C520U/C531U Repair Manual

Table of Contents
1-1-1. Display Picture C520/C531 1-2-1. Component Placement - C520U/C531U Display 1-2-2. Component Placement - C520U/C531U Lower Body 1-3-1. Block Diagram - C520U/C531U Electronics 1-4-1. Wire Connections - C520U/C531U Display 1-4-2. Wire Connections - C520U/C531U Drive Board 1-5-1. LED Indicators - C520U / C531U Display Board 1-5-2. LED Indicators - C520U/C531U Drive Board 1-6-1. C520U/C531U Display Specifications 2-1-1. Display Malfunction Troubleshooting Table - C520U/C531U 2-1-2. Display Malfunction Troubleshooting Table - C520U/C531U, Continued. 3-1-1. Malfunction: Unit will not start (alternator). 3-2-1. Malfunction: Unit will not start (battery). 3-3-1. Malfunction: No RPM value 3-4-1. Malfunction: No resistance 3-5-1. Malfunction: Resistance is heavy. 3-6-1. Malfunction: Telemetry heart rate malfunction. 3-7-1. Malfunction: HTR heart rate malfunction 4-1-1. Mechanical Maintenance Schedule - C531U/C520U 4-2-1. Mechanical Troubleshooting Chart - C520U/C531U.

1-1. Display Picture - C520U/C531U

1-1-1

1-2. Component Placement - C520U/C531U Display

HTR board

Display board HR telemetry receiver board

1-2-1

1-2. Component Placement - C520U/C531U Lower Body

Electromagnet

Battery

Drive board

Reed switch

Flywheel with built-in alternator

1-2-2

1-3. Block Diagram - C520U/C531U Electronics

Sensor L HTR board Sensor R

Display Board

HR receiver board

Alternator Battery Battery charger Drive Board

Electro-magnet

Reed switch

1-3-1

1-4. Wire Connections - C520U/C531U Display

To HTR contact plates (left and right)

To drive board

To display LED1 Display power supply

To HTR board To HR receiver

1-4-1

1-4. Wire Connections - C520U/C531U Drive Board

To electro-magnet

To alternator

To battery charger

To display board

To battery

To reed switch

1-4-2

1-5. LED Indicators - C520U / C531U Display Board

Power Indicator LED1 Lit indicates there is incoming power.

1-5-1

1-5. LED Indicators - C520U/C531U Drive Board

Exterior battery charger fuse F3

Alternator fuse F1 Drive board 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 F2

1-5-2

1-6. C520U/C531U Display Specifications Specification

Power supply Backup power supply Resistance Speed detection Resistance Display method Main window Character window Workout programs Heart rate control programs Heart rate User IDs Motion

Contents
AC alternator 6.4 VA battery Battery automatically recharges or can be recharged via an exterior charger. Electro-magnet Reed switch LEVEL 1 - LEVEL 20 Segment array and numerical LEDs Dot matrix 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 Telemetry heart rate detection Four user IDsUSER1- USER4 Belt operated

Notes

1-6-1

2-1. Display Malfunction Troubleshooting Table - C520U/C531U

Malfunction Cannot start unit Circumstance The display is not lit; I pedal the bike; but the display still doesnt light. When I dont pedal the bike, the display does not light. 1. 2. 3. 4. Inspection and Test Points Inspect cable connections. Inspect drive board fuse. Inspect drive board power LED. Inspect the alternator. Suggested Components 1. drive board fuse 2. drive board 3. alternator 1. battery fuse on the drive board 2. battery Notes

Cannot start unit

Display wont operate

No resistance

I start pedaling the bike, but the display shows no reaction, and values dont change. I pedal the bike and press resistance keys. Resistance values on the display change. But there is no resistance.

1. Inspect battery fuse on the drive board. 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 wont recharge. RPM signal didnt enter the display IC. Inspect RPM signal. 1. Inspect cable connections and the bridge board. 2. Inspect the reed switch and magnet. 3. Inspect the drive board 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 board emits voltage to the electro-magnet.

1. magnet 2. reed switch

1. drive board

2-1-1

Telemetry heart Telemetry heart rate detection rate malfunction malfunction

Contact heart rate malfunction Key malfunction (display) Remote 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 2. telemetry batteries if batteries havent been replaced for a long time. heart rate 2. Inspect heart rate receiver board cable connections. transmitter 3. telemetry 3. Test or replace the heart rate receiver board. heart rate 4. Inspect environment for sources of interference, such as receiver speakers and lights. board 1. Inspect bridge board HTR cable. 1. HTR board C531U 2. Inspect HTR indicator LED on the drive board. 3. Replace the HTR board. 1. Replace the display key switches. 1. display keys 1. Inspect the remote and bridge board wire connections. 2. Replace the remote controller. 1. remote control C531U

Excessive resistance

Total distance

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 board components have an electrical short, sending maximum power to the electro-magnet, causing excessive resistance. 1. Press workout level<>+<>+<stop> to see total distance.

1. drive board

2-1-2

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

Inspect IC

Display board

Inspect alternator wire connections.

F1 fuse

Alternator Reed switch

Drive board

Drive Board
Inspect reed switch

Inspect power and CLK LED indicators.

3-1-1

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 board connections. 2. Inspect battery voltage. Normal: 5.5V or more. 3. Inspect the drive board 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 board

Test battery voltage. Display requires 5.3V or more to operate.

F3 fuse

Battery

Drive Board

Power LED

3-2-1

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 board CLK indicator. 4. Pedal at one rotation per second. Display RPM value: 60.

Display board

Reed switch and magnet

Drive board

Speed sensor

Inspect drive board CLK indicator LED lights when reed switch and magnet make contact.

3-3-1

Troubleshooting
Model: C520U/C531U Malfunction: No resistance Circumstance: Pedal the unit. There is no resistance. Possible causes: 1. Wires are not connected. 2. Drive board 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 board fuse. Inspect whether the drive board emits voltage to the electro-magnet. Inspect drive board 5. Inspect the electro-magnet wires and whether the electro-magnet attracts metal. CON2 voltage LEV 5 6.3V LEV 15 10V

Display board

Alternator Reed switch Drive board 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. 2. Drive board components have an electrical short. Troubleshooting: 1. Inspect all cable connections. Inspect cables for damage. 2. Inspect drive board power components for a short. 3. Replace the drive board.

Inspect IGBTs for a short

Display board

Drive board

Electromagnet

3-5-1

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 board 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 board connections. 3. Inspect the HTR board LEDs.

Display board

HR receiver board

Telemetry heart rate receiver board

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. HTR wires are not connected. 2. HTR board is defective. 3. Display wires are not connected. Troubleshooting: 1. Inspect display wire connections. 2. Inspect bridge board HTR wires. 3. Inspect HTR contact wires. 4. Inspect HTR board indicators. 5. Replace the HTR board.

HTR board indicator LEDs

LED LED1 LED2 LED3 LED4 Name Telemetry HTR contact HTR output Heart rate signal output Explanation Flashes to indicate incoming telemetry signal. Lights to indicate hands on contact plates. Flashes to indicate incoming HTR (contact) signal. Flashes to indicate heart rate signal output to the display

Display board

HTR board

SENSOR-R

SENSOR-L

3-7-1

4-1. Mechanical Maintenance Schedule - C531U/C520U

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

4-1-1