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Service manual Flatpack 2

INTRODUCTION

HOUSEKEEPING POWER

Start-up power on the primary side

Power when rectifier runs

Supply to the secondary from the battery side

BOOST DESCRIPTION

DC/DC-DESCRIPTION

PRIMARY CARD

SECONDARY CARD

SURGE PROTECTION

SERVICE MODUS

USING SOFTWARE FOR DIAGNOSIS

PLEASE SAVE THESE BROKEN PARTS

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EXPERIENCES FAILURES

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WHEN IS THE RECTIFIER OK?

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Introduction
This document describes shortly the basic functions of the Flatpack2 rectifiers intended
for service people:
241115.001
241115.100
241115.200
241115.901

Housekeeping power
Start-up power on the primary side
POWER MANAGEMENT
DZ100 R113R112R111

RectMains
2

R158

1
2

1
2

R157

3
2

Q105

DZ102

3
3
1

C117

BleederP

DZ101

PTC101

+t

1
2

1135
C

D108

R114

D107
1

Vfb
Vstart

3
2

R115
Vccon

Q108
1

U101

Vin

Vout

3
1

C118

Adj
1
2

R117

Rectifer not running


Voltage on gate Q105:
Voltage on source Q105:
Vstart:

20-23Vdc
19-20Vdc
14-16Vdc

Rectifier running:
Voltage on gate Q105:
Voltage on source:
Vstart:

15V
12-13V
15-19.5V

2
2
1

R116

C119
2

VCC

C120

Power when rectifier runs

C206

1
2

T202
1

D204

3
1

C209
2
2

Vfb
1

C207

D202

C208

2
1

D205

Y201
2

1 5

D203
Vstart

TXs

The housekeeping voltage is now provided from T202, 15-20 Vdc on both primary and
secondary side.

Supply to the secondary from the battery side

2
+t

PTC200

R217

Voutput

2
Bleederinput

Q202
1
Bleeder output

Rectifer not running


Voltage on gate/base Q202: 25Vdc
Voltage on source Q202:
20-24Vdc, varying
Rectifier running:
Voltage on gate Q202:
Voltage on source Q202:

15V
12-14V

Boost description

The boost of 241115.100


Topologies:
241115.001: One transistor and one diode, hardswitched
241115.100: Two transistors and one diode, hardswitched
241115.200: One transistor, one diode, and a dI/dt turn-on snubber.
241115.901: Two transistor, double diode interleaved topology and a di/dt turn-on
snubber
Switcing frequency: 85-115kHz, varying over the sinewave.
Output voltage:
350 to 435Vdc, load dependant.
The boost is controlled by the primary controller card.

DC/DC-description
D206

T200

+400V

1
10

L200

R215
GNDHighSide

7
6

Y13

Q201

Y15
2

GateLowSide

C221

C202

T201
2

D201

5
1

C204

C200

1
2

Y14

Y12
1

12

C205

2
1

2
2

7
6

R216

D207

R212

NTC200
-t

5
1

Tempsense
2

C235

C206

Y202

The DC/DC is a resonant halfbrigde LLC converter, working between 200 and 400kHz.
The dutycycle over the transformer is constantly 50%, and is not used for regulation.
Regulation is accomplished by;
1. Frequency variation
2. Boost voltage variation
In addition, the deadtime between the upper and lower transistor varies with load
condition.

1
2

C213

C212

1
2

C211

C201

R211

D200

C203

Q200
GateHighSide

Primary card
Functions:
Boost regulation and control accomplished by ST4981.
241115.901 use Freescale DSP 8014.
Microcontroller:
Mains measurement
Boost voltage measurement, setting and protection
LED control
Fan surveillance
Fan speed setting
Start up/shutdown sequencing
High mains shutdown sequencing
Ambient temperature measurement
Uart communication with the secondary controller board

Secondary card

Output air measurement


Alarm management and setting
Temperature derating and protection
Mains derating
Fan regulation
Current limitation
Power limitation
Current sharing
Can communication
Regulation of the DC/DC controller
Uart communication with the secondary controller board

Surge protection
420V varistor between the phases. Will probably never fail.
In addition, does 241115.901 have 625V varistors to ground.

Service modus
Use this to check:
1. Mosfets in boost
2. Mosfet in DC/DC
To make a test cable, simply use a broken fan cable. Attach the cable as shown on the
picture, with a voltage level of 20Vdc.
Connect to 0V

Connect to +20V

Use a variac and put 3-5Vac on the input,


Yellow led in front shall blink, and the fans will start running.
Check gatesignals on Q200 and Q201.

Gatesignal on boost mosfet(s) should look like this:

If you have any deviation, replace mosfet and as much as necessary of the gate driver
circuitry,

Using software for diagnosis


Use this to check:
CAN communication
Communcation between primary side and secondary side
Alarms
Measurements
Calibrations
How to start it:
1. Put 20-30Vdc on the output of the rectifier. Use oring diode on your supply to
protect it, If canbus is OK, you shall now be able to communicate with the
rectifier.
2. Add 30Vac on the primary side by means of a variac.
3. Check if you can read out the mains voltage on the canbus

Please save these broken parts


We might later ask for destroyed samples of:

The small controller cards


Main transformers
Electrolytic capacitors
Fans

This is important to constantly improve quality

Experiences failures
We have seen the following on earlier versions. These problems should be solved now:
1. The bypass diode in the boost due to manufacturing, Always check this one when
the boost has failed. If failed, it is the reason for boost failure.
2. Secondary card On earlier versions we have seen some failures. This shall be
improved now.
3. Manufacturing error in the main transformer.
4. Fan vibration

When is the rectifier OK?

When running at full power without any alarms. Check power limitation and
current limitation.
Check calibration. Voltage, current, mains and boost voltage.
Check current sharing and communication in a system.
Always perform burn-in after service.