Step 2: The PWM circuit board

For a complicated description of a treadmill PWM (Pulse-Width-Modulation) controller you can visit
You can visit wikipedia for a better definition of PWM.


But basically (as best I can understand) it's an efficient speed controlling circuit that pulses the Voltage and the width of the signal to the motor off and on thousands of times per second. This transfers more power to the load and wastes less power to heat than a resistive type speed controller.

PWM style controller Trim Pots- located near one of the edges of the board.Each Set for specific motor

MIN (Minimum speed-Touch if you dare) adjusting MIN Trimpot may affect MAX, may be necessary to adjust both until desired levels are achieved

MAX (Maximum speed-Touch if you dare) Note that MAX adjustment may affect MIN

IR COMP (Inrush compensation-Don't touch)Improves load regulation by providing minimal speed fluctuation due to changing loads. If the load presented to the motor does not vary substantially,the IR adjustment set at a minimum level. Excessive IR comp will cause control to become
unstable causing motor cogging.

CL (Current Limiting-Don't touch)The CL Trimpot sets the current which limits the maximum current to the motor. Also limits the AC line inrush current to a safe level during startup.

ACCEL (Acceleration Time Period, 0-full speed in seconds)I've never seen one on a treadmill circuit card, only on commercial PWM DC motor controllers. There must be something on the treadmill board that sets the time value..resistor perhaps?

<p>Hey, I could use some expertise here. My treadmills digital consol died and I want to use the treadmill but not spend $100+ on a new consol. I am able to increase and decrease the incline but can't get the tread to move. I will attach the voltage diagram, I made a pwm circuit and tried putting the output on the blue wire hoping it would start the motor but it did nothing. How can I make my Nordic track c2200 work again?</p>
<p>I made a simple 555 timer control box and set up a web page with the build info here. It creates a pulse and send it to the motor controller. <br><a href="http://el34world.com/Misc/Cnc/TreadmillMotor1.htm" rel="nofollow">http://el34world.com/Misc/Cnc/TreadmillMotor1.htm</a><br><br>I also uploaded a you tube video of my controller in action<br>https://www.youtube.com/watch?v=zWk7b0snB9c</p>
<p>We had a similar problem about a year ago. When I removed one of the tread motor brushes, it appeared to spring free. I suspect that it had gotten stuck in its housing. I removed it, inspected the spring, brush and and housing. Everything seemed fine. Re-installed the brush and it's been working fine ever since. Hope that helps.</p>
<p>Just what I've been looking for!</p><p>All I need now is to figure out how to mount the speed pot to the foot pedal.</p><p>I have a sewing machine foot pedal I can use.</p><p>Any advice? Much obliged.</p>
<p>This looks exactly what I have except that the circuit board is fried. Where can I find a design to replace the board?</p>
<p>Hello there! Great material, thank you for posting this. <br><br>Would I be able to adjust the potentiometer to a very slow speed (for the purpose of a conveyor belt) or will I face electrical/mechanical issues with the other components in the treadmill's circuit?<br><br>I appreciate any help! <br></p>
<p>One more thing, I'm assuming that it would be better to find an older treadmill because it would be easier to take apart. Do you have any other recommendations in regards to other things I should keep in mind while shopping around? <br><br>Thanks! </p>
well, for rpm, you want it on the spindle or on the chuck, anyways<br><br>so, you might want to use something like this<br><br>http://www.ebay.com/itm/4-Digital-Blue-LED-Tachometer-RPM-Speed-Meter-Hall-Proximity-Switch-Sensor-NPN-/181299070299?pt=LH_DefaultDomain_0&amp;hash=item2a3644455b<br><br>position the sensor in the right spot, and thats that :)
<p>I have a 2.5hp treadmill motor that I will be using to power my lathe/mill combo (the motor burned out last weekend in the middle of a project). Anyway, I would like to combine the lathe's capability of fwd/rev and the treadmill's speed controller. Here's what the wires look like coming from the switch to the motor through a junction box. I'm pretty sure that this is where the splicing is going to need to happen. </p><p><a class="drag_edit_photoset" href="http://www.instructables.com/files/deriv/FJU/XCG8/HVGXR4GZ/FJUXCG8HVGXR4GZ.LARGE.jpg" rel="nofollow"><img class="IblesFileThumbnailExpanded" src="http://www.instructables.com/files/deriv/FJU/XCG8/HVGXR4GZ/FJUXCG8HVGXR4GZ.SQUARE3.jpg" style="top: 0.0px;left: 0.0px;"></a></p><p> I don't want to run reverse polarity through the speed controller and fry something.</p><p>I want to do what this guy did (almost the same exact machine as mine but I have the older model with a mechanical chickenhead knob switch), but for the life of me can't figure out how he wired it up. If you could help me out with a simple hand drawn schematic or a link to someones page who has already managed it that would be great.</p><p><iframe allowfullscreen="" frameborder="0" height="281" src="//www.youtube.com/embed/IDItLgwDrwo" width="500"></iframe></p><p><a class="drag_edit_photoset" href="http://www.instructables.com/files/deriv/FJU/XCG8/HVGXR4GZ/FJUXCG8HVGXR4GZ.LARGE.jpg" rel="nofollow"> <br> <br> <h4 class="nonImageFileLabelExpanded" style="display: none;left: 0.0px;">lathewiring.png</h4> <br> </a></p>
<p>Well, is your treadmill motor a DC motor? if so, you'll need to wire a switch between controller and a motor. there is a good instructable here:</p><p>http://www.instructables.com/id/SIMPLE-Polarity-Reversing-switch/</p>
<p>I figured out the wiring. I was over thinking it.</p><p>Now I have to figure out how to convert the original treadmill board's reading of MPH to RPM. </p>
Any idea where to get a pulley to fit on a 17mm shaft? I guess I could drill out the center of 5/8 inch bore but I would think it would be difficult to keep it perfectly centered.
old,I know, but just in case... 17mm shaft is very common for USA car alternator pulleys, only it is often referred to as .67 inch. I just put one on my 17mm motor shaft and it was a great fit. I had to drill and tap for a set screw and fields flat on the shaft for the set screw to engage. runs great! marked as 2hp, so something less. ran a jointer and a planer with no problems.
<p>needs to be bored on a lathe, after being carefully centered in a 4 jaw chuck. </p>
I suggest you get a .040 thick shim and us a 3/4&quot; bore pully, find some aluminum sheet that thick and form a little ring so that it fit snugly between the parts. some similar diameter tubing might work, 035&quot;wall is common and might be close enough. Good luck. If you can make your project work with a 16mm it is almost identical to 5/8&quot;
<p>So are these DC motors actually servos or not?<br>I am assuming there must be some kind of signal coming out of the motor to the control board if the motors turn on and off to maintain a set seed. At least with the 4-wire units, and the two wire I guess would have an internal circuit to adjust to speed.<br>Anybody know for sure?<br>I am trying to find an fordable servo to power a bench-top lathe and I require spindle feedback to the control software for treading.<br><br>Thanks for any guidance!!</p>
<p>These are not servos, and they do not have any sort of position or velocity feedback. It could be possible to add an encoder, resolver, tachometer, etc in order to get the feedback you want, but you would have to work that out to fit your specific system and needs.</p>
<p>Can I wire some type of spdt switch in this set up, so I can reverse the drive motor. </p><p>I want to use it to power my metal lathe lead screw, but I need it to go in both derections. </p>
<p>anyone know if the mc-68 controller can take dc input voltage? i have 120vdc system and am looking to control speed of ironworker with it. . will it work?</p>
<p>Great treadmill repair and help here!</p><p><a href="http://www.treadmillsrepair.co.uk/2014/05/york-support-kxtl-230-board.html" rel="nofollow">http://www.treadmillsrepair.co.uk/2014/05/york-support-kxtl-230-board.html</a></p>
Hi, wonder if you have the pcb schematics for a motor controller, I found a 180v dc treadmill motor but I can't seem to locate a controller for one, I've decided that I'd be better off just building one. Any help would be greatly appreciated. My email address is kaighn80@hotmail.com <br>Thanks in advance.
I have a threadmill board 4f33 nordic track, reebock, sears bought on ebay trying to figuire where to wire the 5k potentometer? help Kernbigo
put it between either the input or uot put wire to the motor. an thier u go
Thank's For these PDF's the 1 for the VitaMaster really save my Bacon, I retrieved the motor, PWD an Control Panel but the idot tht I was/am I forgot to take pics to remind me how to wire everything back after tearing all the parts from the TreadMill. After stumbing upon your Thread I was lost, as I'm not an electrical engineer when it comes to figuring out how these things work outside wiring household wiring &amp; 220/240 Machinery&hellip;.Thank's for the wiring Diagrams !!! <br> <br>P.S I wired everything up lastnight &amp; did a Test run hoping nothing would burn up and all is good so far, I adjusted the Min/Max Speed adjustment &amp; Torque alittle bit lastnight as well &amp; if your willing to do so it won't hurt anything but I guess it all depends on what your Min/Max need for speed is &amp; the amount of Torque is required. <br> <br>The 1 item I'm going to test out this am. is removing tht Transformer between the Motor (Yellow Wire) in/Out of the Transformer into the PWD, I'm going to by pass this &amp; see how the motor/PWD work if nothing goes wrong&hellip;.I'm thinking this Transformer is merely a safety feature not sure&hellip;.?
I do not know what to do with 4 wires red black white and green , i want to put a cord to the wall what wires should i connect, this is a tread mill motor, i want to use it to roast a pork
Thanks a lot, I just have a question, are the field windings of treadmill motors connected in series, parallel or separate from the armature? How can I identify the connection of my motor?
add an elbow and a length of 3&quot;pvc and you have a machine gun for tennis balls
Use 1-1/2&quot; PVC 1120 instead of 3&quot;, and use golf balls instead of tennis balls, and you've got an undead-mulching emplacement gun for the Zombiepocalypse.
is that what i think it it is - that is sweet. i could use one to launch tennis balls for my dog to chase
...your dog, and all the others at the dog park. Simultaneously. ;-)
Your unknown PDF comes from the Horizon t64 repair manual. I have this motor and controler. Can you advise me how to use it?
Hi, can you tell me what was the model of your treadmill which you opened? I looked at some but none of them had a sliding pot control, dont want to decode the protocol for the menu selction.
I'm looking for something to power a tricycle or a rickshaw/pedicab for personal use. Would a motor and controls from a treadmill be powerful enough to get the job done?
&nbsp;can you use a dimmer switch for lights as a speed control
No, not likely. A dimmer switch is a rheostat which controls the voltage.
So I am very new to all of the DC Drive knowledge and how it works. I have been doing some research because mine needs to be replaced or repaired. What I have read suggests that a PMW motor will run a lot more smooth and a lot quieter than other types of motors. Is this true? I am looking for an efficient motor that is also quiet. Do I need to get certain <a href="http://www.qie.com/dcdrives.html" rel="nofollow">dc drives</a> for different types of motors, or will they all work together no matter the brand?
I don't have any of the nomenclature you mentioned on my board, it has a digital display as mentioned above. From the schematic attached I only see the one wire which mentions PWM. I have read that i might need a 555 timer?? I havent been able to find a clear answer anywhere. Can anyone guide me in the right direction as to what I need to do to have manual control of my treadmill motor?
Any photos of the sewing machine project?
Type O, its a Lifestyle 2808 treadmill sorry :(
I have a motor and control from a Lifestyle 2802 treadmill. <br>It has a delayed start feature,does any one no how to adjust or disable the delay start . I am going to use the motor for a pig roaster (spit) and I dont want my Piggy to burn before this thing kicks in. I havent timed it but it seems to take 30 seconds to 1 minute before it kick on ?
Hi great information base for treadmills..<br><br>I've got a Power First Treadmill here with a 180V DC motor and controller board.<br><br>The interesting thing is, the board has L W H as you have already covered. But it also has an additional H M.<br><br>Any ideas what the extra H and M are?
I built a pitching machine out of a treadmill motor and used all the same controls from the treadmill but the motor speeds up to the desired rpm but then will slow down for a bit then speed back up...does anyone know a solution to this?
did you pull the flywheel off, the motor needs it to maintain an steady constant speed, moreso than without one. when the motor reaches speed the controller will dial back a bit and unless there is something to keep momentum, the motor will slow down some, then the controller plays catch-up so you get that rise/fall speed effect.
Brilliant-Excellent-I hope you don't mind that I posted a vid link & pics. I'm afraid I didn't catch your name so I can give credit. Thaks again!
Does it slow down from the resistance of shooting out the ball? Did you incorporate the motor with or without the flywheel. If the answer is: it slows down when shooting the ball and the flywheel is incorporated-Try designing it without the flywheel-perhaps
The flywheel is still attached with the wheel mounted to the flywheel...the motor doesn't miss a beat when the ball hits the wheel..just annoying when you have to wait 30 sec after every 2 pitches or so.

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Bio: I like to learn new things.CNC, foundry, Screenprinting, anything electronics related. I like to tear things apart to see how they tick. Unless I ... More »
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