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An Company
1
SAFETY
2
FAULTS
• null output current. If the charger is not able to deliver the proper current in the battery, a
DC fault is created.
3
• 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.
• 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.
• 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.
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.
4
10 - No communication with the Battery Boss (optional)
5
APPENDIX
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).
0 Ω = fuse OK
infinity = replace the fuse
Figure 1
Disconnect the AC power and the battery before removing the cover.
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.
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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
REPEAT THIS TEST WHEN REPLACING AN IGBT MODULE (AN IGBT MODULE
THAT IS OUT OF ORDER CAN MASK AN UNSERVICEABLE RECTIFIER BRIDGE)
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
Disconnect the AC power and the battery before removing the cover.
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.
Figure 4
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
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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
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:
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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
A3
24
20
21
25
26
22
23
EV1
1
+SH
+Vbatt
0Vtrip
M
FORMAT INDICE
28
SCHELEC XXXXX A 4 A 1 1
33
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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