FRO­NIUS Selectiva 2040 User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from 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

Contents
General information 5
Foreword and safety instructions 7
Area of application of these instructions 7
General 7
Safety 7
Explanation of safety notices 8
Warning notices on the device 8
Warning notices inside the device 9
National Fronius Technical Support (TSN) 9
Ordering spare parts 9
Protective measures against ESD 10
Tools and measuring devices 11
Tools required 11
Measuring and testing equipment 11
Replacing components 13
General 15
Safety 15
ESD guidelines 16
Opening the device 17
Opening the 2 kW device 17
Replacing the display PC board 19
Remove the display PC board 19
Installing the display PC board 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 module 35
Installing the power module 36
Update 36
Enter serial numbers 38
Closing the device 40
Closing the 2 kW device 40
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
3
EN

Rating plate and warning stickers 47
Electrical tests 48
Ground conductor resistance 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

General information
5

6

Foreword and safety instructions
Area of applica-
tion of these
instructions
These Service Instructions apply to the following products:
2 kW 2.0
- Selectiva 2040 (4,010,460)
- Selectiva 2050 (4,010,461)
- Selectiva 2060 (4,010,462)
- Selectiva 2070 (4,010,463)
- Selectiva 4020 (4,010,470)
- Selectiva 4035 (4,010,471)
2 kW 2.0 Banner
- Selectiva 2040 (4,010,460,380)
- Selectiva 2050 (4,010,461,380)
- Selectiva 2060 (4,010,462,380)
- Selectiva 2070 (4,010,463,380)
- Selectiva 4020 (4,010,470,380)
- Selectiva 4035 (4,010,471,380)
General The information contained in these Service Instructions is intended only for the use of
qualified service engineers. Do not carry out any actions other than those described in
the documentation. This also applies to qualified personnel.
Maintenance and repair work must only be carried out by an authorised specialist. It is
impossible to guarantee that externally procured parts are designed and manufactured to
meet the demands made on them, or that they satisfy 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 risks:
- Death or serious injury to the operator or a third party
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the device
All persons involved in commissioning, operating, maintaining and servicing the device
must fulfil the following criteria:
- They must be suitably qualified
- They must strictly adhere to the instructions contained in these Service Instructions
In addition to the Service Instructions, all applicable local rules and regulations regarding
accident prevention and environmental protection must also be followed.
All safety and danger notices on the device:
- Must be kept in a legible state
- Must not be damaged
- Must not be removed
- Must not be covered in any way or painted over.
7
EN

Any equipment malfunctions which might impair safety must be remedied before the
device is turned on.
This is for your personal safety!
Explanation of
safety notices DANGER!
Indicates immediate danger.
▶If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.
▶If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.
▶If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
Warning notices
on the device
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.
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.
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 disconnect the charging cable!
Explosive gases. Prevent flames and sparks.
Provide adequate ventilation during charge!
Toujours arrêter la charge avant de déconnecter le câble de charge!
Gaz explosifs. Éviter les flammes et les étincelles.
Prévoir une ventilation adaptée pendant la charge!
¡Detener siempre la carga antes de desconectar el cable de carga!
Gases explosivos. Evitar llamas y chipas.
¡Mantener una ventilación adecuada durante la carga!
Interrompere sempre la carica prima di scollegare il cavo di carica!
Gas esplosivi. Evitare fiamme libere e scintille.
Predisporre una ventilazione adeguata durante la carica!
WARNUNG - WARNING - ATTENTION
ADVERTENCIA - AVVISO
42,0409,0419
8

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.
Warning notices
inside the device 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 device must be disconnected from the mains before starting any
work with the housing 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.
UDC 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)
National Fronius
Technical Sup-
port (TSN)
Please contact your national Fronius Technical Support (TSN) team with any fault ana-
lysis queries.
Ordering spare
parts
For information on spare parts, refer to the Online spare parts catalogue (OETK) at:
https://spareparts.fronius.com
9
EN

Protective meas-
ures against ESD
When performing servicing 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

Tools and measuring devices
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
11
EN

12

Replacing components
13

14

General
Safety DANGER!
Risk of death due to contact with live components when the device is open.
An electric shock will cause serious injury or death.
▶Before opening, switch off the device properly.
▶Unplug the device from the mains.
▶Secure the device to prevent it being switched on again and affix a sign.
▶Using a suitable measuring instrument, ensure that electrically charged components
(e.g. capacitors) have been discharged.
DANGER!
Risk of death due to contact with live components when the device is open.
An electric shock will cause serious injury or death.
▶If the device is switched on with the housing open, do not touch the components
inside the housing.
▶Only use suitable measuring or test probes.
DANGER!
Risk of death due to contact 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 result in serious injury or death.
▶Only trained and authorised service technicians may perform the described activit-
ies.
▶Observe all safety instructions and warnings.
NOTE!
Failure to perform servicing work properly can result in damage to property.
▶Only trained and authorised service technicians may perform the described activit-
ies.
▶Observe all safety instructions and warnings.
A safety inspection must be carried out after replacement, modification, maintenance or
repair work on any component (see chapter Safety Inspections).
15
EN

ESD guidelines NOTE!
Observe ESD guidelines when handling electronic 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

Opening the device
Opening the 2 kW
device
1
If present, the LED diffuser strip must be
removed.
1Remove the LED diffuser strip.
1
1
1Undo the 2 M4x10 TX20 screws on
the device frame.
2
1
1
1
1
1Undo the four M4x10 TX20 screws.
2Remove the housing cover.
17
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23
1Bend the grounding lug upwards.
2Disconnect the display.
3If present, remove the LED strip.
1
1
2
1Undo the two M4x10 TX20 screws.
2Pull the front panel of the housing
upwards and remove it.
1
1Remove the insulating foil.
18

Replacing the display PC board
Remove the dis-
play PC board
1Open the device (see chapter Open-
ing the device).
1
1Open the insulating foil.
1
2
1
1
1Undo the three 4x9 TX20 tapping
screws.
2Take the display PC board out of the
display spacer frame.
19
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Installing the dis-
play PC board
1Remove the protective film from the
display PC board.
1
1
1
2
1Place the new display PC board on
the display spacer frame.
2Fit the display PC board with three
4X9 tapping screws.
Tightening torque = 1.5 Nm
1
1Close the insulating foil.
ATTENTION! ?
Make sure that the insulating foil is
between the display and the housing.
20