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Safety measures and precautions
Trouble-shooting and repairs must be performed by a qualified
electrician!
Potentially lethal grounded voltages!
Always use isolating transformer!
Never connect more than one unit to isolating trans-
former! Keep unauthorised persons away from unit!
Disconnect unit from power supply when not under
supervision!
! Danger of injury caused by unit slipping or falling!
Position charger horizontally and firmly on a solid base. Allow
for unit weight!
Keep workplace clean and tidy!
Clear up tools, measuring instruments and Ieads immediately
after use!
Following repairs, perform safety check with tester as per
DIN VDE 0702 (0701) Partl or in Iine with local safety
regulations!
Testers and tools
* Multimeter e.g. Bosch Digital MMD 301 (0 684 500 301) or
commercially available.
* Volt-ammeter ETT 011.00 from Bosch (0 684 101 100) or
variable precision resistor (rating: 500...2000W) and ammeter
(range 0...200A).
* Variable isolating transformer.
* Test battery: 12V/66 Ah.
* Screwdriver for socket-head Torx bolts (TX25)
* Tester as per DIN VDE 0702, Part1 or in line with local safety
regulations
Testing and trouble-shooting
When testing, watch out tor base contacts, dirty and corroded
plug contacts and kinked/crushed Ieads!
Test step 1:
lncoming/outgoing inspection
1. Check current input at idle and timer S1:
Activate circuit breakers F1 and F2.
Connect charger via variable isolating transformer (230V) and
ammeter to mains.
Set timer to max. charging time and then back to 5 minutes
(1 division = 5 minutes). lt must be heard to tick.
Mentally note or jot down "on" time.
After approx. 5 minutes timer must switch off.
Check no-load current during this period (±10% tolerance):
Switch S2:
Stage 1
Stage 2
Stage 3
Stage 4
Rapid/start stage
lf set values are exceeded, renew transformer.
Reset S2 to stage 1, wait until timer switches off.
After switch-off there must not be any flow of no-load current.
Set timer to continuous charging and then after a short time to zero (0).
No-load current must fbow during this period.
2. Check charging current (only if item 1 OK):
Connect charger to battery (battery voltage approx. 11...12V)
and Bosch volt-ammeter ETT 011.00.
Activate circuit breakers F1 and F2.
3. Connect charger to mains socket, set switch S1 to continuous
charging.
Load battery with tester until following levels are reached
Stage 1
Stage 2
Stage 3
Stage 4
Rapid/start stage
Ammeter af charger must also show reading.
All functions OK?
Yes:
Charger is in proper working order
Perform safety testing as per DIN VDE 0702 (701), Part1 or in Iine
with local safety regulatians!
Check whether each housing secticn has at least 2 bolts with
toothed lack washers!
No:
lf only the ammeter is not working, see test step 3,
item 1. Otherwise continue with test step 2
0.15A AC
0.19A AC
0.23A AC
0.30A AC
2.0A AC
equal to/greater than 28A rms
equal to/greater than 37A rms
equal ta/greater than 45A rms
equal to/greater than 56A rms
equal ta/gr-eater than 150A rms
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