NASAN ST WIN User manual

Rev 8, Dated 27-2-2018
1
ST WIN
Service Manual
Nasan Medical Electronics Pvt.Ltd
© All Rights Reserved

Rev 8, Dated 27-2-2018
2
TABLE OF CONTENTS
1. INDEX
2. PROCEDURES LIST
3. SYSTEM DIAGRAMS AND CONNECTIONS
4. SYSTEM CONFIGURATION
5. PROBLEMS,SOLUTIONS AND MATERIAL REQUIRED TO
SOLVE THE CALL
6. APPENDIX
A. TREADSTAR TABLE
B. USE OF CLAMP METER
C. 15 PIN SIGNAL DETAILS
D. TOOLKIT
E. BASIC PATIENT PREPARATION
F. IMPORTANT NOTE
G. EARTHING
H. STANDARD PROCEDURES
I. PRECAUTIONS
7. SERVICING OF TREADMILL CONTROLLER AND BODY LEVEL USED
WITH HIGH FREQUENCY DRIVE

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1. INDEX
Nature of Problem
Page No
Elevation Related 6 to 11.
Speed Related 11 to 17.
Software Related 18 to 20.
Miscellaneous 20 to 21.
Procedures List 27 to 38.
2. PROCEDURES LIST.
NO PROCEDURE LIST PAGE
NO.
1. Independent testing of the treadmill 27
2. Changing of 10 K10 turn pot. 27
3. Changing of AC motor. 29
4. Changing of Dc motor. 30
5. Changing of AC card+ DC drive Assembly to ACDC
drive combined.
30
6. Changing of actuator. 32
7. Changing of rollers. 33
8. Changing of Rack and pinion. 34
9. Changing of magnet. 34
10. Changing of limit switch 34
11. Changing of Conveyer belt. 34
12. Standard calibration procedure. 35

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3) SYSTEM DIAGRAMS:
Fig 1. BLOCK DIA OF ST-WIN SYSTEM
230V AC
MAINS
STWIN
AMPR
TREADMIL
L & COMPR
TREADMILL
PC
TO
PATIENT
FUSE 2A
POWER CORD
COMING FROM
AC MAINS
ON OFF
SWITCH
15 PIN
CONNECTOR
GOING TO
TREADMILL
(TPC cable)
LED INDICATION
FOR SPEED AND
ELEVATION
9-PIN
SERIALPORT
CONNECTOR
GOING TOWARDS
PC
Fig 2. AMPLIFIER CONNECTIONS

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4) MINIMUM SYSTEM CONFIGURATION
Minimum Requirement of PC for ST-Win system
1. Motherboard: Recommended
MAKE: D-Link/ASUS/INTEL/HIS
CHIPSET: Intel/VIA
SPEED: FSB, 400 MHz and onwards
2. CPU: Recommended
MAKE: Intel P-4, Speed 2.4 GHz, 400FSB
3. RAM: Recommended
Make: Symtronics/Hyundai/Transcend.
Size: 128 MB
Speed: 266 MHz
4. Serial Ports (RS-232): One working free serial port for ST-Win
amplifier.
5. VGA card: 64 bit, 2 MB memory PCI VGA card or onboard.
6. Monitor: 14” color monitor or onboard.
7. SMPS: Recommended
Make: Priya/Mercury/Intex.
Capacity: 300 Watt.
8. Hard disk: Recommended
Make: Seagate
Size: Barracuda 40 Gb 7200 RPM or onwards.
9. Display Settings: Resolution-1024*768
Font-Small font.
Color-16 bit hi color.
10. Key Board: PS/2 with 101 keys.
11. Mouse: PS/2.
12. Operating System: Windows 98/2000/XP/Win 7
13. Stabilizer: 3.5 KVA Servos (For treadmill only).
14. CD ROM: Recommended
Make: LG/Samsung/Sony/ASUS.
Type: Speed 52X
15. Printer: Recommended
Type: HP Laser Jet 1000/HP Laser Jet 1010 of USB port
HP Laser Jet 6L Gold/Pro.
16. Independent earthing connection.

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5) PROBLEMS, SOLUTIONS AND MATERIAL REQUIRED TO SOLVE THE CALL.
PROBLM
NO
PROBLEM PAGE
NO
1. Speed Related.
1. Speed reduction in second stage and onwards 6
2. No speed(conveyor belt is not moving at all) 8
3. Speed and elevation not as per protocol through software 9
4. Speed goes on increasing when we switch on the
TM(Uncontrolled speed)
9
5. Fuse blows as speed goes on increasing. 10
6. Jerk in speed/Speed reduces as patient walks on treadmill 10
7. Elevation is correct but speed incorrect in protocol 11
2. Elevation Related.
1. No elevation 11
2. Treadmill runs smoothly for 1
st
couple of stages, after that
it elevates randomly.
12
3. Treadmill stuck/elevates to its top position 12
4. On/Off switch(mcb) of treadmill trips down 13
5. Treadmill elevates properly up to 1
st
stage only and no
further elevation
14
6. Treadmill elevates/de-elevates slightly 14
7. No medians and no heart-rate. 16
8. While coming down treadmill not stopping. 17
9. Slow speed and slight elevation before 1
st
stage. 17
3. Software Related.
1. PC getting hanged while running software. 18
2. Communication error. 18
3. Noise in ECG when patient walks on treadmill or even if he
stands on treadmill.
19
4. Error of DAO setup or error as ‘STWIN 98 mdb’ file not
found.
19
5. Error as ‘STWIN 98-mdb’ file missing. When we install
DAO Setup for ST Win 3.74 from CD ROM, it works fine. But
when we remove the CD, then an error as ‘.mdb’ file missing
comes.
19
6. Lead 1 is coming inverted 19
7. Spikes during the test due to which HR is more than actual
value.
20
4. Miscellaneous.
1. Treadmill non-functional again and again. 20
2. 10K-10-turn pot getting burned. 21
3. ST-Win amplifier fuse blowing. 21
4. Base line wandering while test is going on. 21
5. Noise observed on lead V6 22
6. Spike in ECG 22

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1) SPEED RELATED.
NOTE: - Always connect Clamp meter before servicing the treadmill through live
wire of AC/DC card/High frequency drive and then check current is in range.
Problem
1.
Speed reduction in second stage and onwards
Background:
In calculating speed of treadmill, we are adhering to the following
principles:
1. We use a pmdc motor, which is required to drive the treadmill with
high speed. To drive the motor and subsequently the treadmill at
different appropriate speed we use dc drive (Refer fig 3 top view).
2. Any medical equipment must be precise, and it should have
continuous feedback. A closed feedback is maintained by following
method:
a. At the side of dc motor our treadmill has a heavy
wheel, which is called as flywheel. There is a
magnet embedded on this flywheel. At
approximately 5 mm from the flywheel, a sensor is
located (Refer fig 4).
b. Each time the flywheel rotates one cycle the sensor
detects it and the LED on AC/DC card flashes. If the
LED is not flashing on every rotation of flywheel
then correct speed will not be detected.
c. Even if the sensor is too near to the flywheel then it
will not detect the speed properly.
(Note: It is essential that the sensor should be between 5 mm
to 7 mm from flywheel and the (d41) LED should flash when treadmill
is running.)
Possible cause:
Generally this happens when the sensor whose function is to sense the
flywheel revolution, is very close to flywheel (Refer fig 3).The solution to
this is that the distance between the flywheel and the sensor should be
between 5mm and 7mm.
Check points/Solution:
1. Check weather sensor connection is loose
2. Interchange sensor connections wires from 2 pin relimate connector
3. If still problem persists, change ACDC drive
4. If still problem persists change ST Win amplifier.
Material
Req.
Sensor coil, silicon oil (200ml).

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Fig. 3 TOP VIEW
AC MOTOR
FRONT
ROLLER
CONDENSOR
GEAR BOX
AC/DC
COMBINE
D CARD
FLYWHE
EL
SPEED
SENSOR
DC MOTOR

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Fig 4. SPEED SENSOR
Problem
2.
No Speed (Conveyor belt is not moving at all)
Check Points/Solution
1. Run test treadmill program (Refer procedure 12) and click
appropriate buttons for speed increase and decrease.
2. Observe the speed increase/ decrease LEDs on back panel of the
STWIN amplifier (Refer fig 2).If LEDs are glowing, then the
problem lies in TPC cable or in treadmill.
3. But if the LEDs are not glowing then the problem lies with
STWIN amplifier or calibration factors are incorrect.
4. Check TPC cable continuity, if needed cut both ends and resolder
the cable (Refer fig 13 for Cable Details).
5. If belt is not moving while testing the treadmill independently
then the problem probably lies on the treadmill side. First check
whether the speed indication feedback LED (Fig 9) is glowing on
AC/DC drive.
6. If it is not glowing, then ensure that 230-volt ac is reaching ac
mains connector on AC/DC card. If 230 volt is present and still
no speed, then change ac/dc drive.
7. The last step is to change the dc motor. But before changing do
the following cold test.
8. Cold test for dc motor:
a. Remove 3-pin top of treadmill from mains supply.
b. Remove all the two wires of dc motor.
c. Ensure that there is no continuity between treadmill body and
all connectors of dc motor.
d. In case of pmdc motor, ensure that the armature resistance is
nearly equal to 2-3 ohms.
Material
Req.
ST win amplifier,AC/DC combined card, silicon oil(200ml).
MAGNET IS
EMBEDDED IN
THE FLYWHEEL
SPEED SENSOR
DC
MOTOR

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Problem
3.
Speed and elevation not as per protocol through software
Solution 1. If conveyor belt is too tight then also this problem occurs. In
that case loosen the belt accordingly and put silicon oil (50-
100ml)under belt
2. Earth voltage should be less that 5V
3. Check continuity of TPC and serial port cable and re-solder if
needed (Refer fig 13 for Cable Details).
4. Check voltage setting of 10k 10 turn pot setting and speed
sensor alignment.
5. Calibrate the treadmill for speed and elevation.
6. Confirm that treadmill and PC, both are connected to one and
the same phase only. Always give power from one and the same
extension board to treadmill.
7. Though the treadmill and PC both are connected on the same
phase, there might be difference in earth to neutral voltage, so
short the both earth points with 24/36 wire externally.
8. Reload the software.
9. If still problem persists, change STWIN amplifier.
Material
Req.
ST Win amplifier, silicon oil (200ml).
Problem
4.
Speed goes on increasing when we switch on the treadmill
(Uncontrolled speed)
Possible cause:
1. When the stress test is started and the program goes into the
first stage, the treadmill should reach a speed of 2.7 km/hr
gradually.
2. But if the speed goes on increasing continuously more than
2.7km/hr (uncontrolled), it means that the feedback path is not
getting completed.
Solution:
1) For this do following steps one by one till the problem gets solved.
a) Check sensor connector is properly connected. Ensure that it is
not loose also.
b) Check continuity of treadmill to STWIN amplifier cable, if needed
re-solder the same.
c) Remove the speed sensor wires & ensure that resistance of
speed sensor is nearly equal to 14 ohms.
d) Check the position of magnet on flywheel and ensure that
magnet is present on flywheel.
e) Ensure that the (d 41) LED on AC/DC drive is blinking.
2) If points 1/2/3 as mentioned above are correct and still this LED is
not blinking, change the AC/DC drive.
(1) This problem also occurs due to failure of IC 324 or IC
374 and LM339 on PCB 141.
Material
Req.
Sensor coil, AC/DC drive, silicon oil (200ml).