C520U/C531U Repair Manual

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Sheila Johnston
6 years ago
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1 C520U/C531U Repair Manual

2 Table of Contents Display Picture C520/C Component Placement - C520U/C531U Display Component Placement - C520U/C531U Lower Body Block Diagram - C520U/C531U Electronics Wire Connections - C520U/C531U Display Wire Connections - C520U/C531U Drive Board LED Indicators - C520U / C531U Display Board LED Indicators - C520U/C531U Drive Board C520U/C531U Display Specifications Display Malfunction Troubleshooting Table - C520U/C531U Display Malfunction Troubleshooting Table - C520U/C531U, Continued Malfunction: Unit will not start (alternator) Malfunction: Unit will not start (battery) Malfunction: No RPM value Malfunction: No resistance Malfunction: Resistance is heavy Malfunction: Telemetry heart rate malfunction Malfunction: HTR heart rate malfunction Mechanical Maintenance Schedule - C531U/C520U Mechanical Troubleshooting Chart - C520U/C531U.

3 1-1. Display Picture - C520U/C531U 1-1-1

4 1-2. Component Placement - C520U/C531U Display HTR Display HR telemetry receiver 1-2-1

5 1-2. Component Placement - C520U/C531U Lower Body Electromagnet Battery Drive Reed switch Flywheel with built-in alternator 1-2-2

6 1-3. Block Diagram - C520U/C531U Electronics Sensor L Sensor R HTR Display Board HR receiver Alternator Battery Drive Board Electro-magnet Reed switch Battery charger 1-3-1

7 1-4. Wire Connections - C520U/C531U Display To HTR contact plates (left and right) To drive To display LED1 Display power supply To HTR To HR receiver 1-4-1

8 1-4. Wire Connections - C520U/C531U Drive Board To electro-magnet To alternator To battery charger To display To battery To reed switch 1-4-2

9 1-5. LED Indicators - C520U / C531U Display Board Power Indicator LED1 Lit indicates there is incoming power

10 1-5. LED Indicators - C520U/C531U Drive Board Exterior battery charger fuse F3 Alternator fuse F1 Drive power Lit indicates there is incoming power. CLK Indicator LED flashes when pedals move. Battery charge Lit indicates there is incoming power to recharge the battery. Battery fuse F

11 1-6. C520U/C531U Display Specifications Specification Contents Notes Power supply AC alternator 6.4 VA battery Backup power Battery automatically recharges or can be recharged via an exterior supply charger. Resistance Electro-magnet Speed detection Reed switch Resistance LEVEL 1 - LEVEL 20 Display method Segment array and numerical LEDs Main window Dot matrix Character window 65% HR TARGET, Heart rate, 80% HR TARGET WORKOUT LEVEL / CALORIES / TIME / RPM DISTANCE / CAL/HR / WATTS / SPEED INTERVAL / RANDOM / HILL / TRACK / ZONE TRAINER / CARDIO / WT LOSS CARDIO, WT LOSS, ZONE TRAINER Workout programs Heart rate control programs Heart rate Telemetry heart rate detection User IDs Four user IDs(USER1- USER4) Motion Belt operated 1-6-1

12 2-1. Display Malfunction Troubleshooting Table - C520U/C531U Malfunction Circumstance Inspection and Test Points Suggested Components Cannot start unit Cannot start unit Display won t operate No resistance The display is not lit; I pedal the bike; but the display still doesn t light. When I don t pedal the bike, the display does not light. I start pedaling the bike, but the display shows no reaction, and values don t change. I pedal the bike and press resistance keys. Resistance values on the display change. But there is no resistance. 1. Inspect cable connections. 2. Inspect drive fuse. 3. Inspect drive power LED. 4. Inspect the alternator. 1. Inspect battery fuse on the drive. 2. Measure battery voltage. Battery voltage should be 5.5V or more. 3. If battery voltage is under 5.5V, pedal the unit at over 50 RPM to recharge the battery. 4. Replace the battery if voltage is under 2.0 and it won t recharge. RPM signal didn t enter the display IC. Inspect RPM signal. 1. Inspect cable connections and the bridge. 2. Inspect the reed switch and magnet. 3. Inspect the drive CLK LED. 4. Inspect the reed switch and its wire. 1. Inspect cable connections. 2. Inspect alternator startup. If alternator will not start unit, there will be no resistance. 3. Inspect the electro-magnet and its wires. 4. Test whether the drive emits voltage to the electro-magnet. 1. drive fuse 2. drive 3. alternator 1. battery fuse on the drive 2. battery 1. magnet 2. reed switch 1. drive Notes 2-1-1

13 Telemetry heart rate detection malfunction Contact heart rate malfunction Key malfunction (display) Remote malfunction Excessive resistance Telemetry heart rate malfunction Contact heart rate malfunction No key function, or continual key function Press remote keys; display shows no reaction. Pedal on the unit; resistance is too heavy. 1. Inspect heart rate transmitter and its batteries. Replace batteries if batteries haven t been replaced for a long time. 2. Inspect heart rate receiver cable connections. 3. Test or replace the heart rate receiver. 4. Inspect environment for sources of interference, such as speakers and lights. 1. Inspect bridge HTR cable. 2. Inspect HTR indicator LED on the drive. 3. Replace the HTR. 1. Replace the display key switches. 1. display keys 1. Inspect the remote and bridge wire connections. 2. Replace the remote controller. 1. Inspect all wire connections and whether screws have created an electrical short. 2. Move the flywheel with your hand to see whether the electro-magnet is stuck on the flywheel. 3. Inspect whether drive components have an electrical short, sending maximum power to the electro-magnet, causing excessive resistance. Total distance 1. Press workout level< >+< >+<stop> to see total distance. 2. telemetry heart rate transmitter 3. telemetry heart rate receiver 1. HTR C531U 1. remote control 1. drive C531U 2-1-2

14 Troubleshooting Model: C520U/C531U Malfunction: Unit will not start (alternator). Circumstance: Pedal on the unit; the display does not light. Possible causes: 1. Wires are not connected. 2. Drive is malfunctioning. Troubleshooting: 1. Inspect wire and bridge connections. 2. Inspect the alternator wires. 3. Inspect wire connections and fuse F1 and power indicator LED on the drive. 4. Replace the drive. 5. Inspect the display IC pins. Display power indicator LED1 Inspect IC Display Inspect alternator wire connections. F1 fuse Alternator Reed switch Drive Board Drive Inspect power and CLK LED indicators. Inspect reed switch 3-1-1

15 Troubleshooting Model: C520U/C531U Malfunction: Unit will not start (battery). Circumstance: Display shuts off when no one pedals. Possible causes: 1. Wires are not connected. 2. Battery voltage is too low. Troubleshooting: 1. Inspect all wire and bridge connections. 2. Inspect battery voltage. Normal: 5.5V or more. 3. Inspect the drive F2 fuse. 4. If battery voltage is lower than 5.5V, pedal at over 50 RPM to recharge the battery. Inspect IC Display power supply LED1. Display Test battery voltage. Display requires 5.3V or more to operate. F3 fuse Battery Drive Board Power LED 3-2-1

16 Troubleshooting Model: C520U/C531U Malfunction: No RPM value Circumstance: 1. No RPM value appears. 2. When you pedal the display shows no response. Possible causes: 1. Reed switch and magnet 2. Wires are not connected. Troubleshooting: 1. Inspect reed switch and magnet. 2. Inspect all cable connections. 3. Inspect the drive CLK indicator. 4. Pedal at one rotation per second. Display RPM value: 60. Display Reed switch and magnet Drive Speed sensor Inspect drive CLK indicator LED lights when reed switch and magnet make contact

17 Troubleshooting Model: C520U/C531U Malfunction: No resistance Circumstance: Pedal the unit. There is no resistance. Possible causes: 1. Wires are not connected. 2. Drive is defective. Troubleshooting: 1. Inspect all cable connections. 2. Inspect whether RPM value appears when one pedals. If not, inspect the reed switch wires. 3. Inspect whether alternator can start unit. 4. Inspect drive fuse. Inspect whether the drive emits voltage to the electro-magnet. 5. Inspect the electro-magnet wires and whether the electro-magnet attracts metal. Display Inspect drive CON2 voltage LEV 5 6.3V LEV 15 10V Alternator Drive Reed switch Electromagnet F1 fuse 3-4-1

Troubleshooting Model: C520U/C531U Malfunction: Resistance is excessive. Circumstance: Pedal the bike; resistance is excessively heavy. Possible causes: 1. There is an electrical short in the cables.

18 Troubleshooting Model: C520U/C531U Malfunction: Resistance is excessive. Circumstance: Pedal the bike; resistance is excessively heavy. Possible causes: 1. There is an electrical short in the cables. 2. Drive components have an electrical short. Troubleshooting: 1. Inspect all cable connections. Inspect cables for damage. 2. Inspect drive power components for a short. 3. Replace the drive. Inspect IGBTs for a short Display Drive Electromagnet 3-5-1

19 Troubleshooting Model: C520U/C531U Malfunction: Telemetry heart rate malfunction Circumstance: Heart rate value does not appear. Possible causes: 1. Telemetry transmitter batteries. 2. Heart rate receiver malfunction. 3. Environmental interference, possibly from lights or speakers. Troubleshooting: 1. Replace the heart rate transmitter strap or its batteries. 2. Inspect heart rate receiver connections. 3. Inspect the HTR LEDs. Display HR receiver Telemetry heart rate receiver 3-6-1

Troubleshooting Model: C531U Malfunction: HTR heart rate malfunction Circumstance: Hold HTR contacts with both hands; Heart rate values are incorrect. Possible causes: 1.

4. Inspect HTR indicators. 5. Replace the HTR. HTR indicator LEDs LED Name Explanation LED1 Telemetry Flashes to indicate incoming telemetry signal.

20 Troubleshooting Model: C531U Malfunction: HTR heart rate malfunction Circumstance: Hold HTR contacts with both hands; Heart rate values are incorrect. Possible causes: 1. HTR wires are not connected. 2. HTR is defective. 3. Display wires are not connected. Troubleshooting: 1. Inspect display wire connections. 2. Inspect bridge HTR wires. 3. Inspect HTR contact wires. 4. Inspect HTR indicators. 5. Replace the HTR. HTR indicator LEDs LED Name Explanation LED1 Telemetry Flashes to indicate incoming telemetry signal. LED2 HTR contact Lights to indicate hands on contact plates. LED3 HTR output Flashes to indicate incoming HTR (contact) LED4 Heart rate signal output signal. Flashes to indicate heart rate signal output to the display Display HTR SENSOR-R SENSOR-L 3-7-1

21 4-1. Mechanical Maintenance Schedule - C531U/C520U Item Inspect and maintain Daily Weekly Monthly 1 Wipe clean unit exterior. 2 Level unit. 3 Inspect screws. 4 Inspect pedals for noise. 5 Inspect seat height adjustment. 6 Inspect seat fore/aft adjustment

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