C520r C531r Cycle Electronics Repair Manual

C520r C531r Cycle Electronics Repair Manual
C520R/C531R Repair Manual (Electronic)
Table of Contents
1-1-1. Display Picture - C520R/C531R
1-2-1. Component Placement - C520R/C520U Display
1-2-2. Component Placement - C520R/C531R Lower Body
1-3-1. Block Diagram - C520R/C531R Display Electronics
1-4-1. Cable Connections - C520R/C531R Display
1-4-2. Cable Connections - C520R/C531R Drive Board
1-5-1. Indicator LEDs – C520R/C531R Display
1-5-2. Indicator LEDs – C520R/C531R Drive Board
1-6-1. C520R Electronics Specifications
2-1-1. Display Malfunction Troubleshooting Table - C520R/C531R
2-1-2. Display Malfunction Troubleshooting Table - C520R/C531R, continued
3-1-1. Malfunction: No start up (alternator)
3-2-1. Malfunction: No start up (battery)
3-3-1. Malfunction: No RPM value
3-4-1. Malfunction: No resistance
3-5-1. Malfunction: Excessive resistance
3-6-1. Malfunction: Telemetry heart rate malfunction
3-7-1. Malfunction: Contact heart rate (HTR) malfunction
3-8-1. Malfunction: Remote control malfunction
4-1-1. Mechanical Maintenance Schedule -C531R/C520R
4-2-1. Mechanical Troubleshooting - C520R/C531R
1-1-1. Display Picture - C520R/C531R
1-1-1
1-2-1. Component Placement - C520R/C520U Display
1-2-1
1-2-2. Component Placement - C520R/C531R Lower Body
Reed sensor
Bridge board
Battery
Drive
board
Electro-magnet
Flywheel with
built-in alternator
1-2-2
1-3-1. Block Diagram - C520R/C531R Display Electronics
Display
Board
Sensor – L
HTR board
Sensor – R
HR receiver
Bridge
board
Electro-magnet
Alternator
Battery
Remote
control
Drive
board
Reed switch
Battery Charger
1-3-1
1-4-1. Cable Connections - C520R/C531R Display
To bridge
board
LED1
Power supply
indicator
Main IC
1-4-1
1-4. Cable Connections - C520R/C531R Drive Board
Bridge board cable connections
To display
To drive
board 接至
To HTR
board
To remote control
To electro-magnet
To battery charger
To alternator
To reed switch
To battery
1-4-2
To bridge board (to
display)
1-5. Indicator LEDs - C520R / C531R Display
Indicator Led1
Lit indicates that there
is incoming power
supply.
1-5-1
1-5. Indicator LEDs - C520R/C531R Drive Board
Exterior battery
charger fuse F3
Drive board power
indicator
Lit indicates incoming
power supply.
Alternator fuse F1
CLK optic sensor
LED
LED flashes when
pedals move.
Battery charger indicator
Lit indicates the
battery is being charged.
Battery fuse F2
1-5-2
1-6. C520R Electronics 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 IDs(USER1- USER4)
Belt operated
1-6-1
Notes
2-1. Display Malfunction Troubleshooting Table - C520R/C531R
Malfunction
Cannot
start unit
Cannot
start unit
Display
won’t
operate
No
resistance
Circumstance
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.
Inspection and Test Points
1.
2.
3.
4.
Inspect cable connections.
Inspect drive board fuse.
Inspect drive board power LED.
Inspect the alternator.
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 won’t
recharge.
RPM signal didn’t 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.
2-1-1
Suggested
Components
1. drive board
fuse
2. drive board
3. alternator
1. battery fuse
on the drive
board
2. battery
1. magnet
2. reed switch
1. drive board
Notes
Telemetry heart Telemetry heart
rate detection
rate malfunction
malfunction
Contact heart
rate
malfunction
Key
malfunction
(display)
Remote
malfunction
Excessive
resistance
Total distance
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 haven’t 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 C531R
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
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
C531R
Troubleshooting
Model: C520R/C531R
Malfunction: No start up (alternator)
Circumstance: Pedal on the bike; the display does not light.
Possible causes: 1. Cables are not connected.
2. Drive board malfunction
Troubleshooting: 1. Inspect all cable and bridge board connections.
2. Inspect alternator wire connections.
3. Inspect cable connections, fuse F1, and PWR
LED at the drive board.
4. Replace the drive board.
5. Inspect the display IC pin connections.
Display
board
Inspect bridge
board wire
connections
Bridge board
Alternator
Inspect the
program IC
Power indicator
EAC 驅動器組
Inspect alternator
wires
Drive
Board
Speed sensor
3-1-1
F1 fuse
Troubleshooting
Model: C520R/C531R
Malfunction: No start up (battery)
Circumstance: Display shuts off if you don’t pedal.
Possible causes: 1. Cables are not connected.
2. Battery voltage is too low.
Troubleshooting: 1. Inspect all cable connections.
Inspect connections at the bridge board.
Inspect the
2. Test battery voltage. Normal is 5.5V or more.
program IC.
3. Inspect drive board F2 fuse.
4. If battery voltage is less than 5.5V, pedal at 50 RMP or faster to replenish the battery.
Display
board
Test battery voltage. The
display requires more than
5.3V to power
up.
EAC 驅動器組
Bridge board
Battery
Power indicator LED
Drive
Board
F3 fuse
3-2-1
Troubleshooting
Model: C520R/C531R
Malfunction: No RPM value
Circumstance: 1. No RPM value appears.
2. Pedal the bike; the display shows no reaction.
Possible causes: 1. Reed switch and magnet
2. Wire connections
Troubleshooting: 1. Inspect the reed switch and magnet.
2. Inspect all cable connections.
3. Inspect the drive board CLK signal
indicator LED.
Display
board
Bridge
board
Drive board
Inspect the CLK
indicator on the drive
board
When the reed
switch and magnet
come into contact, the
LED lights.
Reed switch
3-3-1
Reed switch and magnet
Troubleshooting
Model: C520R/C531R
Malfunction: No resistance
Circumstance: Pedal on the bike; there is no resistance.
Possible causes: 1. Cables are not connected.
2. Drive board is defective.
Troubleshooting: 1. Inspect all cable connections.
2. Inspect whether an RPM value appears when you pedal the bike. If not, inspect the reed switch
and magnet.
3. Inspect whether unit starts via the alternator.
4. Inspect the drive board fuse. Measure voltage from the drive board to the magnet.
5. Inspect the electro-magnet wires
Inspect drive board
and whether the electro-magnet has
attracts metal.
CON2 voltage:
LEV 5 6.3V
LEV 15 10V
Reed switch
Display board
Alternator
Reed switch
Drive board
F1 fuse
Electromagnet
3-4-1
Troubleshooting
Model: C520R/C531R
Malfunction: Excessive resistance
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: C520R/C531R
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.
Heart rate board container
Display
board
Telemetry heart rate receiver board
Bridge
board
Heart rate transmitter strap
(battery location)
HTR board
HR receiver
3-6-1
Troubleshooting
Model: C531R
Malfunction: Contact heart rate (HTR) malfunction
Circumstance: Hold HTR contact plates; heart rate value is
incorrect.
Possible causes: 1. HTR wires are disconnected.
2. HTR board is defective.
Troubleshooting: 1. Inspect display wire connections.
2. Inspect the HTR wire on the drive board.
3. Inspect the HTR bridge board and HTR board
indicator LEDs.
4. Inspect the HTR contacts and their wire
connections.
HTR board indicator LEDs
LED
LED1
LED2
LED3
Name
Telemetry
HTR contact
HTR output
LED4
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
Drive board
HTR board placement
Bridge board
HTR board
Sensor
Sensor
3-7-1
Troubleshooting
Model: C531R
Malfunction: Remote control malfunction
Circumstance: Press remote control keys; there is no response.
Possible causes: 1. Wire from the remote control to the display is defective.
2. Remote control keys are defective.
Troubleshooting: 1. Inspect remote control wire connections.
2. Inspect bridge board wire connections.
3. Replace the remote control.
Inspect the remote
control wire
Display
board
Bridge
board
Remote
control
3-8-1
4-1. Mechanical Maintenance Schedule -C531R/C520R
Item
1
Inspect and maintain
Wipe exterior clean
2
Level unit
3
Inspect screws
4
Inspect pedals for
noise
Inspect seat back
angle adjustment
Inspect seat fore/aft
adjustment
Inspect seat bottom
angle adjustment
5
6
7
Daily Weekly Monthly
◎
◎
◎
◎
◎
◎
◎
4-1-1
4-2. Mechanical Troubleshooting - C520R/C531R
Item
1
2
3
4
5
6
Malfunction
Unit wobbles or rocks.
Seat back angle won’t
adjust.
Pedals make noise.
Seat position won’t change.
Pedals free spin with no
resistance.
Movement seems to catch
while you pedal.
Inspect
Adjust levelers.
Replace seat back
angle shock.
Replace pedals.
Replace the shock
under the seat.
Inspect drive pulley,
flywheel, and belt.
Inspect drive pulley,
flywheel, and belt.
4-2-1
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