FRO­NIUS Selectiva 2040 2kW User manual

/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0264,EN 013-22082018
Selectiva 2040 2kW
Selectiva 2050 2kW
Selectiva 2060 2kW
Selectiva 2070 2kW
Selectiva 4020 2kW
Selectiva 4035 2kW
Service manual
Battery charging system
EN

2

3
EN
Contents
General information 5
Foreword and safety instructions ............................................................................................................... 7
Safety.................................................................................................................................................... 7
Protective measures against ESD ........................................................................................................ 7
Fronius Technical Support.................................................................................................................... 7
Ordering spare parts............................................................................................................................. 7
Service manual contents....................................................................................................................... 7
Tools and measuring devices ............................................................................................................... 7
Changing components.......................................................................................................................... 7
Safety inspection................................................................................................................................... 8
Appendix............................................................................................................................................... 8
Tools and measuring devices .................................................................................................................... 9
General ................................................................................................................................................. 9
Tools required....................................................................................................................................... 9
Measuring and testing equipment......................................................................................................... 9
Function overview ...................................................................................................................................... 10
Device concept ..................................................................................................................................... 10
Intended purpose.................................................................................................................................. 10
Warning notices on the device.............................................................................................................. 10
Warning notices inside the device ........................................................................................................ 11
Software update.................................................................................................................................... 11
Technical data....................................................................................................................................... 11
Options.................................................................................................................................................. 11
Control panel......................................................................................................................................... 12
Error location aid 15
Service codes ............................................................................................................................................ 17
Safety.................................................................................................................................................... 17
General ................................................................................................................................................. 17
Service codes ....................................................................................................................................... 17
Customer service.................................................................................................................................. 23
Changing components 25
General ...................................................................................................................................................... 27
Safety.................................................................................................................................................... 27
ESD guidelines ..................................................................................................................................... 27
General ................................................................................................................................................. 27
Overview............................................................................................................................................... 27
Opening the device .................................................................................................................................... 28
Opening the Selectiva........................................................................................................................... 28
Replacing the display................................................................................................................................. 30
Replacing the graphic display............................................................................................................... 30
Replacing the mains cable......................................................................................................................... 31
Replacing the mains cable.................................................................................................................... 31
Replacing the charging lead ...................................................................................................................... 34
Replacing the charging lead ................................................................................................................. 34
Replacing the fan ....................................................................................................................................... 36
Replacing the axial fan.......................................................................................................................... 36
Changing the internal battery..................................................................................................................... 38
Changing the internal battery................................................................................................................ 38
Replacing the power module ..................................................................................................................... 39
Replacing the power module ................................................................................................................ 39
Closing the device...................................................................................................................................... 41
Closing the Selectiva ............................................................................................................................ 41

4
Safety Inspections 43
Safety Inspections...................................................................................................................................... 45
Safety inspection................................................................................................................................... 45
Responsibility........................................................................................................................................ 45
Area of application ................................................................................................................................ 45
Inspection staff qualifications................................................................................................................ 45
Measuring instruments.......................................................................................................................... 45
Visual inspections ...................................................................................................................................... 47
General ................................................................................................................................................. 47
Mains supply and connecting lines ....................................................................................................... 47
Housing and covers .............................................................................................................................. 47
Adjustment and display devices............................................................................................................ 47
Rating plate and warning stickers......................................................................................................... 47
Electrical tests............................................................................................................................................ 48
Ground conductor resistance................................................................................................................ 48
Insulation resistance ............................................................................................................................. 48
Ground conductor current..................................................................................................................... 50
Contact current ..................................................................................................................................... 52
Function tests............................................................................................................................................. 53
General ................................................................................................................................................. 53
Entering serial numbers........................................................................................................................ 53
Function tests in the service menu ....................................................................................................... 54
Other function tests in the Service menu.............................................................................................. 56
Mains power on/off equipment.............................................................................................................. 57
Indicators and control elements............................................................................................................ 57
Documentation........................................................................................................................................... 58
Documentation...................................................................................................................................... 58
Appendix 59
Circuit diagrams: Selectiva 1~ 2kW ........................................................................................................... 60

General information

7
EN
Foreword and safety instructions
Safety
Protective meas-
ures against ESD
Danger of damage to electrical components from electrical discharge. Suitable measures
should be taken to protect against ESD when replacing and installing components.
Fronius Technical
Support
Please contact your national Fronius Technical Support team with any fault analysis que-
ries.
Ordering spare
parts
Please contact your national Fronius Technical Support team to order spare parts or to
consult on fault analysis queries.
Service manual
contents
Each chapter in the service manual deals with one complete topic. Use each chapter as a
self-contained source of information. A short description of each chapter follows:
Tools and meas-
uring devices
This provides an overview and description of all equipment required for servicing the de-
vice professionally. This equipment includes:
- Tools required
- Measuring and testing equipment
Changing compo-
nents
The "Changing components" section describes how to replace components that:
- have no instructions of their own for replacement and
- require detailed replacement instructions
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. All activities described in the Service Instructions must only be carried out by
Fronius-trained service technicians. Pay particular attention to the "Safety rules"
section in the Operating Instructions for the battery charging system.
WARNING! An electric shock can be fatal. Before opening the device:
- Unplug the device from the mains
- Disconnect the device from the battery
- Put up an easy-to-understand warning sign to stop anybody inadvertently
switching it back on again
- Using a suitable measuring instrument, check to make sure that electrically
charged components (e.g. capacitors) have been discharged.
WARNING! An electric shock can be fatal. If the device needs to be switched on
briefly for testing while the housing is open:
- Do not touch any parts inside the housing
- Only touch parts using suitable measuring or test probes
WARNING! An inadequate ground conductor connection can cause serious inju-
ry or damage. The housing screws provide a suitable ground conductor connec-
tion for earthing the housing and must NOT be replaced by any other screws
which do not provide a reliable ground conductor connection.

8
The "Component-specific data" leaflet, which is enclosed with the replacement part, must
be completed and returned to Fronius.
Safety inspection This section outlines the safety inspection for the device described in this service manual.
It has been structured in compliance with "DIN VDE 0701-0702" and "ÖVE/ÖNORM
E8701-1".
Please also be aware of the requirements and standards relevant to your country, as the
measured values or steps taken during the tests may vary.
Should there be no relevant requirements and standards in your country, Fronius recom-
mends that this test should still be carried out.
Appendix The Appendix contains the complete Spare Parts List and Circuit Diagram for the device.

9
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Tools and measuring devices
General "Tools and measuring devices" offers an overview and description of all equipment needed
to service the device professionally. This equipment includes:
- Tools required
- Measuring and testing equipment
- Ancillary materials
Tools required - Torx screwdriver, TX20
- Torx screwdriver, TX25
- Slotted screwdriver, 3 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

10
Function overview
Device concept The new single-phase Selectiva battery charging systems for 24 V and 48 V batteries fea-
ture a brand new charging process. The successful Active Inverter Technology with the
revolutionary Ri charging process adapts itself to the requirements of the battery and only
charges the battery with the current that it actually needs.
Intended purpose The charger is only for charging batteries as described in the "Technical data" section. Any
use above and beyond this purpose is deemed improper. The manufacturer shall not be
liable for any damage resulting from such improper use. Utilisation in accordance with the
intended purpose also comprises
- following all the information in the operating instructions
- regular checking of the mains and charger leads
Warning notices
on the device
WARNING! Charging dry batteries (primary cells) and non-rechargeable batter-
ies can cause serious injury or damage, and is therefore prohibited.
A number of safety symbols can be seen on the charger's rating plate. The safety sym-
bols must not be removed or painted over.
Do not dispose of used devices with domestic waste. Dispose of them according
to the safety rules.
Possible sources of ignition, such as fire, sparks and naked flames, must be kept
away from the battery.
Risk of explosion! Oxyhydrogen is generated in the battery during charging.
Battery acid is corrosive and MUST be kept away from eyes, skin and clothes.
Ensure an adequate supply of fresh air during charging.
Do not use the functions until you have read all the Operating Instructions.
IP21
1~ NPE 230V 50/60Hz
xxA
xxV
xxxxW
xxA
www.fronius.com
WARNING
Explosive gases. Prevent flames and sparks.
Provide adequate ventilation during charge!
Always stop charging before you disconnect the charging cable!
OVC III
U
AC nom.
I AC max.
P AC max.
U DC nom.
I DC max.
Part No.:
Ser. No.:
Protective class I
XXXX
xxxxxxxx
xxxxxxxx
4,010,xxx
Selectiva xxxx
2 kW

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EN
Warning notices
inside the device
Software update The battery charging system can be updated using a USB stick. Detailed instructions for
the update process can be found in the relevant operating instructions.
Technical data Please refer to the operating instructions for the technical data of the device variants.
Options For information on the connection, function, maintenance and use of options, please see
the Operating Instructions and User Information supplied with the options.
WARNING! An electric shock can be fatal. The housing must never be opened
by anyone other than a service technician trained by the manufacturer. The de-
vice must be disconnected from the mains before starting any work with the hous-
ing open. A suitable measuring instrument must be used to ensure that
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.
Condensador tiempo de descarga < 2 min.
Condensatore tempo di scaricamento < 2 min.
U DC nom. xxV
Part No.:
Ser. No.:
1
2
1 Display
2 Battery CR2032
Ext. Start Stopp (1)
Temperature
controlled charging
Not connected (3)
CAN High (5)
(4) Not connected
(6) CAN Termination
(8) CAN Termination
(10) +13V
(2) Ext. Start Stopp
Temperature
controlled charging
CAN Low (7)
CAN GND (9)

12
Control panel
No. Function
(1) Display
Displays the current charging parameters
Displays settings
(2) "Menu" key
Selects the desired menu
Selects the appropriate symbol to return to the previous display
(3) Up/down keys
Select the desired menu item
Set the desired value
(4) Stop/Start key
For interrupting and resuming the charging process
Confirms a menu item or setting
(5) "Battery cooled down" indicator (blue)
Indicates that a battery has cooled down and is ready for use
On steady: After charging has finished, the set cooling time or optionally the bat-
tery temperature has been reached.
Flashes every second: The water refill indicator has also tripped. More informa-
tion can be found under "Additional functions" in the "Display" section.
(6) "Fault" indicator (red)
On steady: The charger outputs an error. The current conditions do not allow prop-
er charge. While the red indicator is on, charging cannot take place (charging in-
terrupted). The relevant status code appears in the display.
Flashes briefly every 3 seconds: The charger outputs a warning. Charging is
continued despite the adverse charging parameters. The relevant status code and
the state of charge appear alternately on the display.
(1) (8)
(7)
(6)
(5)
(4)(3)(2)

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EN
(7) "Charge" indicator (yellow)
On: During charging
Flashes: If charging has been interrupted
(8) "Battery charged" indicator (green)
On steady: Charging ended.
Flashes every second: Charging ended. The water refill indicator has also
tripped.

14

Error location aid

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EN
Service codes
Safety
General These service codes help to localise and - where technically possible - rectify faults with
the device on-site.
The following information is given for every service code:
- Reason the service code is displayed
- The relevant troubleshooting measure
Service codes
If a fault occurs during operation, specific status codes may be displayed. Faults can result
from the following:
- Battery is connected with reverse polarity
- The voltage of the connected battery is unsuitable
- The device has overheated
- There is a software or hardware fault
- Faults that occur during the charging process (e.g.: Timeout in I1 phase)
If an error message appears on the display and if you cannot resolve the error yourself
WARNING! An electric shock can be fatal. Before opening the device:
- Unplug the device from the mains
- Disconnect the device from the battery
- Using a suitable measuring device, ensure that electrically charged compo-
nents (e.g. capacitors) are fully discharged
- Restrict access to the working area
- Take steps to ensure the metallic surfaces of the device cannot be touched
- Suitable protective clothing and/or equipment must be worn when carrying
out the test or the repair
Causes without status code:
Cause: Blank screen
Remedy:
- Check whether the mains voltage is within the permitted range
- Check wiring
- Replace the display
- Replace power module
Cause:
Faulty display (segments, symbols faulty / not displayed)
Remedy:
- Check wiring
- Replace the display
- Replace power module

18
Cause: Buttons not working
Remedy:
- Check wiring
- Replace the display
- Replace power module
Status codes caused by external factors:
11 Cause: Mains undervoltage or overvoltage
Remedy:
- Check whether the mains voltage is within the permitted range
- Replace power module
13 Cause: External temperature sensor faulty
Remedy:
- Check wiring and temperature sensor
- Replace power module
14 Cause: Electrolyte circulation pump faulty (pressure switch not switching)
Remedy:
- Clean air filter
- Check hosepack for damage
- Check device fuses
- Check that the electrolyte circulation pump is working
- Replace power module
16 Cause:
The External Start-Stop function is activated, but the contacts provided for this are
not closed when charging is started or during charging.
Remedy:
Check if the contacts are closed or if there is bad contact. When disconnecting the
battery, the service code is reset.
17 Cause:
The charger detects an idle three times during a charge and the battery remains
connected. This can happen especially with a bad transition between battery con-
nector and charging connector, for example due to worn charging contacts.
Remedy:
Check the DC connection between the charger and the battery to make sure all
contacts are OK. When disconnecting the battery, the service code is reset.
Status codes in the event of a battery fault:
22 Cause: Battery undervoltage
Remedy:
- Check device settings
- Deep discharge battery
- Replace power module
23 Cause: Battery overvoltage
Remedy:
- Check device settings
- Check type of battery and battery voltage
- Replace power module
24 Cause: Battery too hot (external temperature sensor only)
Remedy:
- Check battery and if necessary, place in a suitable environment
- Check device settings (check limit values)
- Replace power module

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EN
25 Cause: Battery too cold (external temperature sensor only)
Remedy:
- Check battery and if necessary, place in a suitable environment
- Check device settings (check limit values)
- Replace power module
26 Cause: Cell fault detected (RI characteristic)
Remedy:
- Check battery - measure voltage of individual cells > faulty battery
- Check battery for parallel loads - change characteristic if necessary
- Replace power module
29 Cause: Battery is connected with reverse polarity
Remedy:
- Check wiring on the DC side
- Replace power module
Status codes in the event of a charging error:
31 Cause: Timeout in I1 phase
Remedy:
- Check device setting for battery capacity (Ah)
- Check battery voltage, battery temperature, water level, etc.
- Replace power module
32 Cause: Timeout in U1 phase
Remedy:
- Check device setting for battery capacity (Ah)
- Check battery voltage, battery temperature, water level, etc.
- Replace power module
34 Cause: Ah limit exceed
Remedy:
- Check device setting for battery capacity (Ah)
- Check battery voltage, battery temperature, water level, etc.
- Replace power module
35 Cause: Timeout in I2 phase
Remedy:
- Check device setting for battery capacity (Ah)
- Check battery voltage, battery temperature, water level, etc.
- Replace power module
36 Cause: Target voltage in I2 phase not reached (with format characteristic only)
Remedy:
- Check battery voltage, battery temperature, water level, etc.
- Replace power module
37 Cause: Problem with RI charge
Remedy:
- Timeout during main charging phase
- Check assignment of charger to battery size in relation to the charging time
that has been set (design table!)
- Check battery voltage, battery temperature, water level, etc.
- Replace power module
38 Cause: Set charging time cannot be reached
The time in which the battery has to be completely charged is too short!
Remedy:
- Check set time
- Replace power module

20
Status codes in the event of a device fault / primary circuit:
500 Cause: Primary temperature sensor faulty
Remedy:
- AC reset (restart device)
- Replace power module
503 Cause: Primary overtemperature
Remedy:
- Check device location
- Check ambient temperature
- Clean fan
- Replace power module
504 Cause: Ventilator current outside the tolerance
Remedy:
- Clean fan
- Install the fan correctly
- Replace the fan
- Replace power module
505 Cause: Intermediate circuit undervoltage or overvoltage
Often happens in combination with "status code 11"!
Remedy:
- Check the mains voltage
- AC reset (restart device)
- Replace power module
507 Cause: Primary supply voltage outside the tolerance
Remedy:
- AC reset (restart device)
- Replace power module
508 Cause: Power failure
Remedy:
- Check mains, mains connection and/or mains cable
- Peak current interruption (AC reset (restart device))
- Replace power module
510 Cause: Primary EEPROM faulty
Remedy:
- AC reset (restart device)
- Software update
- Replace power module
527 Cause: Phase shifter overcurrent
Remedy:
- AC reset (restart device)
- Software update
- Replace power module
530 Cause: Primary communication not working
Remedy:
- AC reset (restart device)
- Software update
- Replace power module
532 Cause: Microcontroller - fault (e.g.: division by 0)
Remedy:
- AC reset (restart device)
- Software update
- Replace power module