Star Trac E-TRx Technical Manual
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Star Trac E-TRx Technical Manual

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Table of Contents

See also: Owner's Manual
Treadmill Technical Manual
Last updated 03/06/2017
637-4504 Rev. B

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Summary of Contents for Star Trac E-TRx

  • Page 1 Treadmill Technical Manual Last updated 03/06/2017 637-4504 Rev. B...
  • Page 2 Safety Information Tools Product Details  E-TRx  E-TR  S-TRc  S-TRx Power Requirements Product Placement Preventative Maintenance Systems  Power  Display  Drive  Belt & Deck  Elevation Maintenance Mode Part Replacement Procedures  Running Belt ...

  • Page 3: Safety Information

    Safety Information The following pages are intended to educate service technicians on the basic maintenance and service actions for the StarTrac treadmill. By following the enclosed instructions and maintenance schedule, you will extend the life of your equipment and help ensure it will withstand hours of use in your home/facility.
  • Page 4 Tools Qty. Name Model Manufacturer Specifications Multi-meter Various Digital, Continuity Socket Set, SAE Various 1/4" - 5/8" socket Set, Metric Various 4mm - 21mm Socket driver Various Open end wrenches, SAE Various 1/4" - 3/4" Open end wrenches, Metric Various 4mm - 17mm Hex Bit Socket Set, SAE Various...
  • Page 5 Balke Ware), Firefighter Test (Modified Gerkin Protocol), Deck System: Reversible 1” (2.5 cm) composite ARMY Protocol, USMC Protocol, USAF Protocol, NAVY Protocol, three custom workouts and Star Trac Coach™. fiberboard, waxing not required ROLLERS: 3.5” (9 cm) sealed bearings STANDARD FEATURES: Standard Features: Hot Bar...
  • Page 6 Deck System: ROLLERS: 3” (7.6 cm) sealed bearings Reversible 1” (2.5 cm) composite fiberboard, waxing not COLORS: Frame: Star Trac Silver, Shrouds: Slate Gray, required ROLLERS: 3” (7.6 cm) sealed bearings Accents: Black INCLINE RANGE: 0 to 15% in 0.5% increments COLORS: Frame: Star Trac Silver, Shrouds: Slate Gray, SPEED RANGE: 0.5 to 12.5mph (0.8 to 20 km/h) in 0.1...
  • Page 7 Burn Calories, Manual, Increase Endurance, Fitness ROLLERS: 3” (7.6 cm) sealed bearings Test (Modified Balke Ware), Firefighter Test (Modified COLORS: Frame: Star Trac Silver, Shrouds: Slate Gray, Gerkin Protocol) Accents: Black STANDARD FEATURES: Personal cooling fans, INCLINE RANGE: 0 to 15% in 0.5% increments...
  • Page 8 Burn Calories, Manual, Increase Endurance, Fitness ROLLERS: 3” (7.6 cm) sealed bearings Test (Modified Balke Ware), Firefighter Test (Modified COLORS: Frame: Star Trac Silver, Shrouds: Slate Gray, Gerkin Protocol) STANDARD FEATURES: Personal cooling fans, Accents: Black INCLINE RANGE: 0 to 15% in 0.5% increments...

  • Page 9: Power Requirements

    Power Requirements Treadmill Dedicated Circuit Requirement: Star Trac requires a 20 amp dedicated circuit and dedicated neutral for each treadmill installed and operated. Each treadmill requires an outlet of which line and neutral contacts are wired to the electrical power distribution box (circuit breaker box) with dedicated wires. Both the line and neutral wire from an outlet for a treadmill shall be isolated from all other outlet contacts other than the connection at the electrical power distribution box.

  • Page 10: Product Placement

    Product Placement Star Trac recommends that treadmills be spaced a minimum of 20.0 inches (0.5 m) apart to allow safe and easy ingress and egress. More importantly, there must be at least 48 inches (1.25 m) of free space behind the treadmill.

  • Page 11: Preventative Maintenance

    Preventative Maintenance This section provides a list of factory recommended PM requirements. Long-term effects and cost comparisons usually favor following a regular preventative maintenance schedule over performing maintenance actions only when the system fails. Preventative Maintenance Cautions  While maintaining equipment you will want to avoid spraying any liquids directly onto any surface of the unit.

  • Page 12: Power System

    Treadmill Systems Power System The power system supplies AC and DC voltage to different components of the treadmill. There are two parts of the power system, external power and internal power. There are two sub-systems:  External  Internal External The external power is anything outside of the treadmill that supplies power.

  • Page 13: Power Flow Diagrams

    Power Flow Diagrams 1. AC power goes from the breaker box, through the circuit breaker and power lines to the power outlet. 2. AC power continues up through the power cord, through the onboard circuit breaker, on/off switch, and EMI filter to get to the MCB. 3.

  • Page 14: Display System

    Display System The display system controls and commands most of the functions of the treadmill. It is the user interface and the brain of the treadmill. There are five sub systems: 1. Treadmill Operation 2. Watch Dog 3. Personal Cooling Fans 4.
  • Page 15 Heart Rate The users have 2 types of heart rate to use, contact or Polar. Contact heart rate is used by grabbing onto to the metal contacts on the hot/warm bar. Polar is a wireless system that requires the user to wear the Polar chest strap. Components: ...
  • Page 16 Display System Power Flow 1. The user presses the keypad to select programs, speed, elevation etc. Those keystrokes are received by the display electronics which sends the necessary requests down the data cable to the MCB. 2. The watch dog is a part of the display electronics that monitors the systems of the treadmill and will shut down the system if there are any anomalies.

  • Page 17: Drive System

    Drive System The drive system is what makes the treadmill running belt move as well as sends feedback to the display for keeping track of speed. There two sub systems:  Drive Power  Feedback Drive Power Drive power is the VAC going to the drive motor to make it turn. Components: ...
  • Page 18 Drive System Power Flow 1. The user enters what speed they want the treadmill to go by pressing the speed keys or entering the desired speed on the number keypad. 2. The display electronics registers the requests and send information down to the MCB.
  • Page 19 Belt & Deck System The belt and deck system is the main function of the treadmill. There two sub systems:  Rollers  Belt and Deck Rollers The rollers are used to make the belt rotate. It also applies tension and tracking for the belt. Components: ...

  • Page 20: Elevation System

    Elevation System The elevation system controls the incline of the treadmill. There two sub systems:  Elevation Motor  Elevation Sensor Elevation Motor The elevation motor is the muscle that makes the incline go up and down once it has received signals from the display.
  • Page 21 Elevation System Power Flow 1. The user enters the desired elevation by pressing the elevation keys on the display. 2. The display sends a signal down to the MCB through the data cable. 3. The MCB will send the appropriate amount of AC voltage to the elevation motor to make the incline go up or down.

  • Page 22: Maintenance Mode

    Maintenance Mode LED Console: To enter Maintenance Mode, press the 0, 2, and OK keys all together at once. A beep will sound and the console will say Maintenance Mode. Use the Elevation up/down keys to change between Maintenance Mode options. Use the Speed up/down keys to edit the options.
  • Page 23 Embedded Console: To enter the Service Menu, press the Vol +, Ch+, and 3 keys all together at once. Press the option on the touchscreen, or press the number option you want to select on the keypad. The embedded console password is 218. Use the Elevation up/down keys to change between Maintenance Mode options.
  • Page 24 Part Replacement: Running Belt Troubleshooting that must be done PRIOR to replacement: 1. DFR code 800 2. Confirm that the running belt logo ( STARTRAC ) is not 75% worn out 3. Confirm that the running belt is not over tensioned 4.
  • Page 25 Part Replacement: Running Belt Procedure: 1. Remove the front and side bed covers from the machine. 2. Loosen and remove the two bolts that hold the tail roller onto the machine chassis. Remove the tail roller from between the belt and set to the side.
  • Page 26 6. Loosen and remove the bolt that connects the head roller to the chassis of the machine. 7. Remove the head roller and drive belt from between the running belt and set to the side. 8. Loosen the deck retention rods at the 4 corners of the deck.
  • Page 27 13. Replace head roller through the belt and mount into the chassis of the machine. Ensure drive belt is on the head roller before mounting it. 14. Walk drive belt onto head roller and tail roller pulleys. 15. Tension idler t-pin handle. 16.
  • Page 28 17. Replace tail roller through the belt and mount to the chassis of the machine with the two bolts. Tension bolts equally, as they are responsible for overall belt tension as well as tracking. 18. Ensure proper tracking and re-tension belt using stomp test.
  • Page 29 Part Replacement: Deck Troubleshooting that must be done PRIOR to replacement: 1. DFR code 800 2. Confirm that the running belt logo ( STARTRAC ) is not 75% worn out 3. Confirm that the running belt is not over tension 4.
  • Page 30 Part Replacement: Deck Cushion Procedure: 1. Remove running belt, deck, and rollers. 2. Remove old deck cushioning rubber. Use a putty knife or scraping tool to remove all adhesive residues from chassis. 3. After removing all the adhesive, use180 grit sandpaper to remove the remaining remnants and to rough up the surface.
  • Page 31 5. Lay the cushion on the frame with the larger side on the bottom. 6. Align it and press down firmly on various areas of the deck cushion for 30 seconds. For best results, allow at least 15 minutes for the adhesive to cure before putting the deck back on the frame.
  • Page 32 Part Replacement: Rollers Troubleshooting that must be done PRIOR to replacement: 1. Confirm drive belt has right tension 2. Confirm drive belt is not worn 3. Confirm motor has not been adjusted 4. Remove drive belt from roller and check for roller noise Versions / changes: 1.
  • Page 33 Part Replacement: EMI Filter Troubleshooting that must be done PRIOR to replacement 1. Check for 120v AC input from wall. 2. Check for 120v AC out from power switch. 3. Check for 120v AC input to EMI filter. 4. Check for 120v AC output from EMI filter. 5.
  • Page 34 Part Replacement: EMI Filter Procedure: 1. Turn unit off, unplug power cord from the wall, and wait until AC LED on the MCB has gone out. 1. Disconnect red and blue leads going from the power switch/breaker into the EMI filter and the red and blue leads from the EMI filter out to the MCB connector.

  • Page 35: Part Replacement

    Part Replacement Part Replacement: MCB Troubleshooting that must be done PRIOR to replacement 1. Check for voltage input to unit. 2. Check AC LED and V-CON LED’s are on. 3. Verify voltage into the EMI filter is 120v AC. 4. Verify 120v AC voltage out of the EMI filter input cable. 5.
  • Page 36 Part Replacement: MCB Procedure: 1. Turn unit off, unplug power cord from the wall, and wait until AC LED on the MCB has gone out. 2. Remove wiring connectors into MCB for Motor, Speed Sensor, I/O, 12v DC power, Elevation, Power, and Ground wire.
  • Page 37 5. Ensure all wiring connectors are seated fully into the MCB. Check that wires are away from the RPM disc of the motor and are routed properly. 6. Make sure to re-route and zip tie the speed sensor wire around the back of the MCB.
  • Page 38 Part Replacement: Drive Motor Troubleshooting that must be done PRIOR to replacement 1. Check for DFR code 4000 in display 2. Check for voltage input to unit 3. Check AC led & V-CON LED’s on 4. Verify voltage in from the EMI is generating 120v AC 5.
  • Page 39 Part Replacement: Drive Motor Procedure: 1. Remove the top motor shroud and front bumper. 2. Turn unit off, unplug power cord from the wall, and wait until AC LED on the MCB has gone out. 3. Disconnect speed sensor and remove zip ties holding it to the MCB.
  • Page 40 5. Remove the RPM sensor assembly and the RPM disc from the motor. Set aside for use on the replacement motor. 6. Pull and turn the T-pin idler pulley to remove tension on the drive belt. Caution: pinch points. 7. Using a long phillips head screwdriver remove the 4 screws that hold the head roller finger guard in place.
  • Page 41 8. Walk the drive belt off of the headroller pulley. Remove belt from small pulley on motor. 9. Loosen the 4 bolts that connect the motor to the chassis and remove the motor and bleeder wire. Lift motor up and take caution not to damage the bolt threads.
  • Page 42 12. Place the replacement motor into the chassis of the machine; connect with 4 bolts, including bleeder wire. 13. Using a straight edge, align balance wheel with the head roller pulley, apply blue Loctite to the set screws, and tighten. 14.
  • Page 43 15. Mount the RPM disc to the motor shaft using blue Loctite on the set screws. Torque set screws and shaft bolt to 60 – 66 Lb-In. 16. Mount the RPM sensor assembly and ensure appropriate gaping (2mm) of speed sensor and RPM disc.
  • Page 44 18. Re-route the new motor power cable under and behind, or zip tied to the front (as shown) of the elevation motor and plug into MCB. 19. Reconnect dust cover / finger guard. 20. Turn machine on and perform a Speed / Motor Calibration in the Maintenance Mode of the console.
  • Page 45 235 - 230 NEW (post V1.05) Calibration Values: Model Incline Range Min (zero elevation) Max (full elevation) E-TRx / 8-TRx 0% - 20% E-TR / 8-TR 0% - 15% Testing requirements after replacement: 3. Run program on unit. Last updated 03/06/2017...
  • Page 46 Part Replacement: Elevation Motor Procedure: 1. If possible, before replacing the elevation motor, elevate treadmill. 2. Turn Power Off / Unplug from wall 3. Remove the shrouds (both top and front bumper shown in Step 1). 4. Disconnect Elevation Motor wiring harness from MCB and remove ground wire from chassis.
  • Page 47 6. On the under-side of the machine, remove cotter pin, pin, and spacer that connect the motor to the lift bar of the machine. Caution: potential pinch points when the elevation frame weldment (lift bar) is removed from the elevation motor. 7.
  • Page 48 10. Align lift bar with pin with the elevation shaft connector and insert pin, spacer and connect. Don’t forget spacer. 11. With a helper, remove the jack, or 4x4 holding the unit up and return unit to the ground. 12. Using a level ensure treadmill is level and adjust leveling feet as needed.
  • Page 49 14. Verify potentiometer reading is 9.4 – 9.6 Ohms, blue and orange wire of elevation MCB connector, when the treadmill is at zero elevation. 15. Plug unit in, power on and perform an elevation / incline calibration in the Maintenance Mode of the console. 16.
  • Page 50 Part Replacement: LED Display Troubleshooting that must be done PRIOR to replacement 1. Check for DFR code on MCB 2. Check for EE error 3. Check AC led on MCB 4. Check V-CON led on MCB 5. Verify voltage input to MCB 120 volts AC from EMI 6.
  • Page 51 Part Replacement: LED Display Procedure: 1. Using a phillips head screwdriver disconnect upper and lower rear covers from the console. 2. Disconnect the I/O Ribbon cable and the DC Power Cable. 3. Remove all the applicable electrical connections from the back of display electronics board.
  • Page 52 4. From the back of the display, connect the grounding wire to the frame using a washer & phillips head screw. 5. Disconnect 6 screws that connect the console to the machine chassis. 6. Prepare new display for mounting. Last updated 03/06/2017 637-4504 Rev.
  • Page 53 7. Identify all the applicable electrical connections to the back of display electronics board. 8. Connect the E-Stop cable (g) to the J25 connector and connect the rail stop cable (f) to the J5 connector on the display board. 9. Connect the Hot Bar cable (i) to the display board.
  • Page 54 11. Connect the I/O ribbon cable (e) to the display board and ensure it is seated fully. 12. Reconnect new console to the machine chassis. 13. Ensure ground wire is reattached. 14. Replace rear console covers. Turn machine on and run Heart Rate and Keypad Test procedures in Maintenance Mode.
  • Page 55 Part Replacement: LED Console Keypad / Display Electronics Troubleshooting that must be done PRIOR to replacement: 1. Perform a keypad test 2. Check for ribbon cable damage 3. Check ribbon cable is connected to all pins on display board Versions / Changes: 1.
  • Page 56 Part Replacement: LED Console Keypad / Display Electronics Procedure: 1. Remove console from chassis. 2. Disconnect 3 screws that connect the overlay to the plastic console housing. 3. Remove 5 sheet metal screws that hold the Display Electronics onto the metal brace of the console housing.
  • Page 57 5. Remove the overlay and Display Electronics from the plastic console housing, making sure to unhook the 2 clips at the base of the keypad overlay. 6. Remove the keypad overlay from the Display Electronics by removing the 5 extension posts and screw.
  • Page 58 9. Reconnect the keypad overlay and Display Electronics to the console housing. Note: ensure to align tabs at base of keypad to the corresponding holes in the console housing. 10. Reconnect wires back onto the Display Electronics. 11. Remount console onto chassis. Last updated 03/06/2017 637-4504 Rev.
  • Page 59 Part Replacement – Embedded Display Troubleshooting that must be done PRIOR to replacement 1. Confirm power from FCB or MCB ver2 12v DC to CPU 2. Confirm power from the CPU 12v DC to CCB input 3. Confirm Power from Translator to FITCPU 12v DC 4.
  • Page 60 Part Replacement – Embedded Display Procedure: Last updated 03/06/2017 637-4504 Rev. B...
  • Page 61 Part Replacement – Embedded Display Last updated 03/06/2017 637-4504 Rev. B...
  • Page 62 Part Replacement – Embedded Display Last updated 03/06/2017 637-4504 Rev. B...
  • Page 63 Part Replacement – Embedded Display Last updated 03/06/2017 637-4504 Rev. B...
  • Page 64 Part Replacement – Embedded Display Last updated 03/06/2017 637-4504 Rev. B...
  • Page 65 Part Replacement: CCB Troubleshooting that must be done PRIOR to replacement: 1. Check CCB keypad for power lit LED (If no RED led is on follow CCB replacement # 22 2. Check the power for 12v DC input (under 11 volts DC replace power FCB or wire ) 3.
  • Page 66 Part Replacement: CCB Last updated 03/06/2017 637-4504 Rev. B...
  • Page 67 Part Replacement: CCB Last updated 03/06/2017 637-4504 Rev. B...
  • Page 68 Part Replacement: CCB Last updated 03/06/2017 637-4504 Rev. B...
  • Page 69 Part Replacement: CCB Last updated 03/06/2017 637-4504 Rev. B...
  • Page 70 Troubleshooting DFR Codes: The MCB monitors various temperatures, currents and voltages coming in. When the MCB senses an anomaly it will shut down and identify a Drive Fault Record (DRF) code. Under normal operation circumstances, LEDs 1 – 3 blink in a staggered pattern sequence.

  • Page 71: Troubleshooting

    Troubleshooting No Power to the Display NO POWER TO DISPLAY Start Turn treadmill power on Locate AC LED on the MCB Was the line cord output voltage adequate? SOLUTIONS: _________A1_______ Tripped Wall Breaker Measure EMI filter AC input voltage or Bad Wall Circuit _________A2_______ Replace Line Cord _________A3_______...
  • Page 72 No Power To The Display NO POWER TO DISPLAY Measure MCB input Locate V-Con LED on the MCB AC voltage SOLUTIONS: _________A5_______ AC MCB Input Cable _________A2_______ Is the Replace MCB V-Con LED lit? _________B1_______ Was the MCB input AC voltage Replace MCB adequate? Disassemble back display...
  • Page 73 Error Code - Check Speed Systems CHECK SPEED SYSTEM / CHECK MOTOR SYSTEM (AC MOTOR) Start Press # 2 key Press # 4 key Press 0, 2, and start keys simultaneously Does the Does the Screen will display Last Code (2) read “Maintenance Mode”...
  • Page 74 DFR CODE FLOWCHART: DEFINITIONS / MCB LED Blinks DFR Flowchart For #: 1000000, 100000, and 10000 DFR Code = 1000000 DFR Code = 10000 DFR Code = 100000 DC Link Bus Over Voltage / 25 Blinks Brake Gate Drive Fault / 17 Blink Output Peak Over Current / 21 Blink Possible Causes: Possible Causes:...
  • Page 75 DFR CODE FLOWCHART: DEFINITIONS / MCB LED Blinks DFR Flowchart For #: 4000 DFR Code = 4000 Over Temp on Motor or Drive / 15 Blink Possible Causes: (1) Open thermostat wires on drive motor. (2) Drive motor over heating. (3) Faulty MCB.
  • Page 76 DFR CODE FLOWCHART: DEFINITIONS / MCB LED Blinks DFR Flowchart For #: 1000 DFR Code = 1000 Start Faulty Speed Sensor / 13 Blinks Possible Causes: (1) Sensor disconnected. Turn the tread AC power off. Increase PWM to 100 (2) Faulty speed sensor. (3) Faulty MCB.
  • Page 77 DFR CODE FLOWCHART: DEFINITIONS / MCB LED Blinks DFR Flowchart For #: 800, and 400 DFR Code = 800 Solution: DFR Code = 400 Phase Over Current / 12 Blinks Illegal Speed Command / 11 Blinks Possible Causes: Possible Causes: E1_______ Clean the underneath (1) Worn running belt.
  • Page 78 DFR CODE FLOWCHART: DEFINITIONS / MCB LED Blinks DFR Flowchart For #: 200 Start Turn the tread AC power off. DFR Code = 200 Engage motor test mode DC Link Bus Under Voltage / 10 Blinks (#8 after engaging maintenance mode) Possible Causes: Measure AC voltage out of the (1) Low AC voltage from wall.
  • Page 79 DFR CODE FLOWCHART: DEFINITIONS / MCB LED Blinks DFR Flowchart For #: 40, 20, and 10 Start DFR Code = 40 Phase A Circuit Open / 7 Blinks DFR Code = 20 Recycle the tread AC power Phase B Circuit Open / 6 Blinks by turning it off and back on DFR Code = 10 Phase C Circuit Open / 5 Blinks...
  • Page 80 DFR CODE FLOWCHART: DEFINITIONS / MCB LED Blinks DFR Flowchart For #: 2000, 100, 80, 8, 4, 2, 1, 800000, 400000, 200000, 40000, and 20000 Start Recycle the tread AC power DFR Code = 2000 by turning it off and back on Heat Sink Over Temp / 14 Blinks DFR Code = 100 Solution:...
  • Page 81 Embedded No Power Last updated 03/06/2017 637-4504 Rev. B...
  • Page 82 Last updated 03/06/2017 637-4504 Rev. B...

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