IEB FILON FUTURE RF450 Service Manual

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CHARGING SYSTEMS - RESONANCE FREQUENCY TECHNOLOGY

We get electricity into shape.

Service manual

Rev.-No.: EN-1.4.2

FILON FUTURE

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Page 1 CHARGING SYSTEMS - RESONANCE FREQUENCY TECHNOLOGY We get electricity into shape. Service manual FILON FUTURE Rev.-No.: EN-1.4.2 © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 2 Imprint Notes on the instructions The safe operation of the charger requires knowledge that this Service manual provides. The information thus provided has been presented in a concise and well-structured form, with the sections, sub-sections and pages being consecutively numbered. These Service manual documents chargers of the type FILON FUTURE.
Page 3: Table Of Contents
Table of Contents General matters concerning these service manual Safety Explanation of signs and symbols ..................... 7 Qualification of the personnel ......................7 Intended use ............................. 8 Safety instructions on trouble-shooting and maintenance ..............9 Components Power module IEB770 EU ....................... 10 Power module IEB770 US .......................
Page 4 7.5.1 Initial test ............................48 7.5.2 Functional test ..........................49 7.5.3 Module test ............................50 7.5.4 Module replacement ........................51 Repair measures Module fuses ........................... 52 8.1.1 Fuse ratings on name plate ......................53 8.1.2 Fuse ratings EU modules ........................ 53 8.1.3 Fuse ratings US modules ........................
Page 5 Table of Contents Cleaning, inspection and maintenance ................... 76 Disposal ............................77...
Page 6: General Matters Concerning These Service Manual
All documents are protected under the copyright law. Neither the documents as a whole nor extracts thereof must be copied or passed on to any third parties without the consent of the owner. Nor is the usage of the documents’ contents allowed, unless explicitly approved. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 7: Safety
- The operator must have been familiarized with the charging process of the batteries concerned and their handling by having been given special instructions or by having attended training sessions. - Only specialist personnel assigned to their job must work on the charger. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 8: Intended Use
The charger must only be put into operation with the Directive (2014/30/EU) on Electromagnetic Compatibility being observed. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 9: Safety Instructions On Trouble-Shooting And Maintenance
Modifications, additions or conversions that may affect the safety must not be made without the manufacturer’s approval! This shall also apply to the installation and setting of safety devices. Special care shall be taken that spacings, clearances and air paths are not reduced. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 10: Components
CAN connection of the power module fan connection and pilot contact DSP card with CAN termination resistor FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 11: Power Module Ieb770 Us
CAN connection of the power module fan connection and pilot contact DSP card with CAN termination resistor 3.3 EC pump EC pump controller card for the electrolyte circulation FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 12: Housing Options
RF460 (only EU) 290 [11.5] 550 [21.7] 100 [4.0] min. 12.5 [28] RF480 (only US) 430 [17.0] 305 [12.1] 145 [5.8] min. 14.5 [32] Example of the housing RF450 FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 13: Arrangement Of The Components In The Charger
The chargers can be installed as stand-alone or wall-mounted units, depending on the place of use. The mains plugs and charging plugs are installed according to the customer's requirements. The same applies to the color design of the housing. The different housing variants are shown below as examples. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 14: Housing Rf450
This housing variant is only used for EU power modules. power module graphic display (touch screen) charging cable housing door (front) mains cable with mains plug feet charging plug processor card LED display and USB unit FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 15: Housing Rf455
EC pump LED display and USB unit controller card for the electrolyte circulation graphic display (touch screen) FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 16: Housing Rf460
This housing variant is only used for US power modules. power module LED display and USB unit charging cable graphic display (touch screen) mains cable with mains plug housing door (front) charging plug processor card FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 17: Housing Rf550
EC pump LED display and USB unit controller card for the electrolyte circulation graphic display (touch screen) mains terminal housing door (front) FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 18: Housing Rf560
EC pump LED display and USB unit controller card for the electrolyte circulation graphic display (touch screen) mains terminal housing door (front) FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 19: Housing Rf650
EC pump LED display and USB unit controller card for the electrolyte circulation graphic display (touch screen) mains terminal FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 20: Housing Rf750
EC pump charging plug controller card for the electrolyte circulation LED display and USB unit mains terminal graphic display (touch screen) FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 21: Housing Rf950
EC pump charging plug controller card for the electrolyte circulation LED display and USB unit mains terminal graphic display (touch screen) FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 22: Housing Rf1250
4.2.10 Housing RF1250 RF1250 with 12 power modules FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 23: Wiring Diagrams
From 4 modules upwards, an additional terminal block is installed, which divides the mains input cable and enables the connection of several modules per phase. Jumpers are inserted in the terminal block for the neutral conductor (yellow). FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 30: Mains-Side Wiring Us Modules
From 5 modules upwards, an additional terminal block is installed, which divides the mains input cable and enables the connection of several modules per phase. In some cases, bridges are inserted in the terminal block (yellow). FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 31 4 US modules mains-side wiring of 5 US modules FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 36: Charger Settings
- Use the arrow keys to select the desired setting. The parameters of the selected charging curve are displayed on the right. - Confirm the selection of the charging characteristic with "OK". FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 37 - The changed characteristic is activated. - Press the Pause button between 1.5s and 3s to exit the programming mode. - Briefly press the pause button to return the charger to standby mode. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 38: Setting The Service Characteristic (Formation, Desulphation)
(of approx. 3 A/100 Ah) for 24 hours. After the end of the desulphation charging, a charge with the standard setting of the relevant characteristic will be applied with a delay of 30 min, so as to charge the battery to its full capacity. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 39: Expert Mode
- When pressing the button "Expert" on the touchscreen for more than 1 sec, the charger opens the password protected menu. - Type in the password 1234. - The Expert menu will be opened. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 40: Change Charging Parameters In Expert Mode
The following charging profiles can be set, depending on the selected battery type: - IUoU - IUIoIa - IEBfutur - Desulphation 24 hours - Desulphation 48 hours - Desulphation 72 hours FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 41 The standard setting of the relevant charging characteristic will again be automatically activated after three successful formation charges. The formation charge can be activated/deactivated only for the battery type flooded (PzS). FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 42: Read Out Charging History
- A formatted USB stick is available. - The firmware file is stored in the main directory of the USB stick. - The firmware file name is "image512.hex" (rename if necessary, upper/lower case is irrelevant). FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 43 After typing in the password 1234 the process is triggered via the menu item "software update" when the USB stick is inserted. A battery must not be connected. The rest of the procedure is identical to the above procedure. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 44: Troubleshooting And Correction
- communication with connected peripheral devices impaired temperature fault - internal temperature fault TEMP - external temperature fault (optional) FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 45: Error Messages Via The Graphic Display (Touch Screen)
The graphic display (touch screen) of the operating and display unit is used to indicate errors and the status of the device. The error message is displayed in the middle of the screen, as shown in the figure below. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 46: Warnings
7.4 Warnings Warnings will not interrupt the charging process; they merely draw the user’s attention to that fact that there is a problem which is affecting the charging process. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 47: Troubleshooting Flowcharts
If the fault continues, do get in touch with the service technician. x = flashing 7.5 Troubleshooting flowcharts The following flowcharts support you in the targeted troubleshooting and elimination of errors. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 49: Functional Test
7.5.2 Functional test FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 51: Module Replacement
7.5.4 Module replacement FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 52: Repair Measures
- Perform regulation tests on the charger (DGUV V3, TRBS 2131, VDE 0701-0702 as required). - Put the battery charger back into operation and check that it operates correctly. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 53: Fuse Ratings On Name Plate
8.2 Operating and display unit ! W a r n i n g Before carrying out any work with the charger, the safety instructions in chapter "Safety" must be observed! FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 54: Description Of The Operating And Display Unit
When opening the housing door, make sure that the earthing cable attached to it is not damaged or torn off and that no screws etc. fall into the charger. Remove all metallic objects that have fallen into the charger! FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 55: Power Modules
Due to special operating conditions or customer requirements, there may be deviations from the assignment between charger and power modules. Therefore, the nominal voltage of a module to be replaced must also be checked with the installed modules. These must always be identical. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 56: Check Power Modules
CAN connecting cable battery connection (left side: battery plus, right side: battery minus) FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 57 - The housing of the battery charger should not be opened until 5 minutes after disconnecting the device from the battery and mains. This will allow the capacitors to discharge. - Remove the housing screws from the housing doors. - Open the housing door to the side. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 58: Replace Power Modules
The nominal voltage of the new power module must match the nominal voltage of the installed power module. Charger with one power module For a single-module charger, lift the power module upwards after loosening the additional screw (PE connecting cable) in the bottom of the housing. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 59 For multi-modular chargers, the power modules are held in guide rails. The individual steps for module replacement in a multi-modular charger are illustrated below: closed, multi-modular charger without graphic display FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 61 Tighten the screws on the battery busbar connected to the power modules (M6) to 4 Nm. Tighten the nuts on the battery busbar to which the charging cable is attached (M8) to 12 Nm. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 62: Processor Card
Charging is indicated via the LED card and optionally via the graphic display (touch screen). The operating and display unit on the housing door contains the pause button and the USB card. This enables the firmware to be updated and the load history to be read out. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 63: Module Fans
When opening the housing door, make sure that the earthing cable attached to it is not damaged or torn off and that no screws etc. fall into the charger. Remove all metallic objects that have fallen into the charger! FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 64: Replace Module Fan
- Perform regulation tests on the charger (DGUV V3, TRBS 2131, VDE 0701-0702 as required). - Put the battery charger back into operation and check that it operates correctly. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 65: Control Card For Device Options
When opening the housing door, make sure that the earthing cable attached to it is not damaged or torn off and that no screws etc. fall into the charger. Remove all metallic objects that have fallen into the charger! FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 66: Replace Control Card For Device Options
When the charging process is prematurely interrupted, the battery will not be sufficiently charged, so its available capacity will be reduced. The pump can only be re-started after the battery has been disconnected. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 67: Check Ec Pump
When opening the housing door, make sure that the earthing cable attached to it is not damaged or torn off and that no screws etc. fall into the charger. Remove all metallic objects that have fallen into the charger! FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 68: Remote Display (External Display) (O)
8.8.1 Check remote display Procedure: - Check external wiring. - Disconnect external wiring. - Open the remote display. - Check internal wiring and repair if necessary. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 69: Replace Remote Display
When opening the housing door, make sure that the earthing cable attached to it is not damaged or torn off and that no screws etc. fall into the charger. Remove all metallic objects that have fallen into the charger! FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 70: Replace Temperature Sensor On The Battery
Remove all metallic objects that have fallen into the charger! Procedure: - Disconnect the temperature cabling from the processor card. - Remove the cable from the plug socket. - Replace temperature sensor. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 71: Aquamatic Function (O)
The advanced opening of the pilot contact will automatically stop the charging process, so that the charging current doesn't flow anymore. This will prevent the formation of sparks when the battery is separated from the charger. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 72: Id Chip (O)
In chargers with the ID chip option, alternative characteristic curves may be stored in the other program locations in order to carry out charging without the ID chip if necessary. In this case, make sure that the charger/characteristic curve and the battery are correctly assigned. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 73: Timer (O)
- The housing of the battery charger should not be opened until 5 minutes after disconnecting the device from the battery and mains. This will allow the capacitors to discharge. - Remove the housing screws from the housing doors. - Open the housing door to the side. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 74: Replace Li-Ion Can Interface
When opening the housing door, make sure that the earthing cable attached to it is not damaged or torn off and that no screws etc. fall into the charger. Remove all metallic objects that have fallen into the charger! FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 75 - Perform regulation tests on the charger (DGUV V3, TRBS 2131, VDE 0701-0702 as required). - Put the battery charger back into operation and check that it operates correctly. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 76: Maintenance
- The housing of the battery charger should not be opened until 5 minutes after disconnecting the device from the battery and mains. This will allow the capacitors to discharge. - Remove the housing screws from the housing doors. - Open the housing door to the side. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 77 Deliver electronic scrap to your company’s internal disposal department, if there is one, which will see that the scrap is passed on the relevant specialist disposal firms. The packaging of the charger shall be disposed of separately. Paper, cardboard and plastic can be recycled. FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 78 Housing RF750 Terminating resistor CAN Bus Housing RF950 Tightening torques Housings Timer - I - - W - ID chip Warnings Initial test Weight Inspection - L - Li-Ion chargers FILON FUTURE Service manual © 2021 IEB Industrie Elektronik Brilon GmbH...
Page 80 Industrie Elektronik Brilon GmbH Almerfeldweg 40 – D 59929 Brilon Fon: +49 (0)2961/9607-0 Fax: +49 (0)2961/9607-77 www.ieb.de – info@ieb.de Service manual FILON FUTURE B30/B31 - EN - Status January 2021 - Subject to content and technical changes without notice.

This manual is also suitable for:

Filon future rf455 Filon future rf460 Filon future rf480 Filon future rf550 Filon future rf560 Filon future rf650 ... Show all

IEB FILON FUTURE RF450 Service Manual

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