Introduction and maintenance

method of intelligent high frequency

charger
1 Schematic Diagram and Structure

2 Trouble Shooting

3 Maintenance
Schematic Diagram and Structure
Block diagram of high frequency charger

High frequency switching power supply

High frequency charger
Structure
Master switch
Start button Stop button
Nameplate
LCD Cable Rack Warning sign
Operation guide

Precautions

Case
-Front
side view Case- Back side view

LOGO

AC input
Waterproof
plug
DC output
－DIN European standard connector
Internal View
Cable Rack
Master switch AC input line Handle slot
Charger module Handle slot

Copper bar DC power supply Air filter

CAN communication board DC output line
Exploded View

High frequency charging

module
Family of high frequency intelligent charger 3KW-30KW series
(appearance patent product)
Fault Codes and Trouble Shooting
Charger display status and status description
Status display status State description
Self-checking Check whether the battery is faulty, whether it is allowed to charge, and whether the
charger itself is faulty
Ready The self-test is normal and can be charged, please connect the battery and the charger
Charging The battery is charging
Stop charging The charging has been stopped when battery has not been fully charged
SOC is equal to 100% or the charging voltage reaches 98% of the set voltage, BMS issues a
finished charging
stop charging command
The input voltage of the charger is higher or lower than the input voltage range, please
check whether the grid voltage range is within the normal working voltage range of the
Abnormal grid
charger, and whether the zero live wire is connected according to the requirements of the
machine manual
Fan failure Module fan works abnormally
Please connect the The output cable is not connected to the battery or the hardware connection is poor,
battery please check whether the charger DC output connector is connected to the battery
No battery voltage Communication is established, but the charger does not detect the battery voltage
No charge The battery is not allowed to be charged by the charger and is issued by the BMS. Please
check whether the battery status is normal
Fault code and description
Code Fault description
The output voltage of the charger is higher than the preset value, please check the output voltage of the
E01
charger and contact after-sales support
The output current of the charger is higher than the preset value, please check the output current value of
E02
the charger and contact after-sales support
The communication between the internal modules of the charger is faulty, please check whether the
E03
communication bus between the internal modules of the charger is connected normally
The temperature of the charger is higher than the set value, the charger is over-temperature protected,
E04 please check whether the dust net is covered with dust and other foreign objects, affecting the charger's
heat
The output of the charger module is short circuit, please use a multimeter to test the output resistance
E09
value of the module, and contact after-sales support
The battery voltage is too high, issued by BMS, please check whether the battery voltage value is
EB1
abnormal
The battery current is too large, it is sent by BMS, please check whether the battery current value is
EB2
abnormal
The communication between the charger and the BMS is faulty. The charger cannot detect the BMS
EB3 message. Please check whether the communication between the charger and the battery BMS is
established.
The battery temperature is too high, which is sent by BMS. Please check if the battery temperature value is
EB4
abnormal
Detailed description of troubleshooting methods
Error code Troubleshooting method
1. Reconnect the charging module and the main control board after power off,
including the communication line
2. Power on again and check whether the fault still exists
E01,E02,E03
3. If the fault persists, please contact the after-sales replacement module or
control board(Refer to the steps in Part 3 for removing the module）
After switching to a certain module, the fault is eliminated, it can be determined
Identify the
that the fault is caused by the module, the module needs to be sent back to the
problem
manufacturer for analysis and maintenance
1. First visually check whether the cooling and dustproof nets on both sides of
the charger are clean
2. If it is not clean, please cut off the power to clean up the dust;(Refer to the
E04
corresponding steps in Part 3 for removing the air filter）
3. It is possible to power on without dust net and try to troubleshoot
This fault is generally caused by the excessively high internal temperature of the
Identify the
charger due to untimely heat dissipation, and daily cleaning and maintenance of
problem
the heat dissipation and dustproof net
Detailed description of troubleshooting methods

Error code Troubleshooting method

1. After power off, measure the positive and negative ends of the charger's
output with the ohm of the multimeter to check whether it is in a short
E09 circuit state
2. If it is in a short circuit state, please contact the after-sales replacement
module.(Refer to Part 3 for module replacement)
This fault is usually caused by a short circuit in the internal rectifier module
Identify the of the charger, resulting in a short circuit in the output. Replace the module
problem row in turn to find out which module caused the overall short circuit
1. You can try to replace the charged battery system to check whether the
fault still exists；
EB1,EB2,EB4 2. If there is no problem with other charging systems, you can contact the
battery manufacturer to deal with the problem.

Identify the This kind of problem is generally caused by a problem in the battery system,
problem so first eliminate the problem on the battery side.
Detailed description of troubleshooting methods

Error code Troubleshooting method

1. First check whether the charger and battery connectors are inserted into
EB3 place
2. Use a multimeter to measure whether the CAN resistance of the two
holes of the communication pin of the connector is 120Ω
3. Disconnect the connector of the charger and connect the brown and
blue line communication to the debugging charger
4. Check the communication protocol of the charger according to the
battery used by the customer (manufacturer)
If there is no resistance of 120Ω at both ends of the CAN pin, it is
preliminarily determined that the communication cable is disconnected or
Identify the
disconnected. You need to disassemble the charger connector to check
problem
and confirm that the communication cable is disconnected or
disconnected.
Detailed description of troubleshooting methods

Error code Troubleshooting method

1. Check whether the client grid is normal
2. Check whether the power supply line is connected according to the
requirements of the manual
Charger open 3. Disconnect the input power, open the MCB to determine whether the
circuit trip switch is OK
4. Turn off the power supply at the input end of the module in turn to check
which module affects the trip

If the MCB is not tripped after disconnecting the input power of one of the
Identify the
modules, it is determined that the MCB trip caused by the fault of the
problem
disconnected module requires replacing the corresponding charger module.
Maintenance
Daily maintenance
1、For daily use, pay attention to clean the dust on the air filter in time.
2、Don’t use the charger in harsh environments such as high temperature, high humidity and very dusty.

Left air filter

Right air filter

Software upgrade

Some function upgrades of the charger can be supported

The main control board is here
through software update. The following are the steps for how to
update the software:
1. Turn off the charger.
2.Remove the air filter screws on the output side of the charger
and remove the air filter.
3.Remove the metal cover of the auxiliary power supply and the
main control board.
4.The main control board of the charger can be seen on the left
side inside the chassis.
 Software upgrade

5. Find the USB port on the control board.

Program
upgrade
USB
interface

6. Plug the U-driver loaded software into the USB port, and turn on the charger. The software will
update automatically.
Main control board replacement
Proceed as follows:
1. Turn off the charger and remove it from the power grid.
2. Remove the air filter screw on the output side of the charger and
remove the air filter.
3. The main control board of the charger can be seen on the left side
inside the chassis.
4. Unplug the display cable, switch cable, and bus cable.
5. Use a Phillips screwdriver to remove the communication cable.
6. Use a Phillips screwdriver to remove the four screws in the four corners
of the control board and remove the control board.
(The cable location can be seen in the next page.)
Main control board
（3KW）
Cable and connectors on the main control board

Program burning port Program burning port

Switch cable socket
Switch cable socket
Display cable
socket USB port Display cable
socket

Bus port

Bus port CAN communication connector

CAN communication cable
connector
Main control board replacement

The installation steps of the control board are opposite to the removal steps; after
installation, the program is burned in the following two ways:
The First way:
1. Insert the U disk into the USB port on the main control board.
2. Turn on the charger, then the software will be updated automatically.
The Second way:
1. Connect the software writer by program burning port .
2. Select the software by the LCD screen of the writer.
3. Push the “START” button. Then the software will be updated.
Replace the module

The following are the steps to remove the charger's faulty module:
1. Use a Phillips screwdriver to remove the M4 fixing screws on the air filter on both sides of
the charger, and remove the air filter.（ The red circle in the figure below shows the position
of the M4 screws on the dustproof nets on both sides ）

M4 screw M4 screw

Right side Left side

Replace the module
2. Use an external hex wrench or Phillips screwdriver to remove the M5 fixing screws on
both sides of the module;（ Figure 1 shows the location of the screws used to fix the
module in the red circle, and Figure 2 is the detailed view ）

M5 fixing nut

figure 1 figure 2
Replace the module
3. Use an external hex wrench to remove the M5 fixing screws of the positive and negative
fixing copper bars of the module output.
4. Unplug the CAN communication cable connected to the module on the CAN
communication connection board.（ Figure 3 is an external view of the charger after
removing the air filter, and Figure 4 is a detailed view ）

AC input line

CAN
communication line Output positive
and negative
CAN communication copper bars
connection board M5 fixing screw
figure 3 figure 4
Replace the module

5. Use a Phillips screwdriver to remove the AC input cord.（ Figure 5 is the external view of the
charger after removing the air filter, and Figure 6 is the detail view ）
6. Pull out the module.

AC input line

Module AC input line

figure 5 figure 6
Replace the module

The following is the difference between 24V and 48V/80V/120V CAN communication connection
board:
1. 24V charger CAN communication connection board connected to 8pin terminal
2. 48V/80V/120V charger CAN communication connection board connected to 4pin terminal block

4pin communication 8pin communication

cable cable

4pin communication
8pin communication
cable
cable
Replace the module

The following are the steps to install a new charger module:

1. Install the AC input cable
2. Plug in the CAN communication line
3. Install the M5 fixing screws of the positive and negative fixing copper bars of the module
output
4. Install four M5 fixing screws on both sides of the module (it is recommended to pre-
tighten the
copper bar and the module first)
5. Power-on test
6. Install the dust filter on both sides of the charger
Replace the power switch

The following are the instructions for replacing the air switch
(pictured right):
1. First disconnect the main power supply at the input end of the
charger, then use a screwdriver to remove the box cover on the
power switch face of the charger
2. Loosen the 4 screws of the lock wire above and below the switch
and remove the upper and lower wires
3. Pull down the bayonet behind the switch and remove the switch
by hand
4. Take a switch and hang it on the upper edge of the bracket, then
push the snap spring firmly into the bracket
5. Lock the wires at the upper and lower ends of the switch
according to the thread removal sequence. After locking, pull and
pull with hand to check for lock
6. Finally, the chassis cover can be locked with screws.
 Charger output connector replacement
The following are the instructions for replacing the charger output connector:
1. Before removing the connector, use a Phillips screwdriver to remove the two screws fixed on the handle of the
connector, and then remove the screws of the upper and lower wire buckles.
2. Use needle-nose pliers to withdraw the voltage pin, and then use a small flat screwdriver to pry off the limit cover
3. After the above is disassembled, the output line and the communication line can be directly taken out of the connector,
and the connector is disconnected as shown in Figure 1
4. When installing, first put the cable into the position of the communication line inside the REMA head (note the
direction), and insert the output line of the communication line according to the position in Figure 2
(Must be in the end, the brown wire and the red of the main cable of the cable are all close to the "+" pole side), and
then use the limit cover to lock the DIN pin
5. Straighten the wire, take the wire buckle at the position shown in Figure 3 and use 2# screws to compact the output
wire tightly, take the handle and install it in the fixing hole, Turn over and tighten with 1# screw as shown in Figure 4;
6. According to the specifications and voltage requirements of the charger, insert the voltage pin into the REMA head, and
the displayed value is shown in Figure 4. Figure 5 shows the connector accessories.

图1 图2 图3 图4 图5