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Fronius Selectiva 2040, Service Manual

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Fronius Selectiva 2040 Service Manual Download Page 13

Replacing components

13

Summary of Contents for Selectiva 2040

Page 1: ... certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy Selectiva 2040 2kW Selectiva 2050 2kW Selectiva 2060 2kW Selectiva 2070 2kW Selectiva 4020 2kW Selectiva 4035 2kW EN Service manual Battery charging system 42 0426 0264 EN 018 21072020 ...

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Page 3: ...ard 20 Replacing the mains cable 22 Removing the 2 kW mains cable 22 Install the 2 kW mains cable 23 Replacing the charging lead 25 Removing the charging lead 25 Installing the charging lead 25 Replacing the fan 28 Removing the fan 28 Installing the fan 30 Changing the internal battery 33 Removing the 2 kW battery 33 Installing the 2 kW battery 33 Replacing the power module 35 Removing the power m...

Page 4: ...48 Insulation resistance 49 Ground conductor current 50 Contact current 52 Function tests 53 General 53 Function test in the service menu 53 Other function tests in the Service menu 56 Mains power on off equipment 57 Indicators and control elements 57 Documentation 58 Documentation 58 4 ...

Page 5: ...General information 5 ...

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Page 7: ...fy safety requirements Use only ori ginal spare parts also applies to standard parts Each section in the Service Instructions deals with one complete topic Use each section as a self contained source of information Safety The device has been manufactured in line with the state of the art and according to recognised safety standards If used incorrectly or misused however this can pose the following...

Page 8: ... Always stop charging before you disconnect the charging cable OVC III UAC nom IAC max PAC max UDC nom IDC max Part No Ser No Protective class I XXXX xxxxxxxx xxxxxxxx 4 010 xxx Selectiva xxxx 2 kW Ladevorgang immer stoppen bevor das Ladekabel abgezogen wird Explosive Gase Flammen und Funken vermeiden Während des Ladens für ausreichend Frischluft Zufuhr sorgen Always stop charging before you disco...

Page 9: ...t electrically charged components e g capacitors are fully discharged Use an easily legible and understandable warning sign to ensure that the charger is not reconnected to the mains supply before all the work has been completed Inside the device 2 kW 4 010 xxx xxxxxxxx XXXX WARNING Hazardous Voltage Kondensator Entladezeit 2 min Capacitor discharge time 2 min Décharge de condensateur 2 min Conden...

Page 10: ...cing work there is a risk of electronic components being damaged by electrical discharge Always observe the necessary protective measures when hand ling electronic components For more detailed information see the remainder of these Service Instructions 10 ...

Page 11: ...mm Slotted screwdriver 6 5 mm Cross head screwdriver PH2 Socket wrench Socket wrench insert 13 mm Flat spanner 13 mm Diagonal cutting pliers Needle nosed pliers Torque screwdriver with bit insert 1 6 Nm Torque ratchet 1 20 Nm Measuring and testing equip ment Digital multimeter Safety inspection equipment 11 EN ...

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Page 13: ...Replacing components 13 ...

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Page 15: ...ontact with live components when the device is open An electric shock will cause serious injury or death Wait for the capacitors to discharge 2 minutes before starting work Check that all potentials are de energised If necessary discharge the capacitors using a suitable tool WARNING Danger of death due to work that has been carried out improperly Failure to perform servicing work properly can resu...

Page 16: ...onic components and PC boards This primarily applies to ESD compatible Packaging Work surfaces Floors Seating Earthing facilities Ease of handling No guarantee or warranty claims can be made in respect of any improperly handled elec tronic component or PC board 16 ...

Page 17: ...he 2 kW device 1 If present the LED diffuser strip must be removed 1 Remove the LED diffuser strip 1 1 1 Undo the 2 M4x10 TX20 screws on the device frame 2 1 1 1 1 1 Undo the four M4x10 TX20 screws 2 Remove the housing cover 17 EN ...

Page 18: ...e grounding lug upwards 2 Disconnect the display 3 If present remove the LED strip 1 1 2 1 Undo the two M4x10 TX20 screws 2 Pull the front panel of the housing upwards and remove it 1 1 Remove the insulating foil 18 ...

Page 19: ...oard Remove the dis play PC board 1 Open the device see chapter Open ing the device 1 1 Open the insulating foil 1 2 1 1 1 Undo the three 4x9 TX20 tapping screws 2 Take the display PC board out of the display spacer frame 19 EN ...

Page 20: ...y PC board 1 1 1 2 1 Place the new display PC board on the display spacer frame 2 Fit the display PC board with three 4X9 tapping screws Tightening torque 1 5 Nm 1 1 Close the insulating foil ATTENTION Make sure that the insulating foil is between the display and the housing 20 ...

Page 21: ...1 Fit the front panel of the housing see chapter Closing the device 21 EN ...

Page 22: ...ble 1 1 2 1 Remove the two 4x20 TX20 screws 2 Remove the AC connection plate 1 1 1 1 Disconnect the mains cable from the power module 1 1 1 1 After releasing the locking hooks on the strain relief device route the mains cable fully through the opening 22 ...

Page 23: ...e the mains cable Install the 2 kW mains cable 1 2 1 Insert the mains cable into the strain relief device 2 Close the strain relief device by press ing firmly 1 1 Route the mains cable and strain relief device through the opening in the AC connection plate Make sure that the strain relief device locking hooks are fully engaged 23 EN ...

Page 24: ...1 1 1 1 Connect the mains cable to the power module with the correct polarity 1 2 2 4 Fit the AC connection plate and secure with two 4x20 TX20 screws Tightening torque 1 5 Nm 24 ...

Page 25: ...exagon nuts and remove the charging leads Installing the charging lead 1 2 3 4 Item Description 1 Charging lead cable lug 2 M8 brass washer 3 M8 lock washer 4 Size 13 M8 hexagon nut 1 Thread the positive charging lead washer and lock washer onto the M8 bolt as shown and fit the size 13 M8 nut loosely 2 Thread the negative charging lead washer and lock washer onto the M8 bolt as shown and fit the s...

Page 26: ...racket so that the labelling of the cable cross section used faces the lead 1 1 Place the strain relief device bracket and secure with a 4x20 TX20 screw Tightening torque 1 5 Nm 1 1 1 Tighten the two size 13 M8 nuts Tightening torque 15 Nm 26 ...

Page 27: ...1 2 2 1 Fit the DC connection plate and secure with two 4x20 TX20 screws Tightening torque 1 5 Nm 27 EN ...

Page 28: ...x10 TX20 screw on the device frame AC side 1 1 Undo the 5x10 TX25 screw on the underside of the device frame 2 2 3 1 1 1 Press the locking hooks together 2 Use a slotted screwdriver to detach the device frame from the device 3 Remove the device frame 28 ...

Page 29: ... chapter Replacing the mains cable 1 2 3 1 Disconnect the fan cable from the power module 2 Push the locking hook upwards 3 Remove the fan with the fan holder 1 1 2 1 Push the two fan holder locking hooks up or down 2 Pull out the fan 29 EN ...

Page 30: ...n on the housing into the fan holder 1 Clip the fan into the fan holder 1 3 2 1 Use the arrows to check if the fan is installed correctly 2 Check that the fan blades can be rotated easily 3 Check that the fan cable is routed cor rectly 1 1 Clip the fan holder and fan into the device 30 ...

Page 31: ...le 1 1 1 1 Connect the mains cable to the power module with the correct polarity see chapter Replacing the mains cable 1 2 1 Place the device frame on the locking hooks and press firmly 2 Tighten the 5x10 TX25 screw Tightening torque 3 Nm 31 EN ...

Page 32: ...1 1 Fit the M4x10 TX20 screw on the device frame AC side Tightening torque 2 5 Nm 32 ...

Page 33: ...evice 1 2 1 Release the battery lock 2 Remove the battery Installing the 2 kW battery 1 2 NOTE Risk of damage to the device due to incorrectly connected battery Insert the battery ensuring the correct polarity 1 Insert the battery ensuring the correct polarity 2 Check that the battery lock is locked in place 33 EN ...

Page 34: ...1 Fit the housing cover see chapter Closing the 2 kW device 34 ...

Page 35: ...ove the fan including the fan holder see chapter Replacing the fan 1 2 1 1 Remove the two M5x10 TX25 screws for the charging leads 2 Remove the M5x10 TX25 screw on the EMC plate 1 NOTE Possible damage to the device due to defective soldering points When removing or inserting the power module only grasp the heat sink to move it 1 Push the power module out toward the AC side or pull it out 35 EN ...

Page 36: ... the 48 V device the 5x8 TX25 screw for the metal strip fuse on the power module has been undone or the metal strip fuse needed to be changed then this must be retightened Tightening torque 3 5 Nm 1 Fit the fan including the fan holder see chapter Installing the fan 2 Fit the mains cable and the device frame see chapter Install the 2 kW mains cable 3 Fit the housing see chapter Closing the 2 kW de...

Page 37: ...ect a USB flash drive with the latest software If a suitable file has been found on the USB flash drive the Update menu item appears Select and confirm this for the update to start Do not unplug the USB flash drive during the update When the update is complete the device starts automatically 37 EN ...

Page 38: ...pears in the submenu In the service menu enter the serial num ber with the associated checksum check sum and serial number can be seen on the rating plate and confirm with Save ATTENTION If there is no Checksum on the rating plate of the device please contact Technical Support If the serial number does not match the checksum an X is displayed next to Save and it must be entered again 38 ...

Page 39: ...Service menu comprises two sub menus Device Tests function tests Option Tests option tests ATTENTION The Device tests function tests menu item must be used to reset error 551 Hardware change detected 1 Carry out the Device Tests function tests see chapter TARGET NOT FOUND 39 EN ...

Page 40: ...evice 1 1 Fit the insulating foil 2 2 1 1 Fit the front panel of the housing from above 2 Fit two M4x10 TX20 screws Tightening torque 2 5 Nm 3 2 1 If present fit the LED strip 2 Bend the grounding lug into position 3 Connect the display 40 ...

Page 41: ...Place the housing cover and 4 fit four M4x10 TX20 screws Tightening torque 2 5 Nm 1 1 1 Fit the device frames with two M4x10 TX20 screws Tightening torque 2 5 Nm 1 1 If present push in the LED diffuser strip 41 EN ...

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Page 43: ...Safety Inspections 43 ...

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Page 45: ...le to perform a particular test the examiner must decide whether the safety of the device can nevertheless still be verified The examiner bears full responsibility and liability for this decision Justifications for the resulting decision must be documented in the test record under Comments Area of applica tion A safety inspection must be performed after any repair maintenance or modification work ...

Page 46: ...es measures must be adopted to pre vent dangerous contact voltages The measuring range must cover at least 0 25 mA to 19 mA The testing equipment must evaluate the measured current as an effective value regardless of the waveform Fluke 6200 A3 S Contact current The effective inner resistance of the contact current measuring device must be 1 kW to 2 kW Should the current measuring circuit be inadve...

Page 47: ...nd current capacity of mains cables As the way the cables are laid and insulated the ambient temperature and the current capacity can vary the requirements set out in IEC 60364 5 52 are to be observed when changing mains leads Also refer to the applicable requirements and standards in your country Housing and cov ers All housing components insulation components and protective covers must be presen...

Page 48: ... charging system 9 Measuring line Example measuring the ground conductor resistance The measurement is taken between the ground terminal of the device and every conductive part that can be touched and that is connected to the ground conductor Should the original mains cable be with the battery charging system the measure ment must be taken between the earthing of the mains cable and every conducti...

Page 49: ...tages 500 V the test voltage of the measuring device is 500 V for all measurements The insulation resistance must not fall below the following values Measurement Measured value Primary Earth 1 MW Secondary Earth 1 MW Primary Secondary 2 MW Communication Secondary 2 MW Communication Primary 2 MW Communication optional inputs 2 MW Legend Primary AC L1 and N Secondary DC DC and DC Earth PE Communicat...

Page 50: ...etc Connect the mains cable Re connect the DC cables to the battery Note battery voltage take safety precau tions Once the battery charging system has been connected switch it back on The battery charging system must be in charge mode when measuring the ground conductor current as otherwise the measurement result will be unreliable Only the leakage currents that occur at grid frequency may be incl...

Page 51: ...g an ammeter on the N and L conductors PE L1 1 2 9 9 9 N PE L1 N mA 1 Measuring device 2 Battery charging system 9 Measuring line Example measuring ground conductor current dir ectly on the battery charging system using the differ ential current method As with an FI switch the currents between the outer conductor s L and the neutral conductor N are compared using a converter The difference is disp...

Page 52: ...ween a grounded point and the conductive part that can be touched and that is not connected to the ground conductor The contact current must not exceed 0 5 mA PE mA L1 1 2 9 N PE L1 N 9 8 6 2 Ri 1 2kΩ 1 Measuring device 2 Battery charging system 6 2 Touchable conductive part not connected to the ground conductor 8 Isolated setup of test piece 9 Measuring line Ri 1 2 kW 6 2 6 2 Example 6 2 Conducti...

Page 53: ...nge detected is shown To acknowledge this error the serial num ber must be entered correctly and the function tests must be passed Function test in the service menu The battery charging system must be operated in short circuit use the designated adapter Output current Measurement using an ammeter Output voltage measurement using a multimeter the device must be operated in open circuit Open the con...

Page 54: ...menu item consists of two additional options Device tests Options tests The Device Tests menu item contains three tests Fan Test Current Test charging current measurement Voltage Test output voltage meas urement 54 ...

Page 55: ...he menu item once the test has been completed Measuring the charging current Preparations Short circuit the charging lead Prepare the charging current meas urement To start measuring the charging current set the Current Test menu item to ON The charging current Current and voltage Voltage are displayed for checking A tick appears next to the menu item once the test has been completed 55 EN ...

Page 56: ... item and its submenus have been used successfully the error 551 Hardware change detec ted is reset Other function tests in the Ser vice menu Checking of function that also has to be performed All housing components insulation components and protective covers must be present and undamaged Check that all screw connection torques are correct Switching the battery charging system back on again Check ...

Page 57: ...under no load AC disconnection battery charging system must switch off DC disconnection battery charging system must stop charging Switch on AC and DC The correct operation of the indicators and controls must be checked Indicators and control elements Check display for correct function Check that controls work in line with the operating instructions 57 EN ...

Page 58: ...both the measured values and the equipment calibration data used If an individual test cannot be performed the resulting decision must be justified and documented by the examiner Any device that fails a test must be clearly marked as unsafe and the operator informed The device may no longer be used The Safety inspection test record is available on the Fronius Partnerweb 58 ...

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Page 60: ...S INTERNATIONAL GMBH Froniusstraße 1 A 4643 Pettenbach AUSTRIA contact fronius com www fronius com Under www fronius com contact you will find the addresses of all Fronius Sales Service Partners and locations ...

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