Service Manual

An Company I.B. 1521 ; Rev C

TABLE OF CONTENTS

Important Safety Instructions ............................................................................................3 Introduction and Specifications..........................................................................................4 Fault Codes ...........................................................................................................................5 Appendix...............................................................................................................................7

Appendix 1 .......................................................................................................................7 Appendix 2 .......................................................................................................................8 Appendix 3 .......................................................................................................................9 Appendix 4 .......................................................................................................................9 Appendix 5 .......................................................................................................................10 Appendix 6 .......................................................................................................................11 Appendix 7 .......................................................................................................................11 Appendix 8 .......................................................................................................................12 Appendix 9 .......................................................................................................................13 Appendix 10 .....................................................................................................................14

I.B. 1521 ; Rev C

SAFETY

FOLLOW THE CURRENT HEALTH AND SAFETY LEGISLATION IN YOUR COUNTRY FOR PROTECTION AGAINST ELECTRICAL HAZARD. THE VOLTAGES INSIDE THE CHARGER ARE EXTREMELY DANGEROUS AND CAN CAUSE DEATH! QUALIFIED PERSONNEL ONLY ARE ALLOWED TO OPEN THE CHARGER THE CHARGER MUST BE PROPERLY EARTHED. CHECK THAT THE CHARGER POWER SUPPLY IS ISOLATED, BEFORE ANY SERVICING OPERATION. DO NOT OPEN THE CHARGER (BY REMOVING THE COVER) WHEN EITHER A.C. OR D.C. (BATTERY) POWER IS CONNECTED. SWITCH OFF THE CHARGER BEFORE DISCONNECTING BATTERY. MAINTENANCE MUST BE PERFORMED BY QUALIFIED PERSONNEL ONLY. THE CHARGER MUST NOT BE MODIFIED IN ANYWAY AND ONLY GENUINE REPLACEMENT PARTS HAVE TO BE USED.

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REPAIR PROCEDURES POWERTECH CHARGERS

INTRODUCTION AND SPECIFICATIONS

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This manual is intended to be an aid in servicing the PowerTech charger and its content is subject to change without notification. The technician is encouraged to attend the Hawker charger training school and is expected to have some background in electronics and battery charger maintenance before attempting any repairs outlined in this manual. Basic Operational Description Turn on AC power to the charger and it should go through a short initialization routine with the display showing the charger voltage, the software revision, and then display L480. At this point the battery can be connected. The normal procedure for charging is as follows: 1. With the charger idle indicating L480, connect the battery. 2. The display will alternate between IONI and H-00 or H-00, COLD, CAPA, XXXX, COEF, and cY.YY (XXXX = Battery AH Y.YY=Charge Coefficient). 3. Charging is initiated after approximately one minute. If delayed charging has been programmed, the charging is delayed by the programmed time. After start up, the charger measures the capacity, the voltage and the percentage of charge. 4. The Charging light goes out, the COMPLETE light illuminates. If the battery remains connected and dip switch #2 (refresh) is on, refresh or maintenance charging is automatically initiated, depending on the type of battery, to maintain the batterys charge. 5. If dip switch #8 (Equalization charging) is switched to On, the equalization cycle is automatically initiated after 5 complete charge cycles. Otherwise, the equalization cycle can be initiated manually. 6. Disconnect the battery, which is now ready for use. For more information about set up and operation, refer to the PowerTech Owners Manual I.B. 1519.

CAUTION:

To prevent arcing and burning at the connector and possible battery explosion, press the START/STOP push-button first to stop the charge cycle before removing a battery that is currently on charge.

If the charger has a fault occur during any of the phases above it will display a fault code which should aid the technician in finding and repairing the problem. If any of the faults outlined in this procedure can not be corrected in the field, the charger or the defective part may need to be returned to the Life Plus division of Hawker for repair. Contact Customer Service at (800)-238-8658 or the Life Plus division for technical information and warranty claims at 423-238-8088.

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REPAIR PROCEDURES POWERTECH CHARGERS

FAULTS
0 Permanent I=0 display

Page 5/16

null output current. Charger is not charging.

1- dC Fault -> Service Fault

temporary fault. If persisting after three attempts it creates a DF1 fault. It occurs if the charger was
unable to supply the required current. 2- DF1 Fault -> Service Fault

check the mains (480 Vac , 10% on each phase ) check the FU1 input fuses (see Appendix 1) check the G1 rectifier bridge and the G2 IGBT module (see Appendix 2) check the R1 and R2 snubber resistors (see Appendix 4) check the operation of the 7 LEDs (LD1, 2, 3, 4, 11, 12, & 13) (see Appendix 8) check the TC1 transformer (see Appendix 9) replace the A3 main board
3 - DF2 Fault -> Output Fault

check the battery polarity check the F3 output fuse (see Appendix 3) check the Gs output diodes (see Appendix 5) replace the A3 main board

4 - DF3 Fault -> Incorrect Battery

check that the battery matches the charger check the battery voltage (voltage < 1.8 V/cell = battery over discharged) check the battery cells replace the A3 main board

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REPAIR PROCEDURES POWERTECH CHARGERS

5 - DF4 Fault -> Over Discharged Battery

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this fault is just an indication and does not stop the charge check the battery voltage (1.8 V/cell < voltage < 2.0 V/cell = battery over discharged) check the battery cells check that the main board matches the charger type replace the A3 main board
6 - DF5 or DF7 Fault -> Inspect battery

this fault is just an indication and does not stop the charge check the battery condition check the configuration in the menu (charge cables parameters) replace the A3 main board
7 - TH Fault -> Thermal error

check the ambient temperature ( between 0C and 40C) check the correct installation of the charger (refer to the installation manual) check operation of the fans EV01 (see Appendix 6) check the ST1 thermostat (see Appendix 7) replace the A3 main board
8 - No display or Incorrect display

check 3 input fuses FU1 (see Appendix 1) check the operation of the 7 LEDs (LD1, 2, 3, 4, 11, 12, & 13) (see Appendix 8) replace front panel board A2 replace main board A3

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REPAIR PROCEDURES POWERTECH CHARGERS

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APPENDIX
APPENDIX 1 - CHECK OF 3 INPUT FUSES "FU1" Disconnect power. This check is carried out using a multimeter set to the position and the lowest rating (see Fig.1). Repeat the check on the two other fuses.

0 = Fuse FU1 OK Infinity = Fuse FU1 broken

Figure 1

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REPAIR PROCEDURES POWERTECH CHARGERS

APPENDIX 2 - CHECK OF RECTIFIER BRIDGE "G1" AND MODULE IGBT "G2" This check is made with the multimeter in position.

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The check is run in several stages to prevent disconnecting the rectifier bridge G1. All measurements are taken at the IGBT near the bottom of the charger (see Fig.2).

Figure 2

a)

Measurement between 1 and 2: 0.7 V in one direction and Open in the other. rectifier bridge G1 and IGBT module G2 are OK. In this case, the check is terminated. Measurement between 1 and 2: 0.4 V rectifier bridge G1 or IGBT module unserviceable Determine the defective elements: Measurement between 1 and 3: 0.4 V IGBT G2 is OK rectifier bridge G1 unserviceable Measurement between 2 and 3: 0.4 V If one of the measurements (1 and 3 or 2 and 3) is 0.00V IGBT module G2 is unserviceable
REPEAT THIS TEST WHEN REPLACING AN IGBT MODULE (AN IGBT MODULE THAT IS OUT OF ORDER CAN MASK AN UNSERVICEABLE RECTIFIER BRIDGE) WHEN REPLACING THE IGBT,OR INPUT DIODE USE THERMAL GREASE (PART NUMBER TC-1879) ON COMPONENT FOOTPRINT. TORQUE MOUNTING SCREWS TO 31 INCH LBS . TORQUE 3 HEX HEAD SCREWS ON IGBT TO 60 INCH LBS. I.B. 1521 ; Rev C

b)

REPAIR PROCEDURES POWERTECH CHARGERS

APPENDIX 3 - CHECKING OF OUTPUT FUSE "F3" The checking of output fuse F3 is carried out with the multimeter in position (see Fig.3).

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0 = Fuse F3 OK Infinity = Fuse F3 broken

Figure 3

APPENDIX 4 - CHECKING OF "R1"AND R2 SNUBBER RESISTORS The Power Tech chargers have two style snubber resistors. One has two discrete resistors and the other has a circuit board with the resistors mounted on it. The test procedure is the same for both types. Disconnect the mains and the battery before performing this test. Caution: Check voltage across resistors with a meter before touching. If a resistor is broken high voltage could still be present. Inspect resistor connections and look for signs of overheating. To check resistors R1 and R2, disconnect them from the circuit, and place the multimeter in the position (see Fig. 4). Use caution when disconnecting or reconnecting the resistors to avoid damaging the mounting lugs.

330 k = R1, R2 OK Other = replace R1, R2 Figure 4

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REPAIR PROCEDURES POWERTECH CHARGERS

APPENDIX 5 - CHECKING OF OUTPUT DIODES "G3-G4-G5-G6" This check is carried out with a multimeter in position (see Fig.5).

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There are 4 output diodes and if they are good a check on any one of them will verify that they are all good. The indication shall be 0.3V in one direction and Open in the other. If one diode has short-circuited, the measurement will be 0.0V in both directions. Disconnect the wires from the secondary of power transformer TM1 to isolate the defective diodes one by one.

Figure 5

WHEN REPLACING A DIODE, USE THERMAL GREASE (PART NUMBER TC-1879) ON COMPONENT FOOTPRINT AND TORQUE TO 22 INCH LBS.

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REPAIR PROCEDURES POWERTECH CHARGERS

APPENDIX 6 - TESTING OF FANS "EV1-EV2" (THERMAL FAULT)

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Warning: 220VAC should be present at the fans. Use caution when attaching probes to avoid injury. Turn on the charger (AC power with a battery connected). Set the multimeter to position VAC and wait 1 minute. Touch probes on multimeter to the electrical connection points on each fan. a) if the 220VAC is present, check that fans EV1 and EV2 are operating. If a fan is not operating, replace it. b) if voltage 220VAC is unavailable, replace main board A3. If a THERMAL fault persists, refer to Appendix 7.

APPENDIX 7 - TESTING OF THERMOSTAT "ST1" (THERMAL FAULT)

Thermostat ST1 is tested with a multimeter set to the position (see Fig.6) with heatsink cold.

ST1

0 = Thermostat ST1 OK Infinity = Thermostat ST1 defect

Figure 6

WHEN REPLACING THERMOSTAT, USE THERMAL GREASE (PART NUMBER TC1879) ON COMPONENT FOOTPRINT

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REPAIR PROCEDURES POWERTECH CHARGERS

APPENDIX 8 - MAIN BOARD "A3"

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When charger is on, 5 LEDs should be lit all the time. LD1, LD2, LD11,LD12, LD13 should all be lit. LD3 and LD4 will come on if there is a problem with the driving circuit for the IGBT or the IGBT itself. Refer to Appendix 2 to check the IGBT.

Z8

R32

D8

S1

U11

RR1

C65 C64
1 2 3 1

R89 R90 U15

U10

Q13

U22

C30A

1 2 3

D34

U18

D33

C27

CON4

Q20 U23 C77 C76 R120 R119

U8

ON

OFF

Q19

R38

D38

6.144MHZ

D9

REG3 D37 K LD12 DREF1 LD13 K D11 D14 D21 D12 PL1 D28 D31 D15 D32 D13 R41 D18 D19 D10 C34
8DIP300

C49

C50

PD3

U17

R95 R97 R98

Q14

FIL1 FIL2

LD12 LD13

PD4

Q17

I G O

LD11

R31

Q15

C43

Z7

I G O

U13

R102

Q12

D27

D20

D7 D23 D24 D25 D26

CON5

Q11

Q5

D16

D29

R99

Q8

U12

D22

D30

13

Z1 Z2

Z3 Z4

Z5

R54

Q9

R83

Q10

CON1

R80

Q6

S2

Z6

POT5

POT4

REG4

LM311N

ICM7555IPA

U14

D17

POT3

POT1

F5

F4

F3

POT2

LD11

U7

Q18

Q16

Y1

U9

CON6

R100 R101 R96

PROGRAM LABEL

U4

U1 D36 1

REFERENCE LABEL

LD1
+ 1

F1 PD1 C2

LD1 Q3 K
O G I

Q4

LD4 U5 K D5 CON3

REG1 D1

CON2

Q1

Q2

LD2

F2 PD2 C68

K
O G I

D35

LD2 REG2 D2

R10

U6

D6

LD4

LD3 U2 K D3

U3

R2

D4

LD3

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REPAIR PROCEDURES POWERTECH CHARGERS

APPENDIX 9 TESTING OF POWER SUPPLY TRANSFORMER TC1

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The test on power supply transformer TC1 is accomplished with the test unit CO/SUP/01 and the multimeter in the VAC position connected to the terminals of the INPUT CONTROLLER. Disconnect power from charger. Disconnect the plug of power supply transformer TC1 connected to J10 of main board A3. Connect it to the plug of test controller CO/SUP/01. Connect AC power to charger. Set CHANNEL SWITCH 1 to the 220V position. Check for a 220VAC (+-10%) voltage on the multimeter. Set CHANNEL SWITCH 1 to the 24V position. Check for a 24VAC (+-10%) voltage on the multimeter. Set CHANNEL SWITCH 1 to the first 21V position. Check for a 21VAC (+-10%) voltage on the multimeter. Set CHANNEL SWITCH 1 to the second 21V position. Check for a 21VAC (+-10%) voltage on the multimeter. Set CHANNEL SWITCH 1 to position . Check for four voltages at 18VAC (+-10%) by means of CHANNEL SWITCH 2. If any of the voltages are not within specification replace TC1.

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REPAIR PROCEDURES POWERTECH CHARGERS

APPENDIX 10 REFERENCE MATERIAL

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REPAIR PROCEDURES POWERTECH CHARGERS

ITEM NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 R1, R2 FU1 TC1 L01 TM1 G2 A3 EV1, EV2 F3 REF # A2 DESCRIPTION DISPLAY CIRCUIT BOARD FUSE BLOCK, 30A, 3 POLE FUSE 20 AMP CONTROL TRANSFORMER RESONANT CHOKE POWER TRANSFORMER IGBT 200A, 1200V MAIN CIRCUIT BOARD COOLING FAN FUSE, 315A, 204V, DC

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G3,G4,G5,G6 DIODE RS01 SHUNT, 250A, 50MV SHUNT CAPACITOR RESISTOR CIRCUIT BOARD FILTER INDUCTOR

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REPAIR PROCEDURES POWERTECH CHARGERS

Schematic, 3 Phase, VoltageY

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A3

I.B. 1521 ; Rev C