MC2100 Rev B - Treadmill Runs for a couple second then stops

Mars67

Joined Feb 21, 2021
5
I also checked the motor and there is no short to ground. The resistance over the motor is 1 Ohm. Any ideas would be highly appreciated.

Thank you
 

MaxHeadRoom

Joined Jul 18, 2013
23,945
I have yet to get hold of one with the 4 flash error and diagnose the actual reason for the error, the Youtube videos explaining the LED codes are too vague to be of any good.
Max.
 

Mars67

Joined Feb 21, 2021
5
Thank you for the response Max. My experience has been exactly the same. I thought my googling skills were failing me. It has to be a motor controller issue.
 

Mars67

Joined Feb 21, 2021
5
I would like to give some feedback on the 4 flash error on the MC2100ELS-18W controller. I found a short on the K50DDTP (IKW50N60DTP) IBGT between the collector and emitter. I replaced the IBGT and the treadmill is working 100%. It appears as if the 4 flashes indicate an over current protection state.

What I observed was happening, before I replaced the IBGT, is that when the start button is pushed the motor starts to immediately turn at full speed. The sudden inrush of current is high enough to trip a 16 Amp circuit breaker. That is with other appliances also drawing current from the same circuit, so I am not sure exactly how much current was drawn. If the treadmill is the only appliance on the circuit it would not exceed 16 Amps but would immediately go into the 4 blink state. Pressing the stop button would cancel the state.
It appears as if the IGBT failed due to overheating. The back of the IGBT shows signs of melting. It is mounted to a very substantial heat-sink with a silicone insulator between the IGBT and the heatsink. It is held in place with a spring clamp in stead of a screw. The main problem is that the mating surface of the heat-sink does not make contact with the full surface of the IGBT. A part of the IGBT sits below the heat-sink.
Mounting the IGBT higher should address this issue but it also appears as if the spring clamp does not hold the whole IGBT flush against the heat-sink. This appears to be the case when one looks at the damage to the IGBT. A screw would undoubtedly be better.

The damage on the IGBT is clearly visible on this photo. The smooth line on the bottom quadrant of the IGBT is the only part that does not show any heat damage. The part below the line sits below the edge of the heat-sink. It seems as if that smooth line was the only part making proper contact with the heat-sink. It is not that obvious on the photo but metal flowing upwards from that line is clearly evident.6C941BF5-A8A5-4B02-9BEE-55690478F546.jpeg
 
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ymg200

Joined Oct 2, 2015
41
Max, should the status LED be ON if no connectors other than AC power are plugged in? I wonder if I can debug the board that's not connected to the treadmill.
Thank you.
 

MaxHeadRoom

Joined Jul 18, 2013
23,945
The LED should be lit with power applied to the board and nothing else plugged in, I test them stand alone with a 20Hz PWM generator I have made up with some custom boards to provide PWM and stop start into the HD2 socket.
 

ymg200

Joined Oct 2, 2015
41
Thank you Max, you've made my life easier - no need to run to treadmill every time I need to test.
Is heatsink also optional if there is no motor connected?
 

MaxHeadRoom

Joined Jul 18, 2013
23,945
Agreed, I run them off the heat sink when testing and with a motor on the bench with no flywheel attached, i.e. no load.
The built in acceleration is quite slow also.
 

Andrewgeo

Joined Jul 17, 2021
1
Looks like the MOSFET was the problem. I also lubricated the deck under the belt. After it started running, it would slow down when you stepped on the belt. It still does a little at very low speeds of 1 mph and under.
I had the exact same problem with my treadmill running full speed for about a second and then shutting off. I followed this post, found the MOSFET, and replaced it. Treadmill now works great. Thank you for the post.
 
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