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Repair

Manual
An Company
1
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 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 DISCONNECTING BATTERY.

• MAINTENANCE MUST BE PERFORMED BY QUALIFIED PERSONNEL ONLY.

• THE CHARGER MUST NOT BE MODIFIED IN ANYWAY AND ONLY GENUINE


REPLACEMENT PARTS MUST BE USED.

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FAULTS

0 – Permanent “I=0” display

• null output current. If the charger is not able to deliver the proper current in the battery, a
DC fault is created.

1- DC Fault -> Service Fault

• temporary fault if persisting (three attempts) it creates a DF1 fault.

2- DF1 Fault -> Service Fault Rev 2007.07

• check the AC power (240Vac or 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 supply board.

3 - DF2 Fault -> Output Fault

• check the battery polarities.


• 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 supply board.

4 - DF3 Fault -> Incorrect Battery

• check that the battery matches the charger range.


• check the configuration in the menu (range selection between 72 or 80 V batteries) on
48/72/80V chargers.
• check the battery voltage (voltage < 1.8 V/cell = battery too much over discharged)
• check the battery voltage (voltage > 2.35 V/cell)
• check the battery cells.
• replace the A3 main board.

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<voltage < 2 V/cell = battery over discharged)
• check the configuration in the menu (range selection between 72 or 80 V batteries) on
48/72/80V chargers.
• check the battery cells.
• check that the main board matches the charger type.
• replace the A3 main board.

6 - DF5, DF7 Fault -> Inspect Battery

• this fault is just an indication and does not stop the charge.
• check the battery (Temperature, Specific gravity..)
• check the battery condition of use.
• 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 (32°F) and 40°C (105°F))
• check the correct installation of the charger (refer to the installation manual)
• check the correct working on of the fan(s) EV(x) (see Appendix 5)
• check the ST1 thermostat (see Appendix 6)
• replace the A3 main board.
• replace the A1 supply board.

8 - No display or Incorrect display

• check the FU1 input fuse(s) (see Appendix 1)


• check the display contrast setting:

1. When the charger is in the Waiting position (Start/Stop switch set to “0”), 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) on the A3 main
board.
• Check the ribbon cable.
• replace the A2 front panel board.
• replace the A3 main board.
• replace the A1 supply board.

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10 - No communication with the Battery Boss (optional)

• only valid if a Battery Boss is on the battery.


• check that the Battery Boss is working correctly through the display of its green/red LED.
• check that the Battery Boss downloads the data properly to a PDA (Palm Pilot)
• verify that 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.

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APPENDIX

APPENDIX 1 - "FU1" INPUT FUSE(S) CHECK

Disconnect the AC power and the battery before removing the cover.
This check is carried out using a multi meter set to the Ω position and the lowest rating (see Fig.1).

Repeat the check for all the fuses.

0 Ω = fuse OK
infinity = replace the fuse

Figure 1

APPENDIX 2 - CHECK OF "G1" RECTIFIER BRIDGE AND "G2" MODULE IGBT

Disconnect the AC power and the battery before removing the cover.

This check is made with the multimeter in position

The check is run in several stages to prevent disconnecting the rectifier bridge G1. (see Fig.2).

c d e

Figure 2

Note: if one of the LEDs of the main board (LD3 or LD4) is unlit then comes on when connector
J23 is disconnected, module IGBT G2 is out of order.

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.
Determining the defective elements:

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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 ON


COMPONENT FOOTPRINT. TORQUE SCREWS ON IGBT TO 62 INCH LBS. TORQUE
SCREWS ON DIODE BRIDGE TO 31 INCH LBS.

APPENDIX 3 - CHECKING OF "F2" OUTPUT FUSE

Disconnect the AC power and the battery before removing the cover.
The checking of output fuse F2 is carried out with the multimeter in Ω position (see Fig.3).

0 Ω = F2 Ok
Infinity = replace F2

Figure 3

APPENDIX 4 - CHECKING OF "Gs(x)" OUTPUT DIODES

Disconnect the AC power and the battery before removing the cover.

This check is carried out with a multimeter in position (see Fig.4).

The indication should 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.

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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 ≈ 0.3 V = 2nd diode OK


≈ 0.0 V = replace G(x) ≈ 0.0 V = Replace G(x)

Figure 4

APPENDIX 5 - TESTING OF EV(x) FANS (THERMAL FAULT)

Disconnect the AC power and the battery before removing the cover.
Turn on the charger (AC 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 Fan(s) Action


Present Working Refer to Ap.6
Present Not working Replace the non-working
fan(s)
Not present Not working Replace the A3 main
board and/or the A1
supply board

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APPENDIX 6 - TESTING OF "ST1" THERMOSTAT (THERMAL FAULT)

Disconnect the AC power and the battery before removing the cover. This test should be performed
with heatsink cool otherwise ST1 could be on due to heat.

Thermostat ST1 (close to the IGBTs) is tested with a multimeter set to the Ω position (see Fig.6).

0 Ω=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 power and the battery before removing the cover.
Turn on the charger (AC 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 equivalent and between 300V and 370V (depending on the AC voltage
and the output current).

If not, disconnect the AC power and the battery. Check and/or replace the following components:

9
Rx resistors
330KΩ ±5%

RV varistors

Cs capacitors

Figure 8

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APPENDIX 8 - "A3" MAIN BOARD

BFM

COM

Jumper location :

J2 J4
2
Standar Yes No
d
Upload No Yes

R/G indicators
0V

LD 1

LD 2

LD 5
BOARD
LABEL

LD 3 LD 6

LD 7
LD 4

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LED Function Status Comment
ON Normal status
1 +5V supply
OFF No supply
ON Normal status
2 +15V supply
OFF No supply
ON Normal status
3 +12V supply
OFF No supply
ON Normal status
4 +12V supply
OFF No supply
ON No communication
Battery Boss
5 FLASHING Normal status (data transfer)
communication
OFF No communication
ON Activated (charge stopped)
6 Vce protection
OFF Normal status
ON Activated (charge stopped)
7 Vce protection
OFF Normal status

12
G
H

C
D
E

A
F
only on version (1)

L1 G2
V+
14
4
4

FU1 Z01 C1

RV+
B1
Lr

Cs+
M L1 C+ TI1 Cr
A
INPUT E1

u
11
I L2 G1 Vr
FILTER C2
N
B2

RV-
S C-

Cs-
L3
29 30

u
E2
GND
12
V- B2 E2 B1 E1

S1 INTERFACE A4
46 R1 47 49 R2 50

6 TM1 3
3

9
7
8

+ Batt
only on
X3 X1 version (2) + DC
B

OVtrip
23
A2 DISPLAY F2 A
L3
PCB Gs Cd T
X2
TI1 C1 T
Cd
24 L2 E
34 R
RS01 22
Y
29
30 - DC
5

only on version (2) - Batt


X1
X1 X2
27
Electrov. X3 X3
220Vac
X8
25
-SH
26
+SH 2
2

(1) : LP 2010 / PWT 48-170 / 80-105 & 80-120 models


SUPPLY X4 X4 (2) : All models with DC filter
MAIN BOARD
PCB 50
G2-E1
TITRE
49
48
G2-B1 GENERAL ELECTRIC DIAGRAM
X2
47
G2-C1
51 3-PHASE HALF BRIDGE EASYCOM CHARGERS
X7 X5 X5 G2-E2
46
G2-B2
45
X6 G2-C2
52
LIFEPLUS 2004 / 2006 / 2008 & 2010
A1 POWERTECH 48-140 / 48-170 / 80-85 / 80-105 / 80-120
32
31

A3
24
20
21
25
26
22

23

EV1
1

REFERENCE OFSA N°D'IDENTIFICATION FOLIO 1


-SH
-Vbatt

+SH

+Vbatt
0Vtrip

M
FORMAT INDICE
28
SCHELEC XXXXX A 4 A 1 1
33
34

M C e d o c um e nt es t l a p r o pr i ét é d e l a s o c ié t é H AW K ER et n e p eu t ê t re ut i l is é ,

EV2 ST1 r e pr o d ui t ,d i ff u sé et / o u r év é lé à q ui q ue ce so i t s an s au t or i sa t io n é c r it e p r éa l ab l e.
T his docu m ent is the sole pro pert y of H A W K E R a nd c an n ot be us e d, r ep r od u ce d ,
t r an s m it t ed an d /o r d i s cl o se d t o a n y p e rs o ns or co m pa g n ie s w i th o ut hi s pr i or pe r m i s si o n .

H G B A

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Leading Edge Power Solutions
HAWKER
P.O. Box 808, 9404 Ooltewah Industrial Dr.
Ooltewah, Tennessee 37363 USA
LPTC3RM 7/07. Rev. 0 Phone (423)238-5700 (800)238-VOLT Fax (423)238-6060 14
www.hawkerpowersource.com