Repair Manual

An Company

TABLE OF CONTENTS
SAFETY ......................................................................................................................................................3 FAULTS ......................................................................................................................................................4 0 Permanent I=0 disp lay .................................................................................................................4 1- DC Fault -> Service Fault.................................................................................................................4 2- DF1 Fault -> Service Fault ...............................................................................................................4 3 - DF2 Fault -> Output Fault................................................................................................................4 4 - DF3 Fault -> Incorrect Battery.........................................................................................................4 5 - DF5 Fault -> Inspect battery............................................................................................................4 6 DF8 Fault -> Communication Fault................................................................................................5 7 DF9 Fault -> Discharge Circuit Fault..............................................................................................5 8 - TH Fault -> Thermal error ................................................................................................................5 9 - No display or Incorrect display........................................................................................................5 10 - No communication with the EasyControl ......................................................................................5 11 Charger does not indicate a battery is connected........................................................................5 APPENDIX ..................................................................................................................................................6 APPENDIX 1 - CHECK OF 3 INPUT FUSES "FU1"..........................................................................6 APPENDIX 2 - CHECK OF RECTIFIER BRIDGE "G1" AND IGBT MODULE "G2" ..........................6 APPENDIX 3 - CHECKING OF OUTPUT FUSE "F2" .........................................................................7 APPENDIX 4 - CHECKING OF "Gs(x)" OUTPUT DIODES.................................................................7 APPENDIX 5 - TESTING OF EV(x) FANS (THERMAL FAULT).........................................................8 APPENDIX 6 - TESTING OF "ST1" THERMOSTAT (THERMAL FAULT) .........................................8 APPENDIX 7 - TESTING OF THE HALF BRIDGE VOLTAGE............................................................9 PASSWORD PROTECTIONS..................................................................................................................11

SAFETY

FOLLOW THE CURRENT HEALTH AND SAFETY LEGISLATION IN YOUR COUNTRY FOR PROTECTION AGAIN ST ELECTRICAL HAZARD. THE VOLTAG ES INSIDE THE CHARGER ARE EXTREMELY DANGEROUS AND CAN CAUSE DEATH! QUALIFIED PERSONNEL ONLY ARE ALLOWED TO OPEN THE CHARGER. THE CHARGER MUST BE PROPERLY GROUNDED. CHECK THAT THE CHARGER POWER SUPPLY IS ISOLATED, BEFORE ANY SERVICING OPERATION. DO NOT REMOVE THE COVER WHEN EITHER AC OR DC POWER IS CONNECTED. SWITCH OFF THE CHARGER BEFORE DISCONNECT ING 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.

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 half bridge voltages (see Appendix 7) check the operation of the 4 LEDs (LD1, 2, 3, & 4 - see Appendix 8) replace the A3 main board. replace the A1 main board.

3 - DF2 Fault -> Output Fault

check the battery polarity. check the F2 output fuse (see Appendix 3) check the Gs output diode(s) (see Appendix 4) replace the A3 main board. replace the A1 main board.

4 - DF3 Fault -> Incorrect Battery check that the battery matches the charger range. check the battery voltage (voltage < 1. 7 V/cell = battery over discharged) check the battery cells. replace the A3 main board.

5 - DF5 Fault -> Inspect battery

this fault is just an indication and does not stop the charge. It is usually an indication that the
charger timed out at 3 hours and may not have finished the charge. check the battery condition. check the configuration in the menu (charge cables parameters) check that the charger is sized appropriately for the battery capacity replace the A3 main board.

6 DF8 Fault -> Communicatio n Fault

this fault is only applicable to the ATR3020 and ATR3030 contact factory if this fault occurs
7 DF9 Fault -> Discharge Circuit Fault

contact factory if this fault occurs

8 - TH Fault -> Thermal error

check the ambient temperature ( between 32 F and 104 F ) check the correct installation of the charger (refer to the installation manual) check operation of the fans E V (x) (see Appendix 5) check the ST1 thermostat (see Appendix 6) replace the A3 main board. replace the A1 main board.

9 - No display or Incorrect display

check 3 input fuses FU1 (see Appendix 1 ) check the display contrast adjustment:
1. Set Start/Stop switch to 0 (OFF) and hold down and ? simultaneously. 2. When the LEDs flash, adjust the contrast via the ? / ? buttons. 3. Confirm by pressing OK. check the operation of the 4 LEDs (LD1, 2, 3, & 4 - see Appendix 8) replace front panel board A2 replace A3 main board. replace A1 supply board.

10 - No communication with the EasyControl this fault will cause t he charger to only operate in ionic mode. check that the EasyControl is working correctly through the display of its green/red LED. check that the EasyControl downloads the data properly to a PDA (Palm Pilot). verify the wires are connected correctly on the supply board . check LED (LD 5 - see Appendix 8). It should be flashing, indicating data reception. replace the A3 main board. replace the A1 supply board.

11 Charger does not indicate a battery is connected

check that SBX connector is fully mated. check that inline fuse under main board inside charger is good. check that jumper wire on battery side of SBX connector is connected to battery positive and
is in the right location to mate to the charger end.

APPENDIX
APPENDIX 1 - CHECK OF 3 INPUT FUSES "FU1" Disconnect the AC mains and the battery before removing cover. This check is carried out using a multimeter set to the position and the lowest rating (see Fig.1). Repeat the check for all the fuses.

0 = fuse OK infinity = replace the fuse

Figure 1

APPENDIX 2 - CHECK OF RECTIFIER BRIDGE "G1" AND IGBT MODULE "G2" Disconnect the AC mains and the battery before removing cover. This check is made with the multimeter in position. The check is run in several stages to prevent disconnecting the rectifier br idge G1. (see Fig.2).

Figure 2

Note: if one of the LEDs of the main board (LD13 to LD16 ) is unlit then comes on when connector J12 is disconnected, module IGBT G2 is out of order. a) Measurement b etween 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:
6

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 IG BT MODULE THAT IS OUT OF ORDER CAN MASK AN UNSERVICEABLE RECTIFIER BRIDGE) WHEN REPLACING THE IGBT, OR INPUT DIODE USE THERMAL GREASE ON COMPONENT FOOTPRINT. TORQUE SCREWS ON IGBT TO 62 INCH LBS TORQUE . SCREWS ON DIODE BRIDGE TO 31 INCH LBS.

APPENDIX 3 - CHECKING OF OUTPUT FUSE "F2" Disconnect the AC mains and the battery before removing cover. The checking of output fuse F2 is carried out with the multimeter in

position (see Fig.3).

0 = F2 Ok Infinity = replace F2 Figure 3 APPENDIX 4 - CHECKING OF "Gs(x)" OUTPUT DIODES Disconnect the AC mains and the battery before to remove the cover. This check is carried out with a multimeter in position (see Fig.4 ).

The indication shall be 0.3V in one direction and Open in the other. If one of the diodes is 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. WHEN REPLACING A DIODE, USE THERMAL GREASE ON COMPONENT FOOTPRINT. TORQUE AS FOLLOWS: When a copper bar is present : 22 INCH LBS. When no copper bar is present : 13.5 INCH LBS.

0.3 V = 1st diode OK 0.0 V = replace G(x)

0.3 V = 2nd diode OK 0.0 V = Replace G(x)

Figure 4 APPENDIX 5 - TESTING OF EV(x) FANS (THERMAL FAULT) Disconnect the mains and the battery before to remove the cover. Turn on the charger (mains power supply, battery connected and On/Off switch S1 in position 1). Wait for the start of the charge. Set the multimeter to position Vac (see Fig.5 ).

230 Vac

Figure 5 230 Vac voltage Present Present Not present Action Refer to Ap.6 Replace the non-working fan(s) Replace the A3 main board and/or the A1 supply board

Fan(s)

Working Not working Not working

APPENDIX 6 - TESTING OF "ST1" THERMOSTAT (THERMAL FAULT) Disconne ct the AC mains and the battery before to remove the cover. Thermostat ST1 (close to the IGBTs) is tested with a multimeter set to the position (see Fig.6).
0 =STI Ok Infinity = replace STI

Figure 6

WHEN REPLACING THERMOSTAT, USE THERMAL GREASE ON COMPONENT FOOTPRINT

APPENDIX 7 - TESTING OF THE HALF BRIDGE VOLTAGE Disconnect the AC mains and the battery before to remove the cover. Turn on the charger (mains power supply, battery connected and On/Off switch S1 in position 0). Set the multimeter to position Vdc (see Fig.7 ) and measure the half bridge voltages.

Vdc+

Vdc-

Figure 7 Vdc+ and Vdc - should be between 250V and 310V (depending on the mains voltage). If not, disconnect the AC mains and the battery. Check and/or replace the following components: (see Fig.8)

Rx resistors 330K 5%

RV varistors Cs capacitors

Figure 8

APPENDIX 8 - "A3" MAIN BOARD

BFM COM Jumper location :

Standard Upload J22 Yes No J4 No Yes

R/G indicators
0V

Seq uencer

LD 1

LD 2

LD 5 BOARD LABEL

LD 3

LD 6

LD 7 LD 4

10

LED 1 2 3 4 5 6 7

Function +5V supply +15V supply +12V supply +12V supply Easy communication Vce protection Vce protection

Status ON OFF ON OFF ON OFF ON OFF ON FLASHING OFF ON OFF ON OFF

Comment Normal status No supply Normal status No supply Normal status No supply Normal status No supply No Easy communication Normal status (data transfer) No Easy communication Activated (charge stopped) Normal status Activated (charge stopped) Normal status

PASSWORD PROTECTIONS The configuration menu requires a password to access. Please enter the password as 99.

11

G
14

D D

B B

only on version (1)

F F
L1
V+

G2
C1

FU1 M A I N S
L1

Z01 C+
INPUT FILTER

4
Cs+ RV+
u u
B1 E1

L3

C29 30

GND

E2 12 VB2 E2

S1
8 9 7

INTERFACE
6

A4
46

R1

47

49

R2

50

Cs-

RV-

OVtrip

29

30

31

32

22

24 20 21

25 26

23

-Vbatt

+SH -SH

+Vbatt

0Vtrip

34

M
EV2

33

4
L2

TI1
11

Cr

Lr

B1

G1

Vr

E1 C2 B2

TM1
+ Batt

3
only on version (2)
+ DC 23

3
A2
X1
Electrov. 220Vac

X3

X1

DISPLAY PCB
X2
TI1

Gs Cd

Cd C1
24

F2

L3

L2
RS01
only onversion (2)
27 22 - DC - Batt

34

B A T T E R Y

X2 X3 X3

X1

X8

-SH +SH

25 26

2
(1) : LP 2010 / PWT 48-170 / 80-105 & 80-120 models (2) : All models with DC filter

2
SUPPLY PCB
X4 X4

MAIN BOARD
50 49 48 G2-E1 G2-B1 G2-C1

TITRE

X2 X7 X6 X5 X5

47 46 45 G2-E2 G2-B2

51

GENERAL ELECTRIC DIAGRAM 3-PHASE HALF BRIDGE EASYCOM CHARGERS

LIFEPLUS 2004 / 2006 / 2008 & 2010 POWERTECH 48-140 / 48-170 / 80-85 / 80-105 / 80-120
REFERENCE OFSA ND'IDENTIFICATION
FORMAT INDICE

G2-C2 52

A1

A3

EV1

FOLIO

28

SCHELEC
G

XXXXX A 4
B

1
A

ST1

Ce document est la proprit de la socit HAWKER et ne peut tre utilis, reproduit,diffus et/ou rvl qui que ce soit sans autorisation crite pralable. This document is the sole property of AWKER and cannot be used, reproduced, H transmitted and/or disclosed to any persons or compagnies without his prior permission.

12

LSRM.500.10/05.Rev.0

The Name Means Power HAWKER P.O. Box 808, 9404 Ooltewah Industrial Dr. Ooltewah, Tennessee 37363 USA Phone (423)238-5700 (800)238-VOLT Fax (423)238-6060 www.hawkerpowersource.com