switch off the machine, and remove the nut bolts to uncover
the assembly.
2. First fix the actuator box on the actuator by using M 10X 50
mm HEX bolt and 10 mm nut. Use Plain and spring Washers,
Use Lock tight for M10 Nut.
3. Now put this block on the chassis and fit it by using M 12X30
mm Hex bolts using plain and spring washers, in the top side
of the chassis. Use Lock tight.
4. Now fit the Actuator end point on the base Assembly by using
M 10X70 mm Allen Bolt. Use plain, spring washer and M10 Nut
and lock tight.Make sure that the actuator shafts thread
should have two threads visible.
Rev 7, Dated 21-3-2016
32
Upper and Lower limit switch setting Procedure:
Open the top cover of the actuator There are two limit switches in the
Actuator i.e. Top and Bottom. The identification, for the top or upper
limit switch this is actually on top side and the other is lower/bottom
limit switch. There are two nylon pointed gears, this operate the limit
switches. The top gear stops the upper limit switch and lower nylon
pointed gear stop the lower limit switch. Make sure that the bottom
limit switch is operated. To set this switch, loose the star screw which
is fitted on nylon Pointed gear. To set the lower limit switch move this
nylon pointed gear which is in the bottom side, to the lower limit
switch from the right side of the limit switch, this will be operate from
the right side. Now tight the screw which is on the nylon gear.
5. Now give power supply to actuator through mains i.e. 230 V
AC.Use white wires as common wire and use red for up
movement and black for down movement. After elevating the
actuator to its maximum level make sure that there should be
8 mm gap in between actuator sleeve and base assembly
square tube. Now set the upper/top limit switch in Operated
position.
6. Now connect the white and Black wires to the mains, machine
should go down, take at the lower position check the actuator
threads two threads should be visible, then fix the lower limit
switch.
Now connect the actuator through ACDC Drive externally and
connect Pot wire also, the treadmill should go completely
down direction, check Voltage on white and black wire of the
pot. It should be 900MV(+/- 100 MV) if not as per above
mention value then open the top cover of the actuator,
remove the left hand screw of the pot, and also loose right
hand screw an adjust it to 900 MV and fix it properly.
Rev 7, Dated 21-3-2016
33
Actuator pot setting step:
) Treadmill at down position.
2) Remove actuator cover
3) Remove 10k pot which is inside actuator
4) Switch ON treadmill
5) Connect multimeter black probe (common) at pin 3 of J 8
connector which is on high frequency drive PCB 2k8005v3
6) Connect multimeter red probe at pin 2 of J 8 connector which is
on high frequency drive PCB 2k8005v3
Rev 7, Dated 21-3-2016
34
7) Keep multimeter on DC voltage range
8) Rotate pot to set voltage between 250mv to 900mv
9) Now fit pot in actuator and check voltage remains between
250mv to 900mv.during fitting due to gear rotation set voltage
may get change
10 Fit actuator cover
11) Do treadmill calibration.
Procedure
7.
Steps
Changing of Rollers.
Procedure
8.
Steps
Changing of Rack and Pinion.
Procedure for changing BACK ROLLER.
1. Switch off the treadmill and remove the 3 pin plug.
2. Remove end caps of the treadmill.
3. Loosen the M 10X100 Allen bolts.
4. After loosening the bolts, back roller is shifted in front
direction.
5. The belt is then loosened.
6. Loosen the M 10X30 bolts by using M8 Allen keys.
7. Remove the Wooden board.
8. Remove the 4 wooden board support angles by M 10X 20
Allen keys.
9. Now completely remove the M 10X 100 Allen bolts so that the
roller is completely free for removal (Take another person for
help because the roller is heavy)
10. Fix new roller in that place.
11. Apply reverse procedure for fixing new roller.
12. Take care while setting the conveyer belt that it does not
misalign anywhere.
Procedure for changing FRONT ROLLER.
1. First remove the back roller by referring the above procedure.
2. Loosen the M 10X100 Allen bolts of back roller.
3. Remove the front roller locating plate by loosening the M 6X
16 Allen bolts.
4. Lift the front roller so that the timer belt is removed.
5. Then remove the front roller so that new roller can be fixed.
6. Apply reverse procedure for fixing the front roller.
1. Give some support to the m/c and elevate to some height.(use
small stool for this purpose).
2. Remove the front and back covers to open the assembly.
3. Remove all connecting wires, handles etc.
Rev 7, Dated 21-3-2016
35
4. Remove the DC Choke, ACDC card, 10 K pot along with
mounting plate.
5. Remove the support ply and limit switch.
6. Remove chain lock and chain (Take help of cycle mechanic if
not possible).
7. Remove the right and left rack support plate.
8. Now remove the grub screw and pinion can be removed from
the chassis.
Procedure
9.
Steps
Changing of Magnet.
Procedure
10.
Steps
Changing of Limit Switch.
Procedure
11.
Steps
1. Switch OFF the machine and remove the front and back cover.
2. Rotate the flywheel manually so that magnet is in accessible
position.
3. Loosen the bolts and remove the magnet.
4. Replace with new magnet.
1. Switch OFF the machine and remove the 3 pin plug.
2. Remove the front and back cover to expose the assembly to
the person.
3. Remove the connection wires from the ACDC drive.
4. Remove the M 3X 30 Allen bolts to remove the limit switch
from limit switch mounting plate.
5. Replace the old limit switch with new one.
6. Use the same old wires for connection if they are not damaged
else use new.
7. Align the limit switch according to the stopper plate.
8. Switch ON the treadmill.
9. Test the limit switch manually, i.e. whether it stops when
touched with finger.
Changing of Conveyer Belt.
1. Switch OFF the m/c and remove the 3 pin plug.
2. Mount the 46 L pulley on the front roller.M6 X6 mm grub
screw is being
used to fix the 46 L pulley on to the roller by
a key of 8 X 8 X 25 mm.Front roller assembly is prepared and
fitted on to the chassis.
3. Loosen all 4 mid support angle of the chassis and align them
in one straight line.
4. OSL board to be kept on the above 4 angle(locating it at 15
mm gap from 46L pulley+centering of OSL board with respect
to the chassis).Then make all base points on to the OSL board
through drill of 11mm and a counter sink of 22mm drill.
Dismantle all the 4 support angles by numbering them.
5. Now take the conveyer belt and roll it on the front roller.
6. Then roll it on the back roller. After that push the wooden
board inside the conveyer belt and adjust its position
properly.
Rev 7, Dated 21-3-2016
36
Procedure
12.
Steps
Standard calibration procedure.
1. Go to ‘Utilities’ menu to do the following connecting work,
Test treadmill.
Test acquisition.
Calibration grade.
Calibration speed.
Delete printouts from printer queue..
Utilities.
2. Test treadmill
For testing the Speed and Grade of the treadmill select the ‘Test
treadmill’ option from ‘Utilities’ option. A dialog box is displayed as
shown below with speed and grade buttons. User can test the treadmill by
increasing / decreasing the speed and grade buttons by pressing the arrow
button seen on the dialog box.
Treadmill tester
3. Test acquisition
‘Test acquisition’ is used to test the connectivity between the amplifier
and PC port. When you click on ‘Test acquisition’ option the message will
come” Please switch ON the amplifier.” In case of any loose contact or
other problem, error message “The hardware unit is not working
properly” is displayed.
A) Calibrate grade
For calibrating the grade of the treadmill go to the ‘Utility’ menu and
press Calibrate grade’ option. A dialog box will appear on the screen as
shown infig 1.
Rev 7, Dated 21-3-2016
37
Fig 1
1. When the treadmill reaches to its maximum elevation press ‘OK’
button. When ‘OK’ button is pressed treadmill starts moving down and
following message as shown in fig 2 is displayed.
Fig 2
2. After the treadmill reaches its minimum elevation press ‘OK’ button.
When ‘OK’ is pressed calibration constants for grade are calibrated and
stored. These calibration constants are displayed in ST-Win configuration
dialog box.
3. If an error is detected this message appear on the screen,
Fig 3
B) Calibrate speed
For calibrating the speed of the treadmill go to ‘Utility’ menu and select
‘Calibrate speed’ option. This will display the dialog box as shown in the
figure below. Count the number of seconds for 14 rotations and enter the
number in the edit box. Do this for one more time and enter the count in
the second edit box. Press ‘OK’ button to move to next stage of the
protocol.
Rev 7, Dated 21-3-2016
38
Treadmill speed calibration.
Above explained process will be carried out upto 7 stages of BRUCE
protocol.
At the end of 7th stage, speed calibration constants are calculated and
saved.
These constants are displayed in ST-Win configuration dialog box.
C) Store configuration settings on floppy.----Now this feature
is not used
Settings done using configure menu option or through ‘Configure system’
button on Installation dialog box can be stored on a floppy. For this purpose
go to ‘Utility’ menu and select the option ‘Store configuration of setting
on floppy’. All the setting will be copied to floppy.
D) Restore settings from the floppy. --Now this feature is not
used
Choose this option from ‘Utility’ menu to install the setting saved on the
floppy. When pressed this button, setting stored in the floppy are restored
in the newly installed software.
--E) Delete printouts from printer queue …
To delete printouts from printer queue go to Utility and select ‘Delete
printouts from printer queue. .’Option. ‘Printer and Fax’ dialog
box will be displayed. Select the printer which is connected to ST win
unit and double click on it. It will display that documents stuck in the
queue and if those documents in the queue are not required then right
click on it and select ‘cancel’ option. It will delete the documents in
queue.
Rev 7, Dated 21-3-2016
39
H. Precautions:
1. Precaution to be taken while testing the AC-DC drive
1. Do not touch any part on dc drive except its cover during ON condition.
Otherwise you will experience a hazardous shock and the DC drive will be damaged.
2. As the AC/DC drive is floating, do not connect earth or ground to it. This
will damage the dc motor circuit of the card.
3. While interchanging AC/DC drive, always refer to wiring diagram.
2. Earthing:
The Earthing for the system should be proper. This is to ensure patient safety
and for no interference of line voltage fluctuations. For correct earthing procedure,
refer to work order booklet and get it done and approved from licensed electrician
only.
If the earthing is not proper, leakage currents may pass from the amplifier to
ground through the patient. If the current magnitude is large, it can be harmful for
the patient.
3. If earth wire is showing 0 Volt, check whether it is connected
or not.
4. General precautions for using the treadmillRead this section before operating the treadmill. Keep the area underneath
the treadmill clear.
Do not start the treadmill when someone is standing on the belt.
Do not leave a patient unattended on the treadmill.
Do not stop the treadmill if someone is walking on it except in case of
emergency.
Keep speed and grade at minimum when patients are getting on the
treadmill.
5. Check voltage before replacing/touching any part.
Rev 7, Dated 21-3-2016
40
Fig 12. Earthing Procedure
Checking of voltages:
1) Earth to neutral voltage: Insert the pins of multimeter between
E and N.
2) Earth to live voltage: Insert pins of multimeter between N and
P.
Rev 7, Dated 21-3-2016
41
CABLE DIAGRAMS
1. TPC CABLE DETAILS.
15 Pin D type (M) 15 Pin D Type (F)
conn
conn.
04
04
05
05
06
06
07
07
08
08
09
09
10
10
11
11
Color
Orange
Yellow
Green
Blue
Violet
Grey
White
Pink
**Short Shield to pin no 4 of (F) conn.
2. STWIN TO SERIAL PORT CABLE DETAILS.
09 Pin D type (M) 09 Pin D type (F)
conn pin no.
conn pin no.
02
02
03
03
05
05
Shield open and Shield open and
cut
cut
Rev 7, Dated 21-3-2016
42
Color code
Black
Green
Red
Data for Servicing Treadmill Controller and Body level
used with High Frequency Drive
CONTENTS
1. System diagrams and connections.
2. Photos of serviceable parts (PCBs).
3. Problem, solutions and material required to attend the call.
4. Appendix.
a) Cable diagrams.
b) Assembling and disassembling of Treadmill parts.
c) Replacing AC-DC combined card with High frequency drive.
1. System diagrams and connections:-
1)
SYSTEM DIAGRAMS:
PC
230V AC
MAINS
Body level
Unit
Controller
TREADMILL/
High Frequency Drive
Fig 1. BLOCK DIG. OF Treadmill Controller SYSTEM
Rev 7, Dated 21-3-2016
43
TO
PATIENT
Body
Level
Cable from
treadmill controller
to body level
Speed
Up
Speed
Dn. LED
Treadmill
Controller
Elevation
Dn. LED
Fig 2. Treadmill Controller + Body level system.
Fig 3. Back Panel of Treadmill Controller system
Rev 7, Dated 21-3-2016
44
Elevatio
n UP
Power
LED
2. Photos of serviceable parts (PCBs):Magnet embedded in
the flywheel
Speed Sensor
DC Motor
`
Fig 4. SPEED SENSOR
To
Emergency
stop switch
From
AC
Mains
MCB
Mains
Indication
Fig 6. FRONT PANEL CONNECTION
Rev 7, Dated 21-3-2016
45
From Treadmill
Controller
MM+
Mains
230V/
50Hz
L
N
Connector
for AC
motor
E
C
Up
Dn
Speed
Sensor
Connector
Elevation
Sensor
Connector
Fig 7. High frequency drive connections
Rev 7, Dated 21-3-2016
46
15 Pin TPC
Connector
Conn
ector
for
DC
motor
Connection of limit switch if high frequency drive is to be used
in Treadstar and Compact Machine:Note: - we can not use high frequency drive in compact machine which has Thyron DC
Motor.
Fig 8. Limit switch connections for compact machine.
NOTE:• Testing of limit switch:1) First check that there is continuity between C (common) terminals of limit
switch with NC (normally closed) terminal of limit switch. And there is no
continuity in between C and NO (normally open) and NC and NO.
2) Sometime there is continuity between C and NO and C and NC are open in
few limit switch
due to wrong marking on them then in that case use NO Terminal as NC
and do all connection to NO terminal instead of NC.
Rev 7, Dated 21-3-2016
47
2. Problem solutions and material required to attend the call.
SPEED RELATED
Problem
1
Speed
reduces in
second
stage and
onwards
Check Points
Corrective Action
1. Check distance
between Flywheel of DC
Motor and Speed Sensor
is in between 5mm to
7mm.
If not, place it at correct
position.
2. Check calibration
factor in S/W, if it is
correct, Calibrate the
Treadmill for speed and
elevation and then check
if problem is solved on
recalibration. If not follow
below points.
If Calibration factor is not
correct then correct it
from factor written on
treadmill and then
calibrate the Treadmill.
2. Check LED1 on High
frequency drive
flashes each time
when the flywheel
completes one cycle.
If not, Check whether
sensor connection is
loose, if yes, correct
it
Interchange sensor
connections wires
from 2 pin relimate
connector.
If problem persist
change
Treadmill controller.
MATERIAL
REQD. TO
ATTEND CALL
Sensor coil.
High Frequency
Drive.
If
still
problem
persists, change High
frequency drive.
2
No Speed
(Conveyor
belt is not
moving at
all)
1. Run test Treadmill
program from S/W under
utilities menu and click
on appropriate buttons
for speed increase and
decrease and check the
speed increase/
decrease LEDs on front
panel of the Treadmill
Controller (Refer fig 2)
flashes.
2) Check if TPC cable is
OK by checking its
continuity.
3) Still belt is not
moving while testing the
Treadmill independently
then the problem
probably lies on the
Treadmill side. First
remove top cover from
Treadmill and check
whether the mains
Rev 7, Dated 21-3-2016
48
If LEDs are not flashing
then the problem lies in
Treadmill Controller or
calibration factor is
incorrect. If possible
check with another
Treadmill Controller. If
LEDs are glowing now
then change Treadmill
Controller.
If not cut both ends and
resolder the cable (Refer
cable dig.1 for Cable
Details).
If it is not glowing, then
ensure that 230-volt AC
is reaching at mains
connector on High
Frequency Drive, If 230
volt is present, still LED
is not glowing then
change High Frequency
Drive.
High Frequency
Drive, Treadmill
controller, TPC
cable, DC Motor
indication LED2 is
glowing on High
frequency drive.
If LED is glowing, still
belt is not moving then
change high frequency
drive
4) The last step is to change the DC motor. But
before changing do the following cold test.
Cold test for DC motor:
a. Remove 3-pin top of Treadmill from mains
supply.
b. Remove all the two wires of DC motor
c. Ensure that there is no continuity between
Treadmill body and all the connectors of DC motor.
d. In case of pmdc motor, ensure that the armature
resistance is nearly equal to 2-3 ohms.
3
Speed and
elevation not
as per
protocol
through
software.
Check calibration factor
in S/W, if it is correct
Calibrate the Treadmill
for speed and elevation
and then check if
problem is solved on
recalibration. If not follow
below points.
Confirm that Treadmill
and PC, both are
connected to one and
the same phase only.
Always give power from
one and the same
extension
board
to
Treadmill and ensure
that Earth voltage is
less than 5V.
Confirm that earth point
of PC and Treadmill is
shorted with 24/36 wire
externally.
Check continuity of TPC
and serial port cable.
Setting
and
speed
sensor alignment.
Check if and speed
sensor alignment is OK.
Also If conveyor belt is
too tight then this
problem occurs.
4
Speed goes
on increasing
when we
switch on the
Treadmill.
(Uncontrolled
speed)
If Calibration factor is not
correct then correct it.
If not connect both
treadmill and PC to
same phase.
If not short the both
earth points with 24/36
wire externally.
If needed re-solder the
same (Refer cable
dig.1
for
Cable
Details).
If not place it correctly.
In that case loosen the
belt accordingly and put
silicon oil under the belt.
Check sensor connector
is properly connected.
Ensure that it is not
loose.
If not connect it properly.
Check continuity of TPC
cable between High
frequency drive and
Treadmill controller.
if needed re-solder the
same
Rev 7, Dated 21-3-2016
Treadmill
controller, silicon
oil.
49
Sensor coil, High
frequency drive.
5
Jerk in
speed/Speed
reduces as
patient walks
on Treadmill.
Remove the speed
sensor wires & ensure
that resistance of speed
sensor is nearly equal
to 14 ohms.
If not Change speed
Sensor
Ensure that the LED1
on High frequency drive
is blinking.
If not then change high
frequency drive.
Check if silicon oil is
added below conveyor
belt.
If not add silicon oil
below conveyor belt from
both side.
Check if Conveyor belt is
not loose.
If yes correct it.
Check if High frequency
drive is able to provide
sufficient current to DC
motor. For it
Adjust resistance
equal to 3.5K across
P4 of J6 with respect
to shunt by adjusting
pot P3.
If not run test Treadmill
option from software
under utilities and
increase the speed up
to 10 km/hr in steps of 1
km/hr, ask a person to
walk on Treadmill. Here
the actual speed is
reducing; adjust
compensation trim pot
(P3) slightly so that
sufficient current is
supplied to DC motor.
Silicon oil, sensor
coil, High
frequency drive.
If still problem persists
then
change
High
frequency drive.
6
Elevation is
correct but
speed
incorrect in
protocol
Check if Treadmill
and Treadmill
controller is
connected on one and
the same phase.
Measure (1) Earth to
neutral voltage,
(2). Earth to line
voltage, for
treadmill, PC and
Treadmill controller
by removing the 3pin power cord, it
should be nearly
equal if all is
connected on same
phase.
Check if Treadmill
connected on UPS
supply.(It should be
on stabilizer)
Check if all three
equipments are
connected on one and
the same earthing.
If not, connect them on
same phase.
Sensor coil, TPC
cable, Treadmill
controller.
If not connect it on UPS
with stabilizer.
If not connect all
equipment on same
earthing.
Also Refer point3 and 4.
Rev 7, Dated 21-3-2016
50
ELEVATION RELATED.
1
No
Elevation
Run test Treadmill
program and click
appropriate buttons
for Elevation increase
and decrease and
check if
the LEDs on the Front
panel of Treadmill
controller are
glowing.
If problem persist
then check treadmill
independently i.e.
short pin 1 & 7 of the
15-pin d type
connector and check
whether the Treadmill
is elevating or not.
The last step is
change the Actuator.
2
3
Treadmill
runs
smoothly
for first
couple of
stages,
after that it
elevates
randomly.
Treadmill is
stuck
/elevates to
its top
position
If the LEDs are not
glowing then the
problem lies with
Treadmill controller or
the calibration factors
might be wrong.
Check with new
Treadmill controller
If on shorting
treadmill is elevating
then problem is in
Treadmill controller
check with another
one.
But if it is not
elevating on shorting
then change high
frequency drive
to
This occurs if 10K Pot of
Actuator doesn’t work
properly.
If not adjust/change
it properly.
10K pot,
High frequency
drive, Actuator
If problem persists check
with another high
frequency drive
.
The last step is to
change the Actuator.
Check Treadmill
manually from 15 pin
connector on high
frequency drive i.e.
Short pin 1 & 7 of the
15-pin d type
connector and check
whether the Treadmill
is elevating or not.
If still problem
persists then problem
is in Treadmill
controller
Rev 7, Dated 21-3-2016
Treadmill
controller, High
frequency drive.
Actuator.
51
If working, OK but if it is
not working then
remove Actuator’s
connections from
high frequency drive
and put in extension
board to check
Actuator.
Connections:
Grey +
BlackDOWN
Grey + RedUP
Warning: Do not
put red and black
simultaneously it will
physically burn the
Actuator
Change the Treadmill
controller.
Recalibrate
the
Treadmill check the
High frequency
drive, Actuator,
treadmill
controller.
Treadmill through test
Treadmill option.
If
still
problem
persists, isolate the
Treadmill from
PC and test the same
Independently for
elevation (Refer
STWin service manual
Procedure 1, page26**)
4
No medians
and no
heart rate.
Check If amplitude of
R wave is not less
than 0.4cm in QRS
detection lead.
If it is less than 0.4
cm then Change the
QRS detection leads
from menu option so
that the Q detection
lead is with tall R
wave.
Amplify
the
detection lead.
QRS
Increase the gain
After doing any one of above three options,
wait till the heart rate settles to correct value.
Once the heart rate settles, click relearn
buttons 3 to 4 times so that the medians get
updated correctly.
Rev 7, Dated 21-3-2016
52
MISCELLANEOUS
Problem
1.
Treadmill becomes non-functional again and again.
Possible Cause:
6. No Servo make voltage stabilizer is used for Treadmill even though
the supply voltage is fluctuating.
7. Voltage Stabilizer is not stabilizing the voltage.
8. Type of Stabilizer is other than Servo.
9. There might be leakage of current.
10. Problems due to slower configuration.
Solution:
6. Use 3.5 KVA Servo Stabilizers for Treadmill.
7. Ensure that in spite of changes in supply voltage at mains, the output
voltage is stable. For this, change the analog meter switch of
stabilizer to INPUT mode, Connect digital voltmeter (D.M.M.) to
output of the stabilizer. Now you are observing input voltage to
stabilizer and output voltage of the stabilizer. Here the out put voltage
displayed on D.M.M. should not vary by more than 2-3 volts even
though the input voltage changes by more than 10-20 volts.
8. If this output voltage to Treadmill is also varying with changes in
supply voltage, the stabilizer needs to be repaired immediately.
9. There are different types of voltage stabilizers used for voltage
stabilization. One is the On-OFF type of stabilizer. Here depending
upon the input voltage range, the relay inside the stabilizer operates
to stabilize the output voltage. But this relay operation generates a
spike at the output. This spike creates a problem to DC motor speed
control circuit and hence the Treadmill stops working. Another type of
stabilizer is SERVO STABILIZER. This stabilizer has built-in servomotor, which rotates continuously with change in supply voltage. The
shaft of this motor selects the appropriate winding of the VARIAC so
as to stabilize the output voltage at 230 volts. Hence there are no
spikes in the output voltage of the stabilizer.
10. This SERVO type is recommended for Treadmill.
Problem
2.
Solution
Material
Req.
Spike in ECG
Use branded SMPS for PC
Intex make SMPS
Rev 7, Dated 21-3-2016
53
4. APPENDIX:a) CABLE DIAGRAMS:1. TPC CABLE DETAILS.
1. NC
2. +5 VDC
3. NC
4. Ground
5. Speed Feedback
6. Grade Feedback
7. Grade increase
8. Grade Decrease
15 Pin D type (M) conn.
02
9. Speed Increase
10. Speed Decrease
11. NC
12. NC
13. NC
14. NC
15. NC
15 Pin D Type (F) conn.
02
04
05
06
07
08
09
10
11
04
05
06
07
08
09
10
11
Color
Black
Brown
Red
Orange
Yellow
Green
Blue
Violet
Gray
**Short Shield to pin no 4 of (F) conn.
Note: - if TPC cable of STWin amplifier is to be used with high frequency
drive then make one extra connection of pin 2 as shown above.
2. TREADMILL CONTROLLER TO SERIAL PORT CABLE DETAILS.
09 Pin D type (M) conn pin no.
02
03
05
Shield open and cut
09 Pin D type (F) conn pin no.
02
03
05
Short Shield to pin no 5 of (F)
conn.
Color code
Black
Brown
Red
3. TREADMILL CONTROLLER TO BODY LEVEL CABLE DETAILS.
09 Pin D type (M) conn pin no.
02
03
05shorted to 09
07
08
Rev 7, Dated 21-3-2016
09 Pin D type (M) conn pin no.
02
03
05shorted to 09+Shield
07
08
54
Color code
Black
Brown
Red
Orange
Yellow
b) ASSEMBLING AND DISASSEMBLING OF TREADMILL PARTS:
Precaution: While removing any treadmill part first check how it is connected to it
i.e. its correct position w.r.t some fixed part of treadmill so that there will be no
problem on mounting it back to treadmill.
1) Fitting front and side handle to Treadmill:•
For front handle
a) First place front handle in its appropriate position matching with slot
of
Treadmill on both side and then fix it with four M10X25mm Allen bolt
at four
drill of Treadmill two on both side as shown in fig9.
Fig.9
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55
•
For Side handle
a. First keep side handle facing one end to front handle and other end to
bottom slot of treadmill as shown in fig. And then fix its one end facing
front handle with M10X25mm Allen bolt and other end facing bottom
drill of Treadmill with M10X10mm bolt and M10nut as shown in fig10.
b. Similarly connect second side handle to other side of treadmill.
Fig.10
2) Removing back and front roller from Treadmill:For bottom Roller:
a) First remove two end cap of treadmill as shown below.
2
1
After removing
End cap
End Cap
Fig.11
b) Remove two side handle by removing Nut bolt arrangement used in fitting side
handle as described in point 1 under heading “Fitting front and side handle to
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56
Treadmill”. c) Remove top cover of treadmill by removing seven M6X16mm button
head Allen bolt as shown in fig.12.
Top
1
2
3
Removing
M6X16mm
Treadmill
without
top cover
Fig.12.Treadmill after removing top cover
d) Loose two M10X70mm Allen bolt of bottom roller as shown in fig.13.
1
2
Two
M10X70mm
Allen bolt
Fig 13
e) Remove six M10X30mm Allen CSK bolt from wooden board as shown in fig.14.
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Fig14
f) Remove two M10X70mm Allen bolt of bottom roller as shown in fig.13 (2).
g) Now remove bottom roller from treadmill.
1
2
Fig.15. Treadmill after removing the back roller
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•
For removing front roller:-
h) First remove wooden board from treadmill as shown in fig.16 (1)
Precaution: On back side of wooden board there are two rod to hold the conveyor
belt to its correct position as shown in fig. 16(2).While removing wooden board hold it
properly as its back side rod can damage conveyor belt which is in between these two
rod
i) Then remove M10X100mm full thread Allen bolt by removing M10 nut attached
with it as shown in fig.16 (3)
1
2
3
Fig.16
j) Remove M8X30mm fixed bolt which is on other end of roller as shown in fig.17.
Fig.17
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k) Now remove front roller as shown in fig. 18.
1
2
3
4
Fig.18. Treadmill after removing front roller
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3) Removing Bearing of front and back roller.
a) First remove Bearing lock from both side of roller with aid of inner Pliers as shown
in fig19.2.
1
Bearing
lock
2
Bearing lock after
removed from roller
Outer
Plier
Fig.19
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61
Inner
Plier
b) Then Press Shaft other end so that bearing will come out from it as shown in
fig.20.1 and then remove Bearing from it as shown in fig20.3.
1
2
Roller
3
Fig.20:- Removing Bearing from Roller.
Note:-Follow same step for removing all four bearing from roller.
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Roller
Shaft
4) Removing actuator from Treadmill:a) First place one support like stool below treadmill as shown in fig.21 so that it will
not fall directly after removing of actuator.
b) Then remove top M10X35mm Actuator mounting bolt by removing M10 nut as
shown in below fig21.
Removing
M10X35mm
bolt and M10
nut
Fig. 21
c) Remove M10X70mm Actuator pipe mounting Allen bolt by removing M10 nut from
it as shown in fig.22.
M10 Nut
M10X70mm
Allen bolt
Fig. 22
d) Now remove actuator wiring from high frequency drive, and then actuator can be
easily removed from treadmill.
NOTE: - For Upper and lower limit switch setting Procedure see Procedure
6. “Changing of Actuator” on page 32 to 34.
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5) Removing DC Motor from Treadmill:a) First elevate treadmill to its middle position with aid of actuator.
b) Remove DC motor connection from High frequency drive.
Warning: - Do not disturb two bolt of DC motor adjuster (M10X30mm hex bolt).
c) Remove DC motor fly wheel retainer plate by removing M12 hex bolt as shown
in fig 23.
Fly wheel
retainer
plate
Fig23
d) After removing fly wheel retainer plate remove timer belt which is attached to the
plate.
e) Now remove four M10X40 hex bolt plus plain spring by removing M10 nut attached
with it as shown in fig.24 and then DC motor can be easily removed from treadmill.
M10X40 hex
bolt+M10 nut
Fig.24
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5) Removing conveyor and Timer belt from Treadmill:a) For removing conveyor and timer belt we have to remove two front and back roller
from treadmill and then this belt can be easily removed from treadmill.
Note: - For removing two rollers, refer point 2 under heading removing
back and front roller from Treadmill.
c) REPLACING AC-DC COMBINED CARD WITH HIGH FREQUENCY
DRIVE:a) Mains connection:
Connect three wire from CON10 of AC-DC card directly to J1 (mains) of high
frequency drive.
Ensure L, N, E of AC-DC card connect to L, N, E of high frequency drive.
b) E.S (CON12) and MCB (con13) connection:Leave these two connections as it is on treadmill.
C) AC Motor connection:
For doing AC motor connection first remove three wires from CON10 of AC-DC card
and then connect common wire of it directly to terminal C (on connector J2) of high
frequency drive.
For doing connection of UP. and DN. wire of CON11 refer fig.8 under heading
Connection of limit switch if high frequency drive is to be used in Treadstar
and Compact Machine.
d) Upper and lower limit switch (con15, con7) connection:Remove wire from these two connector and do taping on them as we have already
done limit switch connection according to fig.8 in step C (AC Motor connection).
e) DC motor connection:Remove two wire A+, A- from (con15) of AC-DC card and connect it directly to M+,
M- (connector J7) of high frequency drive.
Do taping of remaining two wire of con15 (F+, F-) as we didn’t use DC motor which is
having field connection now.
f) 15 pin D type female connector connection:Connect 15 pin D type male connector from treadmill controller /STWIN amplifier
directly to 15 pin D type female connector on treadmill.
Ensure that connection of cable between 15 pin D type male connector from high
frequency drive to 15 pin D type female connector on treadmill is according to TPC
cable detail as describe in Appendix above. As we require pin no. 2 connection of 15 pin
D type connector in case of high frequency drive which is not needed in AC-DC card.
g) Sensor wire connection:
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Connect two wires of Speed sensor from con8 of AC-DC card directly to J3 of high
frequency drive.
Connect three wires of Elevation sensor from con6 of AC-DC card directly to J8 of high
frequency drive.
D. Silicon oil refilling
Silicon oil refilling is required after every 4 months to maintain smooth
operation of treadmill belt. Follow the below steps to pour silicon oil below
belt.
1. Take 20 ml silicon oil in insulation syringe
2 .Pour all 20 ml blow front both side.
3. Take again 20 ml of silicon oil in springy and pour all 20 ml below back
both sides.
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4. Take 20 ml of silicon oil and pour from bottom side evenly.
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