Power Saver BC-012-20A User manual

Three Stages
BATTERY CHARGER
BC–012–20A
SERVICE MANUAL
Warning!
Qualified personnel who are familiar with the risks involved
and relevant regulations may only carry out maintenance and
repair work.
To avoid electrical shock and short circuit causing
component damage, disconnect input power cable before
working on the device. Safety instructions are required to be
observed at all times.

CONTENTS
ASSEMBLY DRAWING AS1
SYSTEM BLOCK DIAGRAM BD1
TROUBLESHOOTING
Problems & Solutions TS1
PCB Connection and Part List TS2
Checking Procedures TS3~TS4
COMPONENT LOCATION LY1
CALIBRATION PROCEDURES CA1
SCHEMATIC DIAGRAM SD1~SD3

DRAWN APPD TITLE: PART NO.
KM BANKU PowerSaver S
y
stem Block BC-012-20A
CHKD DATE SHEET REV.
TM 10/06/2005
Computer Power Ltd Diagram 01/01 F

DRAWN APPD TITLE: PART NO.
KM BANKU PowerSaver BC-012-20A
CHKD DATE SHEET REV.
TM 10/06/2005
Computer Power Ltd Assembly 01/01 F

DRAWN APPD TITLE: PART NO.
KM BANKU PowerSaver S
y
stem Block BC-012-20A
CHKD DATE SHEET REV.
TM 10/06/2005
Computer Power Ltd Diagram 01/01 F

TROUBLESHOOTINGGUIDE TS1
A. Assembly procedures
Follow the assembly drawing AS1, remove the cover and keep all parts for further assembly.
1. Remove SC1 x 4
2. Remove SC2
3. Disconnect CN8
4. Remove PN1 lower cover
5. Disconnect CN2, CN3, CN5 and CN7.
6. Remove SC3 X 4 and SC4 X 2.
7. Remove PN2 top cover, to allow inspection on component side.
8. Remove SC5.
9. Remove PN3 bottom cover, to allow checking the component from solder side.
10. Hold the PC board carefully. To prevent damage of the components along the PC
board side, do not bend the left and right hand side heatsink.
11.Remove the SC6 X2 and SC7 X 2 screws from heatsink only when the transistor
or diode is required to be changing.
12. Remove SC8 and NU1.
Symptom Possible cause and solution
AC input is normal but
the LED display are off.
Check input fuse F2.
If F2 fuse blown up then
follow the checkpoints.
1. Check Q1~Q6.
2. Check R8, R12, R35~R36.
3. Check D3, D4, D6 and D33.
4. Check C3~C4.
5.After verified above components are in good condition,
then re-install F2 fuse of same type and rating.
AC input and the LED
display are normal but no
DC output, check fuse F1
if blown up.
1. Check D7, D8 and D17.
2. After verified above components are in good condition,
then re-install the F1 fuse of same type and rating.
AC input and DC output
are normal but LED
display and charging
mode are abnormal.
1. Check CN2, CN3 and CN7 connection.
2. Check Q9 and Q10.
3. Check D34~D38.
4. Replace above component if necessary.
Cooling fan is not working
if the device is getting
hot..
1. Check CN5 connection.
2. Check Q14.
3. Replace above component if necessary.

TROUBLESHOOTING GUIDE TS2
B. PC Board Connection:
Modules Symbolic implications
MAIN BOARD
W1
CN2
CN3
CN5
CN7
CN8
GROUND
LED DISPLAY BOARD
BATTERY SELECTOR
COOLING FAN
VOLTAGE SELECTOR
POWER SUPPLY SELECTOR
LED DISPLAY BOARD
CN2 TO MAIN PC BOARD CN7
C. PARTS LIST
Main PC Board:
1. T1 : TRANSFORMER
2. Q1 ~ Q4 : TRANSISTOR JP13009
3. F1 : OUTPUT DC FUSE
4. F2 : INPUT AC FUSE
5. C3~C4 : E CAP 4.7UF/ 50V
6. R8, R12, R35, R36 : RESISTOR 5.1 OHM 1/4W
7. D3~D4 : DIODE HER305
8. D6, D33 : DIODE MBR20100
9. D17 : DIODE 1N5404
10. D7~ D8 : DIODE 30CTQ060
11. Q9~ Q10 : TRANSISTOR C1815-Y
12. D34 ~ D38 : DIODE 1N4148
LED Display Board:
1. LD1, LD2 : GREEN LED
2. LD3 : YELLOW LED
3. LD4 : RED LED

TROUBLESHOOTINGGUIDE TS3
D. Equipment Setup:
Perform the following checking procedures, setup the equipment as
followings:
1. DC Power Supply 1.5A or above , set to 12.0VDC.
2. Oscilloscope (OSC) 20MHz or above x 1
Set the Time/Div to 2.0 us and set the Volt/Div to 2 Vdc.
3. Digital Multi-Meter (DVM) , set to DC Volt.
E. Checking procedures:
Follow the assembly drawing AS1, remove the cover and keep all parts for
further assembly
1. Refer to the components location LY1.
3/!Connect the DC power supply (-) to the battery charger output (-). !
Connect the DC power supply (+) to the F1 fuse FC1.
3. Set the DVM to DC Volt, connect the (+) to U1 pin 12 and connect the (-)
to U1 pin 9. The normal reading should be between 10~12VDC. ( If the
reading is out of this range, check if the equipment DC power supply
setup is correct or not)
4. Connect the OSC (+) to U1 pin 8 and (-) to U1 pin 9 to check the wave
form and then connect (+) to U1 pin 11 and (-) to U1 pin 9 to check the
waveform again. The following wave form (fig.1) should be appeared
otherwise U1 is damaged.
Fig.1

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KM BANKU PowerSaver Com
p
onents BC-012-20A
CHKD DATE SHEET REV.
TM 10/06/2005
Computer Power Ltd Location 01/01 F

Battery charger calibration procedures CA1
A. Equipment Setup:
Perform the following calibration procedures, setup the equipment as followings:
1. Adjustable Electronic Load, 30A 30VDC or above.
2. Digital Multi-Meter (DVM).
B. Calibration procedures:
1. Check insulation tape must good condition on the heatsink both sides. Replace new tape
if any damaged.
2. Re-assembly the parts as per assembly drawing AS1 carefully.
Connect CN2, CN3 and CN7 onto the PC board but keep the cover open until the
calibration procedures are completed.
3. Select the battery selector to “GEL” and the Voltage selector to 13.2VDC
4. Connect the DC Electronic Load (+) to the charger output (+), the DC Electronic Load (-)
to the charger output (-).
5. Connect the DVM (+) to the charger output (+)., DVM (-) to the charger output (-).
6. Set the DC Electronic Load to “zero” , connect the Charger to 230VAC, the CHARGER
ON
And FLOAT LED should light up. If not back to page TS1.
7. Set the DC Electronic Load to “5A”, the CHARGER ON and ABSORPTION LED will light
up. If the ABSORPTION LED is not light up then adjust the VR5 to keep the
ABSORPTION LED light up.
8. Switch the battery selector from “GEL” to “FLOODED”, the DVM should read between
14.4~14.8VDC. If not then adjust the VR2 to get the reading between 14.4~14.8VDC.
9. Switch the battery selector to “GEL”, the DVM should read between 14.0~14.4VDC, if not
then adjust the VR3 to get the reading between 14.0~14.4VDC.
10. Set the DC Electronic Load to “1A”, the CHARGER ON and FLOAT LED will light up. the
DVM should read between 13.0~13.4VDC. If not then adjust the VR4 to get the reading
between 13.0~13.4VDC.
11. End of calibration, re-assembly the cover.

VR
VR
VR
AUX
AUX
AUX
VR
AUX
AUX
V+
AUX
V+
7
9 8
8
C9
+
C10
+
R18
T2
T2
D13
Q5
D14 R26
R24
D10
R31
R
R29
R32
C19
C16
R30
C17
C18
R21
C13
C12
+
VR1
R20
R33
C14
+
D6
1
3
2
R22
C11
+
R40
C30
+
Q7
D33
1
3
2
CN3
1
2
3
VR3
VR4
R27
VR2
R28
C15
R39
R37
J2
J3
D39
C39
+
R59
Q11 D40
R60
R61
C40
C42
C43
C44
C20
+
CN1
1
2
3
D11
D12
Q6
R94
D17
CN7
1
2
3
R96
R97 R98
R99
CN8
1
2
T1
15
13
3
1
7
5
9
18
11
2
C59
+
R100
R23
R25
L1
2
1
C41
D7
D8
R15 C8
R14 C7
R62
R57
VR5
C36
+
R34
Q8
ZD1
R95 D9
F1
C28
R19
R38
U2
+ -
3
2
6
7
5
4
8
1
U1
GND
7
VCC
12
11
22
33
44
55
14
14
15
15
16
16
9
9
66
13
13
10
10
8
8
11
11
D5
U3-10
U3-11
T1-PIN9
T1-PIN5
U2-PIN4
CN8-PIN1
DRAWN APPD TITLE: PART NO.
KM BANKU PowerSaver
BC-012-20A
CHKD DATE SHEET REV.
TM 10/06/2005
Computer Power Ltd
Schematic
02/03 F

5
4
1 2
3
4
R2
R3
C1
+
C2
+
T2
D1
R5
C3
+
R7
1/4W
R8 Q1
D3
R9
C4
+
R11
Q2
D4
D2
T2
C5
Q3
R35
R12
R10
Q4
C21
RT2
t
BR1
-+
C24
C25
L2-1
L2-2
C26
V1
CN4
1
2
3
F2
R58
J1
RT1
t
R6
R36 C6
R13
T2
T1-PIN5
T1-PIN9
DRAWN APPD TITLE: PART NO.
KM BANKU
PowerSaver
BC-012-20A
CHKD DATE SHEET REV.
TM 10/06/2005
Computer Power Ltd Schematic
01/03 F

V+
AUX
V+
V+
V+
V+
V+
V+
V+
V+
V+
V+
VR
VR
VR
VR
VR
VR
VR
VR
VR
VR
VR
VR
CN2
1
2
3
4
5
6
7
8
R42
R43
C31
+
Q9
D34
R51
Q10
D35
R50
D38
R47
R52
R54
C33
D36
R53
U3A
+ -
7
6
1
U3C
+ -
9
8
14
U3B
+ -
5
4
2
U3D
+ -
11
10
13
D37
C38
R46
U4B
+ -
5
4
2
R76
R77
R79
D50
R78
D51
D52
R84
U4A
+ -
7
6
1
R81
R82
D53
R83
C49
+
Q16
R92
C51
R85
R93
C52
C53
C54
C37
R44
R41
R86
R80
R55
C32
R66 C55
R65
R75
R74
CN5
1
2
R68
R70
R67
R71
D49
D46
U4C
+ -
9
8
14
R69
C58
D47
Q14
C56
U4D
+ -
11
10
13
D48
R73
D54
R91
Q15
R90
C50
R88
R87
R89
R72
R48
R45
R
R49
C57
RT7
U3-11
U3-10
U3-6
U4 Pin4
CN2 Pin1
CN8-PIN1
U1-PIN4
U3-6
DRAWN APPD TITLE: PART NO.
KM BANKU
PowerSaver
BC-012-20A
CHKD DATE SHEET REV.
TM 10/06/2005
Computer Power Ltd
Schematic
03/03 F