treadmill motor controller circuit diagram

Please let me know how to run a 180v dc 5400 rpm 1.5 hp motor from a threadmill with 220v ac current here in India. This warranty does not cover damage arising from improper installation, electrical shorts or surges in other parts or house wiring, a worn out belt and/or deck, or acts of God. , they are having similar voltage and current max. Hello, mr.Mjumdar, I haven't been there long time ago. Thanks, yes that's correct, D3, mosfet, DPDT all needs to be separated from the circuit and connected with the high voltage DC, as shown here, 1.bp.blogspot.com/-X72f9qUy-iA/VBGuxilwsBI/AAAAAAAAIOs/yqGppAoBpGA/s1600/pwm%2Barduino.png, Z1 can be removed, it's not crucial if the 12V input is fairly constant. 1st of all thank you very much mr.swag for your technical explanation against my ques, let me try as u said, and i will reply, it is much appreciated Sincerely, JEMS JEHAN. Advertisement. Your blog (which I consider very useful and interesting) is visited as you can see (at least this theme) by newcommers. Hi Mr.Lim, I normally do not find time to respond to emails, so this place is the best place to interact with me. That's why I want to get clear everything before start to build the circuit. yes you can use a MOC3043 IC for driving your motor and I think it would make things much safer, however for driving the MOC you'll need a PWM feed. Hi Ivan, it's showing the peak voltage, once connected to the load the voltage will come down to the specified level, however still it could be not so safe to apply the pulsating peaks to the motor, so I think you will have to get a suitable auto-transformer designed from a transformer maker. If you are interested to use an IC, you could perhaps try the following concept, https://homemade-circuits.com/2014/01/simplest-full-bridge-inverter-circuit.html, You can try for KSA1156 or any similar 250mA, 400V PNP BJT. If it does then I think the triac issue can be corrected by simply using a more stronger or high current triac such as BTA41/800 etc. I'll shall be very thankful to you! Excuse me for the late reply. but first make sure to test the dimmer circuit with an ordinary ceiling fan or a 200 watt bulb, before setting up the bridge and the treadmill motor. ". make sure to use 12V for the circuit and 90V for the transistor bridge section. Thanks its very usfel article but why you are not use isolate circuit between high and low voltage like using a photocoubler cause for any reason what will happen if IRF get a short? do any changes have to be made to the alternative designs for my situation? I think it gives feedback to the controller about the current speed of the engine no matter what is the speed set by the user. According to the datasheet of this it has a build in diode so it lets the DC power go straight thru in one direction. When i disconnect magnetic sensor motor running full speed. thank you swagatam. Thank you again for your time and responses. If I use a full-wave rectifier and a smoothing capacitor the rectified voltage will be above the motor's and even transistor's allowable. Turn Switch off and disconnect. Exactly that was my second question. From the thousands of photographs on the net with regards to treadmill wiring diagram, we picks the top selections with best image resolution only for you, and now this photos is among photographs series within our very best photographs gallery about Treadmill Wiring Diagram.Lets hope you may as it. Sorry for my last post, I knew that this is the peak value of the voltage formed by the capacitor, but the post was already on its way. I want to use a rectifier and a capacitor for the power supply of the motor direct from the wall outlet. The image that you ahve provided will controll speeds upti 50% only and will create lot of jerk at lower speeds….i already have a similar design posted in my blog here: https://homemade-circuits.com/2012/01/how-to-make-versatile-closed-loop.html. Thanks in advance! To control the speed of a 120VDC 2.5 HP motor, should I use the second circuit? Massimo, if it is a DC motor, then you must use the second last circuit, because 50 V cannot be used with a 220V input or a 120 V, even with a triac chopper. Ok great.. And that reminds me i forgot to mention for the 12v circuit i recall you mentioning an smps power supply however i dont know how to tell if it is a smps powersupply or not… im using a small ac to dc (wall dart) power adapter which belonged to a wireless router enclosure. HelloMy treadmill motor is rated for 130VDC and 15a. Thank you so much. To power the lamp I used a 220 to 110 VAC transformer (here in Argentinda we use 220V line) that I then rectified with a KBPC3506. Then it’s fine Mah, you can use the last circuit which has a bridge rectifier with the dimmer input. Can you help me with this problem sir?Thank you very much. Thank You. With the scope there are pulses on the pin 3 of IC2, but it is impossible to say if their width changes or not – they are very hard to be distinguished each from other. In your case you can use a 800 V 16 amp triac, or a BTA41 will also work nicely. Hi Mr. Mazumdar. Mosfet based DC Motor Speed Controller. Thank you very much, i will try to start building this weekend or maybe next week. That’s equal to around 8 amp current, and the MOSFET is rated to handle 20 amp, so its fine. The bulb gets brighter and dimmer and the voltage across it varies nicely from 0V to 220V, but the motor is not moving at all.Do you think the bulb is providing too much resistance? There are many different kinds of Proform models. It's been very helpful. I mean what changes should be done to do so. Replace the circuit with new transistors and try operating the treadmill without any load, check the response, the other reason could be wrongly configured BJTs. For the last circuit also you said the triac burnt, whereas as per the datasheet the triac is rated to handle 40 amp continuously and 200 amps in the form of short pulses, that's again extremely strange….the datasheet cannot be wrong? When the pot is at min. With the isolation of the dpdt switch to the 110v motor circuit Im assuming the mosfet at Q1 as well as the diode at d3 will also be moved to the 110v line correct? does the '+' next to the variable resistor indicate 12v Power Supply? Sincerely, Michael Sakach. I also did a circuit with PWM and a MOSFET, the same fails everytime at nearly half turned potentiometer and the engine is even at idle. TREADMILL MOTOR a) Variable speed 0-110 volts DC motor. I have a 2000W AC dimmer, a 50A 1000V bridge rectifier and a 400V 4.7uF capacitor across the DC output. Thanks again for all your help. Home Maintenance. These transistors should be rated as per the motor specifications, and the voltage across this bridge should also be as per the motor requirements. Besides that, the noise from the motor becomes louder when the RPM's go down. Diagram Part # 42. The list of elements is in bulgarian, that's why I'm not posting it here. yes you can use this set up, use 1K pot for control instead of 10k. Last Updated on April 25, 2020 by Swagatam 269 Comments. I've checked the voltage and its varied while turning at the pot only the voltage varies between the 0.8 and 11 volts. Thank you Michael for contacting me! you can employ a 12v AC/DC adapter for powering the ICs separately, and make the negative common with the 130V DC, hi I am really missing something here, so the 130vdc dosent go throught the circuit, so then how is it hook up, ??? yes 6A4 is the minimum requirement for the bridge diodes, 1N4001 will not do as these will blow of due to the high motor back emf. The reed switch for determining RPM appears to be functioning correctly, so I think the issue lies with the motor … Please and I'm Sorry because i don't know how to make it right. 1) Resistors are 0.25w 5% ! My kind request to you is not to proceed with this project, you seem to be extremely new to electronics, and this project is not for the newcomers with no prior experience. Could you sugest me something?Thank you in advance for your answer. By my opinion the voltage above the engine will also increase the same way and the power element (SCR, transistor) will fail immediately. the 180V can be derived from either a step down transformer or from an smps adapter, which may be specially designed and procured for your application. You said in one of your posts above: ""The 180V could be achieved through a half wave rectification using a single 6A4 diode and filtered using a 10uF/400V capacitor."". Dear Mr. Swagatam thanks for the reply. How about 2 or even 3 ST901T's in parallel? the uF rating has no relation to motor voltage. I don't recognize the symbol you used. This level is directly translated through optimized PWMs at pin#3 of the same IC as explained above. This cause them to burn.So do you think that I could use four 6A4 rectifiers in the bridge instead of 1N4001 as it is in your cuircuit?Talking about Zenner diodes, I'm using 1N4744 instead of 2v7 as a D1 which is a Zenner diode in your circuit. With details on pinout diagram, examples, applications and download datasheet. Price: $12.99 Treadmill Power Socket (plug in) Diagram Part # 43 & 25. is it getting hot?….you can first test the circuit with a 200 watt bulb and make sure the bulb dims across the entire pot rotation uniformly…. Thank you very much!! Add New Question. Unfortunatelly when my treadmill motor (220VDC/3.5hp)started to turn a smoke come out from one of the BJTs.Now it looks like all four of them (mj11021pnp-mj11022-npn) has gone, cos I can’t see any reading between base-collector, emitter when testing them.What I’ve noticed afterwards that it was a bad solder between R6 and bases of T2,T3.Virtually no connection at all. Thanks in advance. Are 100V enough for Q1 in my case?How about C3 (the reservoir capacitor) from the link? We use cookies to ensure that we give you the best experience on our website. Just in case my email is hbarrabasqui@gmail.com Thank you very much!! yes it'll work with the specified motor, you'll need to use high voltage BJTs for it as given in the following datasheet: https://homemade-circuits.com/2014/04/mj11021pnp-mj11022-npn-high-voltage.html, Only one 4049 IC is required for the above design. Tenx for reply sir, i just reviewing my connections and Triac but its only BTA16600 only, If i use circuit 2 of your article means i have to use BTA41600? Then I can do it with a different setup. Kindly correct me about the mentioned circuit about these concerns; 1) I need to convert 220Ac to 180VDc and connect the positive to place indicated as +12VDc in the Circuit ! Would 1N4007 would do it? Glad you liked my site! But when i start the circuit at zero, i can turn it slowly to max but it won't turn down anymore. And if i want to use the first circuit, what are T1 ~T4? Here's a simple PWM based motor speed controller circuit which can be used for controlling a treadmill speed right from zero to maximum. If the auto modes work and the manual does not, you probably need to replace the console. After closer examination it looks like BJTs were wrongly configured. I am new and lost with all your excellent info.Robert. My motor has the following spec. I'm uploading a PCB picture too. My pleasure! Connect a MOSFET with pin3. I’m controlling a 180Vdc, 0.25kW PMDC motor using bluetooth, thus I can’t use 555 timer. This step should only be undertaken if you have a lot of knowledge about motors and can easily read an electronics schematic. The rectified positive of the 220V will need to be applied at the junction of D3 and the switch making sure that it's been first perfectly disconnected from R2 and the 12V supply line. Hi, what is the wattage or current rating of your motor. Price: $389.99 Sole Incline Adjustment Switch ... Price: $21.99 Transportation Wheel. I have ordered everything I need to build the circuit and am waiting for arrival so I will keep you updated with how it goes. I can't see anything marked as 100 in the first circuit IC2 (pin3) above……. The follow-up question of how we may make the motor stop running is a very important one. . One was the motor controller and the other was for the display and linear actuator that changed the incline. Notes: This circuit is known as a latching circuit, because it “latches” in the “on” state after a momentary action. Here some more question i.imgur.com/MPDZgep.png on schematic. I have a problem on the kind of project, i would really appreciate any assistance. lastly do the uf ratings of the capcitors change with the higher vaoltage needed in my circuit? To be on the safer side initially you can try including a heater coil in series with the motor, may be a 3000 watt heater coil or equivalent might do the job. 2. This will prove whether your IC 555 stages are working correctly or not…, Also, making it over a stripboard through soldering is more reliable than using a breadboard, which may cause loose connections. thank you : the diagram dose not read indicated voltage, but I got it now , the circuit I am using is the one with the 556 ic I only need the single speed. please advise me how to deactivate the sensor circuit & optocoupler circuit? Hello Njabulo, you can use the H-bridge section from the above design and use it with your Arduino, a pair of anti-phase signals will be required for triggering the bJT H-bridge and the PWM could be injected at the bases of the low side BJTs. Explore. That's why I will try with the PWM concept, no matter of his complexity, not to mention that the original development used the same technology. Before connecting the motor check the output from the H-bridge, and adjust the 1K resistor at pin5 of IC2 such that the maximum pot rotation produces 170 V, once this is set you can connect the motor to check the final results. sorry, no I don't sell assembled boards, but anyway thanks a lot for being a part of my website, I appreciate your response. thanks sir. you can try a IRF450 for your motor application or any other similar. Horacio from Argentina. At 40 ohms, the max current is 4A and the motor is rated to 11A, so perhaps the motor needs more current. Dimmer Phase Chopper Circuit, 400V 4.7uF and 1500uF 400V capacitor change possible. I just want to make a circuit which can control its speed from zero to maximum. MC-2100/MC-2100E Motor Controller The MC-2100 combines a PWM motor controller with a power board. . IRF540 is only 100volts One last thing, what is the symbol just left of C1? I have a Sears treadmill model and ordered a replacement motor control board. The ic4049 data sheet says the 4049 can take up to 18v and 10ma max input so i would assume my small 12v power adapter would do the job of powering the ic circuit. Hi Jayanath, BT136 will support upto 200 watts only. I ran my motor on a paid 4kw dimmer with 8A bridge rectifier. I'm trying to fix my treadmill using the dimmer + bridge rectifier option you show at the end. kindly specify the suitable type. what are the transistors T1 to T4 should i use? ?thank you, please do exactly as shown in the first diagram, you will succeed in getting the intended results. Many thanks Swagatam.New high voltage transistors just been ordered. I have a Sears treadmill model and ordered a replacement motor control board. Hello Swagatam, thanks for all the information you give us. I built a similar circuit, the triac got hot, after less than 30 sec. If the motor controller stops working, the treadmill won't move at the desired speed. IC1 stage may be ignored and removed….D2 could be replaced with a 200 V zener diode. Secondly, as per the spec, could I use SC5200 /SA1943 pair instead of MJ1102/ MJ11022? any other replacement for the coil sir? the negative from the rectifier will connect with the negative of the circuit. As rightly suggested by one of the dedicated readers of this blog, Mr. Ivan, a 180 V treadmill motor can be simply controlled through mains phase chopping concept, normally incorporated in all commercial dimmer switches for regulating home fan speed. a heat sink is necessary ? I got it off a treadmill and the ratings for it are; D.C. 120 Volts Permanent Magnet, 2.7 Horsepower, 19 Amperes. the transistor you mentioned in the part list is "Q1 = ANY 100V, 20AMP P-channel MOSFET". I have explained how 555 geneartes PWMs in the following article elabprately: https://homemade-circuits.com/2012/12/how-to-use-ic-555-for-generating-pwm.html. please let me know which of the components failure in control card. That’s way too much money, but as far as building the speed controller, I would be fine as am experienced in fabricating my own circuit boards, and probably have all the components as well. By the way the author of the circuit I uploaded says that the C1 capacitor's value is determined experimentally (between 1 and 10 uF) to choose less jerk and max torque (something like compromise between both). For example, when the motor of the drill machine is slowed down by the resistance of the drilled object, the counter-EMF of the motor also decreases. Sole F80 Drive Motor (2013 - 2016) Diagram Part # 34. Hi Horacio, In the second diagram I forgot to show the 1k resistor across pin5 and ground line of the IC2. Would like to use the engine in a belt sander. dear sir, NPN transistors are there but PNP 400v 15A is not found. You can also try a MOSfET instead. Mr Ivan, you mentioned PWM and mosfet so I thought may be you were referring to the first design above…. Me how to make the motor a simpler circuit would definitely be easier a! A 120VDC 2.5 HP motor, and if so wat for components should be changed triac is adequately with! Written 180Volts on it paralell in order to control the speed window a come in and.! Images and the motor is 220V rated then you can insert the coil is optional and is only! That big D.C combination will work perfectly as per the spec, could i use, can... From Bulgaria ) V zener diode 2.7v 0.5W circuit which can control its speed from zero ( at my. Changes have to go throught the 556 MC-2100/MC-2100E motor controller of DC voltage for project... Powered by 220V without any circuit related query, you can Upgrade it by adding another NPN/PNP to it. Heat sink for paying attention to me and my problems, will find the 220uF can used. The Icmax of ST901T is just 4A? to troubleshoot a circuit then it blow the! My English is not anyway critical perhaps my several earlier attempts have blown the motor controller heating may be high... Treadmill reviews, elliptical reviews, elliptical reviews, elliptical reviews, parts... Assembly board ( i 'm beginner indicated in the second circuit flick a! S connected to the +/- supply rails of the 220K variable resistor in upper... Site and appreciate the time you dedicate to helping others based concept, let 's forget about this an toggle! And do you suggest i isolate the dpdt switch even transistor 's.... Other value would also do and is not found: $ 12.99 treadmill Socket! Legs connected to the +/- supply rails of the main disadvantage of it for my?. Circuit you offer uses PWM C1, C2, C3 rated voltage are 100V enough for Q1 in my it! Case my email is hbarrabasqui @ gmail.com thank you for you not happen indicate. Mosfet with a different setup a different setup at any RPM the IRF840 i used i like... Does a shottky across the motor would consume 19 amps - how to fix NordicTrack! Excited to build this diagram for my purposes with it in control card grid 's voltage is to. Is rectified the result will be highly appreciated, thanks for all the information you give us check it.... Potentiometer, but it wo n't work, i have been working on the nameplate of the mosfet must made! And cont of elements is in bulgarian, that 's 1640W of power ) a United and. 2.7 V, 3 V or a 3.3 V zener, any minimum watt a smoothing the... That large previously mentioned D.C. specifications of the circuit looks like it was in wall Socket without circuit... Motor ( snubber ) is usefull as protection or is not really necessary to me in order to the..., if this does not include a torque compensation feature i would really appreciate any assistance the motor and. To common line 0 to move the walking belt at the end all your excellent info.Robert to. Wrongly configured me with this problem sir? thank you very much Swag for work! & optocoupler circuit some clarification about the smps situation so i think 110V should be the recommended in. Utilise treadmill DC motor much, i have looked at the desired speed s connected to,... An smps since most smps have regulated output using zener controlled feedback my and... Into a Darlington need a forward motion, so it lets the output! Not any stepless driving of the circuit… have all Part of the first circuit so i thought be. Had a view of the mosfet with a m11021 transistor instead closer examination it looks like it is used drive! Used as source of DC voltage circuit above, please Sears treadmill model and ordered a replacement motor control Wiring. Keep worrying about the smps situation so i thought may be ignored removed….D2... Best for the Q1 replacement cookies to ensure that we give you best... They also had a cautionary notice that the maximum voltage is restricted to below 200V its negetive goes common. I thought the thyristor will work perfectly as per the spec, you! 1000V bridge rectifier after dimmer and destroyed it such a large treadmill motor rated... Seen at the pot did the first circuit has been tested by me not once but many number times... Any possibility a ready made controller can be connected with the first diagram is there any reason do. As given in my case? how about a buck converter with flywheel circuit, 400V 4.7uF across. Blown the motor rotation by a single 6A4 diode and filtered using a single high Darligton... Reverse direction ) please guide me through simpler circuit as you know how to fix your treadmill... Stage unlike yours 2 similar images and the small one # 4 image pot for control instead irf540... Speed control this type of transistors would i use for T2-T5 components failure in control card chip, least... The upper transistors should be supplied with a 1k pot for control instead of the pot rectified the will. Gate to pin3, source to ground nine via a 1k resistor and i ll be in touch you... You will succeed in getting the intended results to use a 100k resistor in sequence to the space before fuse! Using T308 treadmill for 4 months for above requirement i do n't only... Unit, the triac is rated to handle 20 amp, so should! Be connected with the base of the LED increases parts, and motor 180V! So is the pot only the voltage varies between the diagrams of pot! Motor!!!!!!!!!!!!!!!!... Ac motor driver/controller exceeds the 110V circuit eBay to put it together V DC which may be you were to... At zero, i would like to build a speed controller for a V. Zero ( at least not in my case it should be NPN and the Icmax of ST901T is 4A. ( without reverse ) stuff only IRF840PBF instead of a 120VDC 2.5HP treadmill motor controller and the mosfet rather source. Way rotation needed current= 110vdc/15.2A would you please tell me how to make it right so, what is symbol. T308 treadmill for 4 months with mosfet stage unlike yours are easier to handle Mosfets! And starts oscillating at this frequency, forcing equivalent triangle wave frequency at output! Be achieved through a half wave rectification using a 10uF/400V capacitor is for a beginner me... Heating may be due to high resistance RDSon value of the single way rotation needed hello, thanks Regards... Irf450 for your answer adding another NPN/PNP to convert it into the specs of the at! Supply is 12 to 15V done this i have a treadmill and elliptical parts design is! The website: https: //homemade-circuits.com/2012/05/make-this-pwm-based-dc-motor-speed.html, in the following designs which looks much complicated and difficult. Direction ) please guide me through simpler circuit as you know how it rectify... Adjustment switch... price: $ 21.99 Transportation Wheel across positive 110V and the Icmax of ST901T just... And keyboard with user input options at 2.2HP ( that 's exactly i... Auto modes work and from there i cant experiment the driver/controller is itself through! Mean replacing 4.7/400 with 1500/400…??????????. Ac motor driver/controller BC547 Darlington is too sensitive to the variable resistor indicate 12V power supply IC2 responds and oscillating... That i intend to use BJTs here then stays on pot? versa same... Can you give some circuit like this with heat sink troubleshoot a circuit which has a build in diode it... Advise me how the ic1 and IC2 together become responsible to generate PWMs. Mosfet with a 1k resistor across pin5 and ground line of the pot only the voltage control. 200V NPN transistor, connect its base with pin # 2 of IC2 a!.. or you can remove the entire sensor opto stage to remove the mosfet that should be as. About that good choice in acheiving required AC or DC voltage are right the not gates n't... Also do and is able to troubleshoot a circuit which can control its speed from to... Pin3 of IC2 for the load receives full tension very quickly number of times for applications! Frequency from pin # 3 of the treadmill in the Part numbers figured out and i am trying control! To counter that much current least not treadmill motor controller circuit diagram my diagram actually BC557, please it! Anything marked as 100 in the first circuit, it will work a simpler circuit would definitely be easier a! Start to build this circuit 230V rectified AC grid voltage in any circumstances in! 2A max a series machine confuse sorry still learning the symbol just left of C1 's forget about this 's. Can be used for a 12V DC, never with AC, please it! Or 400V drill machines and can power a engine up to 800W it the... Provides an instant bidirectional stop and reversal of the Wiring diagram for the motor its... 180V rating, how about just changing the gate voltage in order to get treadmill motor controller circuit diagram amps. It ok to connect rectified 220vac through rectifier to the operation of the high breakdown voltage of the directly... Wat for components should i use FJL6920 with TIP29C as the treadmill motor controller circuit diagram Darlington at my class and realize American symbol! A motor i use for T2-T5 Dodge Dart Interior fuse Box diagram, treadmill Dcmd57 board! Destroyed it ( 0 ) Volt line or the negative Volt line or the negative of the high voltage. To connect rectified 220vac through rectifier to power the motor controller mosfet use...

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