I.B. 1521 ; Rev C

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

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.

I.B. 1521 ; Rev C

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INTRODUCTION AND SPECIFICATIONS 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 battery’s 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 Owner’s 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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FAULTS 0 – Permanent “I=0” display

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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I.B. 1521 ; Rev C

5 - DF4 Fault -> Over Discharged Battery

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 0°C and 40°C)

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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I.B. 1521 ; Rev C

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

b) 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.

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APPENDIX 3 - CHECKING OF OUTPUT FUSE "F3"

The checking of output fuse F3 is carried out with the multimeter in position (see Fig.3).

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.

Figure 4

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

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APPENDIX 5 - CHECKING OF OUTPUT DIODES "G3-G4-G5-G6" This check is carried out with a multimeter in position (see Fig.5). 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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APPENDIX 6 - TESTING OF FANS "EV1-EV2" (THERMAL FAULT) 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)

ST1

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

0 = Thermostat ST1 OK Infinity = Thermostat ST1 defect

Figure 6

WHEN REPLACING THERMOSTAT, USE THERMAL GREASE (PART NUMBER TC-1879) ON COMPONENT FOOTPRINT

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APPENDIX 8 - MAIN BOARD "A3" 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.

LD12

LD13

LD1

LD11

LD2

C30

A

PROGRAM LABEL

REFERENCE LABEL

R80

R83

D8

R97

R10

0

+

-

+

-

+

-

+

-

R32

D10

Z1

Z2

Z3

Z4

C27

C34

PO

T5

Q2

Q4

Q5

Q6

R98

R96

D9

R10

1

R10

2

RR

1

R38

R2

R10

R41

R31

C2

+

C43

+

C49

+

C50

+

C68

+

PO

T1

PO

T3

PO

T4

PO

T2

REG3

I G O

IGO

IGO

REG4

I G O

Q3

18

113

15

ON

OF

F

Q1

U7

1C

ON

11

CO

N3

D13

D15

D28

D29

D31

D32

K

K

K

F1

F2

F3

F4

F5

F5

F5

S2

R95

D6

D4

R99

R54

K

K

FIL

2

1C

ON

6

FIL

1

U18

CO

N4

CO

N5

CO

N2

LD1

LD2

RE

G1

RE

G2

PD

1P

D2

D1

D2

U6

U3

D36

U4 U1

LD3

LD4

U5

U2

D3

D5

D16

D17

D20

D27

LM31

1NU

148D

IP3

00U

17

Q1

2

Q1

7

Q1

5

Q1

8Q

16

Q1

9

D38

U9

U8

U10

S1

U11

Z8

D33

D34

6.144MHZ

Y1D

37

K

LD11

U2

2

PD

4P

D3

LD12

K

LD13

D11D14D21D12

PL1

D30

D22

U12

Z6

Z5

D26

D23

D25

D24

DREF1

D18

D19

Q1

4

Q1

1Q

8Q

9Q

10

Z7

ICM

755

5IP

A

U13

D7

D35

U23

U15

1 2 3

1 2 3

Q13

C65

C64

C77

C76

Q20

R89

R90

R12

0R

119

LD4

LD3

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APPENDIX 9 – TESTING OF POWER SUPPLY TRANSFORMER “ TC1” 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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APPENDIX 10 – REFERENCE MATERIAL

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ITEM NUMBER REF # DESCRIPTION

1 A2 DISPLAY CIRCUIT BOARD

2 FUSE BLOCK, 30A, 3 POLE

3 FU1 FUSE 20 AMP

4 TC1 CONTROL TRANSFORMER

5 L01 RESONANT CHOKE

6 TM1 POWER TRANSFORMER

7 G2 IGBT 200A, 1200V

8 A3 MAIN CIRCUIT BOARD

9 EV1, EV2 COOLING FAN

10 F3 FUSE, 315A, 204V, DC

11 G3,G4,G5,G6 DIODE

12 RS01 SHUNT, 250A, 50MV

13 SHUNT CAPACITOR

14 R1, R2 RESISTOR CIRCUIT BOARD

15 FILTER INDUCTOR

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Schematic, 3 Phase, VoltageY

A3