Treadmill motor / voltage, controller board issue

Discussion in 'The Projects Forum' started by animateme, May 27, 2011.

  1. animateme

    Thread Starter New Member

    May 27, 2011
    10
    0
    Hi,
    I am having some troubles with my Nordic Track EXP1000 treadmill and hope that someone here can help me determine the probable issues. The problem started when the treadmill would stop running in the middle of a workout session, about after 25 minutes of operating. Only the motor would stop running but the console would stay on. I noticed that the motor and the transformer were extremely hot and there was even a light burning smell. After about 5 minutes of cooling off, the treadmill could be again restarted. I visually checked the motor while the treadmill was running and noticed sparks coming from the inside. I also checked the voltage, which is supposed to be at 95V max, and the reading I got on the voltmeter fluctuated rapidly between 10 to 100V at maximum speed.

    I assumed that the brushes were probably worn and were causing these sparks and maybe also the voltage fluctuation. I proceeded to replace the brushes and took the motor to a service shop where they resurfaced the commutator with a lathe.

    After installing the serviced motor, the sparks are still there and I now find that when someone is walking/running on the treadmill the CUR LIM light comes on constantly and the motor begins to speed-up and slow-down irregularly, making a noise as if it was being forced. Also, when there is load on the motor from a person on the walking belt the sparks are much greater. I checked the voltage again and it is the same, fluctuating rapidly between 10 to 100V, getting different readings in between.

    I checked the AC voltage going into the control board and it is at 110V, constant. The issue is with the voltage feeding the motor. For example, readings are: 40, 10, 80, 100, 20, 10 V, all these within 3 to 4 seconds.

    I am positive that the issue is not the walking belt as this was replaced a few months ago and the treadmill had been running fine after that.

    Could the issue be on the motor? Could it be the motor controller board? Is it normal to have these fluctuating voltage readings? Any suggestion on what else I could test or try?

    Thank you very much in advance for any help provided.
     
  2. animateme

    Thread Starter New Member

    May 27, 2011
    10
    0
    Sorry to "bump" this one but... any ideas from the experts here? Thanks.
     
Loading...