Service Manual FP2 Rectifier Family

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
10
EXPERIENCES FAILURES
10
WHEN IS THE RECTIFIER OK?
10
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 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
20-24Vdc, varying
Rectifier running:
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.

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Service manual Flatpack 2

Start-up power on the primary side

Power when rectifier runs

Supply to the secondary from the battery side

USING SOFTWARE FOR DIAGNOSIS

PLEASE SAVE THESE BROKEN PARTS

WHEN IS THE RECTIFIER OK?

Rectifer not running

Power when rectifier runs

Supply to the secondary from the battery side

Rectifer not running

The boost of 241115.100

Output air measurement

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

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

Using software for diagnosis

Please save these broken parts

The small controller cards

This is important to constantly improve quality

When is the rectifier OK?

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