(Gil document code 64840201-Z1687) Energy Storage Unit

SERVICE MANUAL: ENERGY STORAGE UNIT

Contents

1. INTRODUCTION..........................................................................................................................4

2 TECHNICAL DATA .....................................................................................................................5

2.1. General Data ................................................................................................................5
2.2. Battery Pack Data ........................................................................................................5
2.3. Battery charger group (SP)........................................................................................................7
2.4. Equipment Classification and Relevant Standards .......................................................8
2.5. Conditions for Transport and Storage ...........................................................................8
2.6. Standards .....................................................................................................................9
2.7. Electrical interfaces.......................................................................................................9
2.7.1. Battery charger power board (SP1).....................................................................................10
2.7.2. Battery charger control board (SP2) ....................................................................................11

3. INSTALLATION .........................................................................................................................14
3.1. Setting to work ............................................................................................................14
3.2. Functional description .................................................................................................14
3.2.1. ZCS Resonant control ......................................................................................................14
3.2.2. Battery charger fault and SCR gate ...............................................................................15
3.2.3. Overcharge.........................................................................................................................15
3.2.4. Overcharge time ................................................................................................................16
3.2.5. Battery voltage % ..............................................................................................................16
3.2.6. Charger current %.............................................................................................................17
3.2.7. Lamp circuit ........................................................................................................................17

4. CORRECTIVE MAINTENANCE...............................................................................................19
4.1. Fault finding of the Energy storage unit ......................................................................19

5. REPLACEMENT .........................................................................................................................20
5.1. Replacing small fuses .................................................................................................20
5.2. 55 A Fuse ...................................................................................................................20

6. ADJUSTMENTS..........................................................................................................................21
6.1. checking Battery V max. and frequency calibration ...................................................21
6.2. Test points ..................................................................................................................21

7. SPARE PARTS LIST ..................................................................................................................23

4522 129 05272/10318000 (00.1) 3

(Gil document code 64840201-Z1687) Energy Storage Unit

1. INTRODUCTION

The Energy Storage Unit is a rechargeable battery assembly consisting of a battery pack,
battery charger and control box interface. The Energy Storage unit is intended for use with the
HF Generator in the BV300 plus system plus and BV Pulsera series of Mobile Surgical
stands.

This document has been originally written in English language.

WARNINGS

1) use an isolated scope

2) disconnect the plus and negative contacts on the battery before replacing fuses
3) do not touch HV parts

The warning label on the battery charger box means that HIGH VOLTAGE is
present inside the box. Once the box is opened, it is necessary to proceed
very carefully because high voltage leads (on relays SP1-Z1 and SP1-Z2) are
exposed. Touching these leads could cause injury.

4522 129 05272/10318000 (00.0) 4

(Gil document code 64840201-Z1687) Energy Storage Unit

2 TECHNICAL DATA
NOTE
The Energy Storage Unit must be powered by medical insulating transformer as required for
C-UL Certification
2.1. GENERAL DATA

Temperature
Operational temperature 10° C < T < 40° C
Cooling Internal fan

Dimensions
Size 360 x 260 x 299 mm max. (width x length x height)
Mass 36 kg

Mains data
Voltage 230 Vac ± 10%
Mains frequency 50/60 Hz
Mains current 1.5 A

Charging data
Current see Fig 1
Charge percent see Fig 2

Loading Data
Output voltage 234-366 Vdc ( ± 2,5 V )
Output current 50 A max.

2.2. BATTERY PACK DATA

Temperature
Storage: -25° C to 55° C Short term ( 5 weeks )
-25° C to 40° C Long term
Charging: -25° C to 40° C
Decharging: -25° C to 40° C

NOTE
The life of the battery is shortened when the temperatures exceed those given above.
Incorrect charging/discharging can also result in a shortened life.

Dimensions of assembled battery pack

Size 360 x 260 x 294 mm max. (width x length x height)
Mass 32 kg

Batteries
Type 6 cells monoblock (Hawker energy 0819-0020)
4522 129 05272/10318000 (00.0) 5
(Gil document code 64840201-Z1687) Energy Storage Unit

Number 26
Voltage 12 Vdc (each battery)
Charge 2.5 Ah

Figure 1 shows the values of the current and voltage during the battery charge. V1 indicates
the battery voltage that can be measured between Sp2 (+Batt) and Sp5 (−Batt). C1 indicates
the corresponding battery charge current measured between Tp1 and Tp6.

C1

V1

Fig 1 Values of current and voltage during the normal battery charge

4522 129 05272/10318000 (00.0) 6

(Gil document code 64840201-Z1687) Energy Storage Unit

0% 20% 40% 60% 80% 100%

ON 370
charge 313 319 326 335 352 367
OPEN circuit 307 312 320 326 332 337
360

350

340
voltage (V)

ON charge
OPEN circuit
330

320

310

300
0% 20% 40% 60% 80% 100%
charge (%)

Fig 2 Battery charge function of the voltage during the normal battery charge

2.3. BATTERY CHARGER GROUP (SP)

The battery charger is controlled by a Unitrode UC 3867, ZCS resonant controller. It uses an
ON time set by the UC3867and can vary from 5 µs till about 12 µs and variable frequency
technique, less than 1 kHz when the battery pack is fully charged to 65 kHz when the battery
pack is fully discharged.
The charging current is a function of the battery voltage.

Is present the ability to perform an overcharge till 402,5 V ± 2,5 V.

The battery charger presents three variable frequency outputs (0 Hz till 10 kHz) indicating the
battery voltage status, the charge current status and the elapsed overcharge time.

Dimensions of the charger group

Size (w/o cables) 211 x 250 x 72 mm max.
Mass 4 Kg

Charge
Full charge Voltage 366 ( ± 2.5 V )
Full charge Current <20mA
Maximum charge current approx. 450mA
4522 129 05272/10318000 (00.1) 7
(Gil document code 64840201-Z1687) Energy Storage Unit

Fuses
Mains feeding fuse SP1- F1 1.6 A (5x20 Type T)
Mains feeding fuse SP1- F2 1.6 A (5x20 Type T)
auxiliary transformer feeding fuse SP1- F3 100 mA (5x20 Type T)
Battery charge output fuse SP1- F4 1 A (5x20 Type T)
Energy storage output fuse SP1- F5 55 A (19.4x78.3 Type FF)
Auxiliary circuits fuse (+12V) (not replaceable) SP1- F6 160 mA (5x20 Type T)
Auxiliary circuits fuse (+12 Vac) (not replaceable) SP1- F7 400 mA (5x20 Type T)
Vcache fuse (+5V) (placed outside the charger) SP1- F8100 mA (5x20 Type T)

2.4. EQUIPMENT CLASSIFICATION AND RELEVANT STANDARDS

Type of protection against electric shock: Class I

Degree of protection against ingress of water: None
Method of sterilization or disinfection: None
Degree of safety for anesthetics: None
Mode of operation: Continuous connection to mains in charging state.

2.5. CONDITIONS FOR TRANSPORT AND STORAGE

The following values are applicable when the Energy Storage Unit is contained in the
packaging provided by manufacturer.

Environmental
Temperature: -25° C to 40° C long term
-25° C to 50° C short term ( 5 weeks )
Pressure: 70 - 110 kPa
Humidity: 5 - 95%

Vibration
Frequency: 10 - 150 Hz
g value: 0-2
Amplitude: 0 - 0.15 mmt

Shocks
g value: 0 - 10 g
Pulse duration: 6 - 10 msec.

4522 129 05272/10318000 (01.0) 8

(Gil document code 64840201-Z1687) Energy Storage Unit

2.6. STANDARDS

The Energy Storage Unit is developed and manufactured with observance of a number of
directives, regulations and standards ( e.g. IEC, UL, CSA). Information regarding the
compliance status with standards and product approvals can be obtained from:

Gilardoni S.p.A.
Quality Assurance Department
Via Arturo Gilardoni 1
23826 Mandello del Lario (LC)
Italy

Fax No.: 39-0341-705111

Tel No.: 39-0341-735046

2.7. ELECTRICAL INTERFACES

For the electrical interfaces of the Energy Storage Unit to the HF Generator, see the table
below:

OUTPUT POWER CABLE CONNECTOR TO HF GENERATOR BACK PANEL SIGNALS

Pin 1-4 P12 Pin 1-4 + BATTERY

Pin 2 P12 Pin 2 Not connected
Pin 3-6 P12 Pin 3-6 - BATTERY
Pin 5 P12 Pin 5 Polarization

For the electrical interfaces of the Energy Storage Unit to the 230 V supply, see the table
below:

CABLE SK1 Wire Description

Connects the Pulsera supply to Battery charger power board

Yellow/green Power GND

Wire 1 230 Vac
Wire 2 230 Vac

Cable SHA4-X1 (Control Unit Cable) Description

Connects the Pulsera System to the Energy Storage Unit, see the table below:

Pin 1. Battery charger fault

Pin 2. Common output
Pin 3. Battery voltage %
Pin 4. Charge current %
Pin 5. Common input ( 5 V )
Pin 6. Z1 ON / OFF
Pin 7. Z2 ON / OFF
4522 129 05272/10318000 (00.0) 9
(Gil document code 64840201-Z1687) Energy Storage Unit

Pin 8. Overcharge enable

Pin 9. Battery charger ON / OFF
Pin 10. Overcharge completed
Pin 11. Overcharge time
Pin 12. N. C.
Pin 13. Overcharge enable OK
Pin 14. Reset
Pin 15. N. C.

Cable SA-H1 (Lamp cable) Description

Connects the Energy Storage Unit to the output LED Lamp , see the table below:

Pins Description
P3 Pin 1 + 12 VAL (max current 100 mA) (UL isolated)
P3 Pin 2 D of Q6 just under P3

2.7.1. BATTERY CHARGER POWER BOARD (SP1)

NOTE
This board does not have adjustable devices. See battery charger control board to set ESU.
T4 transformer: primary 1-5 and secondary 9-10 against 7-6 secondary winding is an isolation
transformer according to UL recognition

The following tables show the battery charge power board connectors and flying leads:

Mains cable W1 - W2 power line

(SK1) Y/G ground

Connector P2 connects the power board to the control board

01 P2 Zero Battery
02 P2 Zero Battery
03 P2 Zero Battery
04 P2 Vcc
05 P2 −Vcc
06 P2 Cache Voltage
07 P2 Zero Battery
08 P2 Voltage feedback
09 P2 Current feedback
10 P2 Battery voltage
11 P2 Fuse detector
12 P2 Current protection 1
13 P2 Current protection 2
14 P2 Z1 command
15 P2 Z2 command
16 P2 Gate drive 1
17 P2 Gate drive 2
18 P2 SCR gate
4522 129 05272/10318000 (01.0) 10
(Gil document code 64840201-Z1687) Energy Storage Unit

19 P2 Led lamp drive

20 P2 Timing

Lamp output P3 Pin 1 + 12 VAL (max current 100 mA) (UL isolated)
P3 Pin 2 D of Q6 just under P3

Connecting the charger to SP 3 + BATT (OUTPUT)

the HF generator SP 6 - BATT (OUTPUT)

2.7.2. BATTERY CHARGER CONTROL BOARD (SP2)

Input voltages: ± 12 V (± 5% )
11V(± 5% ) Vcache when the system is ON
+ 5 V (± 5% ) Vcache when the system is OFF

Protection: maximum loading current

maximum loading voltage

Control inputs: Z1 ON
Z2 ON
Battery charger ON/OFF
Overcharge Enable
Reset

Output signals: Battery charge FAULT

Battery charge level (frequency)
Battery charge current (frequency)
Overcharge time (frequency)
Overcharge Enable OK
Overcharge completed

The following table shows the battery charge control board connectors:

Connector P1 connects the control board to the power board

01 P1 Zero Battery
02 P1 Zero Battery
03 P1 Zero Battery
04 P1 Vcc
05 P1 −Vcc
06 P1 Cache Voltage
07 P1 Zero Battery
08 P1 Voltage feedback
09 P1 Current feedback
10 P1 Battery voltage
4522 129 05272/10318000 (01.0) 11
(Gil document code 64840201-Z1687) Energy Storage Unit

11 P1 Fuse detector
12 P1 Current protection 1
13 P1 Current protection 2
14 P1 Z1 command
15 P1 Z2 command
16 P1 Gate drive 1
17 P1 Gate drive 2
18 P1 SCR gate
19 P1 Led lamp drive
20 P1 Timing

Connector P2 connects the control board to the system control:

01 P2 Battery charger fault (output) (active low)

02 P2 Common output (system ground) ( Input )
03 P2 Battery voltage % (output) (0 – 10 kHz)
04 P2 Charge current % (output) (0 – 10 kHz)
05 P2 Common input ( 5V system) ( Input )
06 P2 Z1 ON / OFF ( Input )
07 P2 Z2 ON / OFF ( Input )
08 P2 N. C.
09 P2 Battery charger ON / OFF (Input)
10 P2 Overcharge completed (output) (active low)
11 P2 Overcharge time (output) (0 – 10 kHz)
12 P2 Overcharge enable ( Input )
13 P2 Overcharge acknowledge (enable OK) (output) (active low)
14 P2 Reset ( Input )
15 P2 N. C.
16 P2 N. C.

Test points

TP1 Charge current feedback 1V = 1A internal test point

TP2 Overcharge time 0 Hz to 10 kHz internal test point
TP3 Charger current % 0 Hz to 10 kHz internal test point
TP4 Voltage feedback internal test point
TP5 Battery voltage % 0 Hz to 10 kHz internal test point
TP6 0 volt reference for each test point internal test point
TP7 Gate driver internal test point

Indicators

D11 yellow lit when the battery charge is below 90%, shut off when the charge is
over 90%
D12 yellow lit when the battery charge is below 90%, shut off when the charge is
over 90%
D13 yellow lit when the battery charge is below 50%, shut off when the charge is
over 50%
4522 129 05272/10318000 (01.0) 12
(Gil document code 64840201-Z1687) Energy Storage Unit

D22 yellow lit when the OVERCHARGE ENABLE signal is received

D23 yellow lit when the BATTERY CHARGER is OFF
D24 yellow lit when the RESET signal is received
D25 yellow lit when the system is ON
D26 red lit when either the BATTERY CHARGER is OFF or there is a fault on the
charger
D27 yellow lit when the system is OFF, when the system is ON the light depends on
the overcharge time
D28 yellow lit when the OVERCHARGE ENABLE signal has been received
D29 yellow lit when an OVERCHARGE cycle has been completed
D30 yellow lit when the Z1 relay is closed
D31 yellow lit when the Z2 relay is closed
D32 yellow lit when the system is OFF, when the system is ON the light depends on
the charge current (higher is the current, higher is the light intensity)
D33 yellow lit when the system is OFF, when the system is ON the light depends on
the battery voltage (higher is the voltage, higher is the light intensity)

Adjustments

RX6 Used to set the 10 V reference voltage (factory set)

R71 Used to set the no load charger voltage at 366 ± 1 V (factory set)
R72 Used to set the Ton at about 7.7µs (factory set)
R116 Used to set the battery voltage to frequency circuit (factory set)
R118 Used to set the battery current to frequency circuit (factory set)

4522 129 05272/10318000 (00.1) 13

(Gil document code 64840201-Z1687) Energy Storage Unit

3. INSTALLATION

For the installation procedure, see ‘Replacement of Energy Storage Unit’ in Section 6 of the
System Manual Corrective Maintenance.

After a replacement, make sure that all the Energy Storage Unit cables are reconnected.

3.1. SETTING TO WORK

Switch ON the system and check whether there is a Battery failure message on the Stand
display.
If the message indicates a need to recharge, the mains plug should be left plugged in for at
least 6 hours. Neither the Mobile Viewing Station or the Stand need to be switched ON for
recharging to take place.

No programming is required for the Energy Storage Unit.

A 24 hour charge time is recommended after installation

The OVERCHARGE MODE is set on the base of the discharges of the battery pack.

3.2. FUNCTIONAL DESCRIPTION

Hereafter is given the functional description of how the ESU battery charger operates.

3.2.1. ZCS RESONANT CONTROL

The heart of the battery charger is the UC3867(SP2 U14) that is a Zero Current Switching
(ZCS) Resonant Mode Power Supply Controller.

Its outputs A (pin 11) and B(pin14) drive the SP1 Q1 and Q2 power switches, the command
pulse train can be tested at Tp7 on SP2.

The maximum switching frequency is about 65 kHz, the minimum is < 1kHz. the frequency
depends on the battery charge status.

The pulse length is set in factory at 7.7 µs ± 10 % turning R72; however the pulse length can
vary depending on the load current flowing in the batteries, with a minimum of 5 µs ± 10 %.
This current is sensed by the SP1 current transformer T3 and fed to pin 10 and pin 15.
If at pin 15 there is a voltage higher than 3 V the UC3867 shuts off, and signal at pin 16 is
low.
The signal at pin 16 in normal condition is 5 V.
It is possible to shut off the battery charger sending low the BATTERY CHARGER ON/OFF
command.
4522 129 05272/10318000 (01.0) 14
(Gil document code 64840201-Z1687) Energy Storage Unit

3.2.2. BATTERY CHARGER FAULT AND SCR GATE

The charger voltage is monitored using the resistor ladder, made by R14, R15 and R16 on
SP1.
The scaled voltage is fed to SP2, here it is compared by Q1A with a 10 V reference and if the
charger voltage is > 10 V than SP1 Q3 is triggered.
Once that Q3 bas been triggered the charger voltage falls to 0 V, the scaled voltage is
compared by Q1B with a reference of about 2.7 V and as the voltage is less than the
reference the BATTERY CHARGER FAULT signal is triggered, the led D26 is lit and the
signal on SP2 1P2 pin is low.

3.2.3. OVERCHARGE
The cyclic overcharge can be carried out only when the system is shut off, the
OVERCHARGE ENABLE signal has been sent, the OVERCHARGE OVER signal is high l
and the battery voltage is greater than about 350 V.

The OVERCHARGE ENABLE signal is sent sending low the signal at SP2 12P2 pin, led D23
lights.
The OVERCHARGE ENABLE OK signal is stored «high» at pin 13 of SP2 U24, it is stored
even if the ESU had to be unplugged, because in this case U24 is fed by the 5 V Vcache.

When the system is shut off the signal at SP2 5P2 pin is low.

The OVERCHARGE OVER signal at pin 12 of SP2 U23 has to be high; this means that time
counter and the OVERCHARGE COMPLETED signal have been reset.

The battery voltage is monitored by a resistor ladder on SP1 made by R19, R20, R21, R22
and R23; the scaled voltage is compared by Q2C with a reference of 7.2 V± 1%. When the
battery voltage is greater than 350 V the OVERCHARGE is enabled, the signal at pin 1 of
SP2 U1 is high.

When the OVERCHARGE is enabled the time count can start too.

When the battery voltage is in the range (402,5 V, 405 V) and the charge current is less than
about 50 mA the OVERCHARGE COMPLETED signal at pin 4 of SP2 U7 becomes low, it is
stored«high» at pin 9 of SP2 U24, it is stored even if the ESU had to be unplugged, because
in this case U24 is fed by the 5 V Vcache.

The OVERCHARGE COMPLETED signal drives low the signal at pin 10 of SP2 P2 and led
D29 is lit. the OVERCHARGE OVER SIGNAL at pin 12 of SP2 U23 goes low, the signal at
pin 1 of SP2 U1 goes low too.
Once the overcharge is completed the battery voltage goes back to about 365V.

The overcharge can be stopped when the time count is in excess of three hours. In this case
the signal at pin 13 of SP2 U2 goes low, it is stored«high» at pin 10 of SP2 U24, it is

4522 129 05272/10318000 (01.0) 15

(Gil document code 64840201-Z1687) Energy Storage Unit

stored even if the ESU had to be unplugged, because in this case U24 is fed by the 5 V
Vcache. The OVERCHARGE OVER SIGNAL at pin 12 of SP2 U23 goes low, the signal at
pin 1 of SP2 U1 goes low too.

3.2.4. OVERCHARGE TIME

The overcharge can be carried out just for a period of three hours at 50 Hz, this time interval
has been chosen not to damage the battery pack.

The time base is taken using the mains frequency taken at pin 7 of the transformer T4 on
SP1.
The timing signal can flow only if the signal at pin 11 of SP2 U16 is high.
The switches of SP2 S1 must be set as follows: 1,2,3,4,5,6,8 are ON, 7 is OFF.
At pin 1 of SP2 U10 there is one pulse every 60 s at 50 Hz ; with the mains at 60 Hz there is
one pulse every 50 s.
The overcharge count is enabled if and only if there not a BATTERY CHARGER FAULT
alarm, the OVERCHARGE has been enabled and the OVERCHARGE COMPLETED signal
has been reset.
The SP2 U5 translates the one per minute pulse count in a current proportional to the time
count; the pin 8 of SP2 U8 converts the current output of U5 at pin 4 in a voltage signal
proportional to the pulse count.
The voltage at pin 8 of SP2 U8 increases of about 40 mA every 60 s at 50 Hz and every 50 s
at 60 Hz.
This voltage is scaled and supplied to pin 7 of SP2 Q4 whose output at pin 3 is a variable
frequency signal, this signal can be picked up at Tp2.
The frequency of this signal is proportional to the overcharge elapsed time as 55.5 Hz every
60 s at 50 Hz and every 50 s
at 60 Hz.
The following table shows the relationship between the overcharge elapsed time and the
frequency of the signal at Tp2.
time, min ( 50 Hz ) 30 45 60 90 120 150 180
time, min ( 60 Hz ) 24 36 48 72 96 120 144
kHz, Tp2 1,5/1,8 2,3/2,7 3,15/3,45 4,7/5,3 6,3/6,9 8,0/8,6 9,7/10,1

The frequency of the signal at Tp2 is supplied at pin 11 of SP2 P2 only when the system is
switched on, in this case the intensity of the light of led D27 depends on the frequency.

SP2 U3 saves the information of the elapsed time even when the ESU is unplugged, because
in this case U3 is fed by the 5 V Vcache.
When the count has reached the 180 min the signal at pin 13 of SP2 U2 goes low, the signal
OVERCHARGE OVER at pin 12 of SP2 U23 goes low too and the overcharge is interrupted.

3.2.5. BATTERY VOLTAGE %

The battery voltage is monitored by a resistor ladder on SP1 made by R19, R20, R21, R22
and R23; the voltage is scaled and fed to pin 7 of SP2 Q7 whose output at pin 3 is a variable
frequency signal, this signal can be picked up at Tp5.

4522 129 05272/10318000 (01.0) 16

(Gil document code 64840201-Z1687) Energy Storage Unit

The following table shows the relationship between the battery voltage and the frequency of
the signal at Tp5.

Batt. Volt 260±1 270±1 290±1 310±1 330±1 350±1 365±1

freq. kHz 1.50/2.10 2.20/2.95 3.70/4.55 5.10/6.25 6.65/7.75 8.30/9.20 9.90/10.10

The frequency of the signal at Tp5 is supplied at pin 3 of SP2 P2 only when the system is
switched on, in this case the intensity of the light of led D33 depends on the frequency.

3.2.6. CHARGER CURRENT %

The charge current is picked up by the SP1 R24 , 1 Ohm 0.6 W resistor, it is scaled and fed to
pin 7 of SP2 Q8 whose output at pin 3 is a variable frequency signal, this signal can be picked
up at Tp3.

The following table shows the relationship between the charger current and the frequency of
the signal at Tp3

curr. mA 25±10 50±10 100±10 150±10 250±10 350±10 450±5

Freq. kHz 0.440/0.660 0.880/1.320 1.950/2.650 2.900/4.000 5.150/6.350 7.800/8.600 9.950/10.05

The frequency of the signal at Tp3 is supplied at pin 4 of SP2 P2 only when the system is
switched on, in this case the intensity of the light of led D32 depends on the frequency.

3.2.7. LAMP CIRCUIT

This circuit is used to show the battery charge status during the battery charger when the
system is shut off by means of a variable frequency light source.

The light source modulation is as follows:

System ON lamp lit indicates that the ESU is powered and working
Lamp off indicates a fault in the battery charger
System OFF slow flash in the range 0 % to 50 % full battery voltage, approx. 1 Hz
quick flash from 50 % to 90 % full battery voltage and I charge > 50mA± 5 mA,
approx. 6 Hz
lamp lit when battery charge >90% and I charge < 50mA± 5 mA

The light source frequency depends on the battery voltage and the charger current.

The battery voltage is monitored by a resistor ladder on SP1 made by R19, R20, R21, R22
and R23; it is scaled and compared to two references.

The charge current is picked up by the SP1 R24 , 1 Ohm 0.6 W resistor, it is scaled and
compared to one reference.

4522 129 05272/10318000 (00.1) 17

(Gil document code 64840201-Z1687) Energy Storage Unit

When the system is off and the charge is in the range (0 % , 50 %) the light source shows a
slow flash, the D11, D12 and D13 leds are lit.

When the system is off and the charge is in the range (50 % to 90 %) the light source shows a
quick flash, the D11, D12 leds are lit and the D13 led is shut down.

When the system is off and the charge is > 90% the light source shows a still flash, the D11,
D12 and D13 leds are shut down.

The frequency can be tested at pin 3 of SP2 U13.

4522 129 05272/10318000 (00.1) 18

(Gil document code 64840201-Z1687) Energy Storage Unit

4. CORRECTIVE MAINTENANCE

4.1. FAULT FINDING OF THE ENERGY STORAGE UNIT

Fault indication Description

The BATTERY CHARGER FAULT signals the case when the charger output is below the
threshold of about 120 V.

Be sure that the BATTERY CHARGER ON/OFF is LOW, led D23 is lit.
Check fuse SP1-F4. If the problem remains check if the charger current at SP2 Tp1 is 450
mV, if it is the case shut off the ESU for about one minute than restart.
If the problem remains check the GATE DRIVE SIGNAL at SP2 Tp7. Replace the Energy
Storage Unit if no pulse is detected

Low battery charge indication (%)

Measure with a scope the frequency between Tp3 and Tp6 and between Tp5 and Tp6.
Check the charge current and voltage. See Fig 1, ‘Values of current and voltage during the
battery charge’. Replace the Energy Storage Unit if not according to the charge curve.

Charge Lamp off

Check the Charge lamp and the +12 Val power supply. Check the SP1 fuses: F1, F2 and F3.
If the +12 Val power supply is OK but the charge lamp is off replace the Energy Storage Unit.

4522 129 05272/10318000 (00.1) 19

(Gil document code 64840201-Z1687) Energy Storage Unit

5. REPLACEMENT

The only field replaceable items are the fuses.

5.1. REPLACING SMALL FUSES

• Switch off the system
• Disconnect the + battery lead and then the -lead.
• Replace the blown fuse.
• Reconnect the battery leads in reverse order (first the - lead, followed by the + lead).

5.2. 55 A FUSE
• Switch off the system
• Disconnect the + battery lead and then the -lead.
• Remove both fixing nuts and disconnect the brown wire from the battery filter.
• Replace the blown fuse.
• Reconnect the brown wire.
• Refit the fixing nuts.
• Reconnect the battery leads in reverse order (first the - lead, followed by the + lead).

4522 129 05272/10318000 (00.1) 20

(Gil document code 64840201-Z1687) Energy Storage Unit

6. ADJUSTMENTS

No adjustments are required, but the following sections show how the factory calibrations can
be checked.

6.1. CHECKING BATTERY V MAX. AND FREQUENCY CALIBRATION

Battery Vmax check

• Open battery charger box for access to boards (SP2 = battery charger control board and
SP1 = battery charger power board).
• Disconnect the fastener either wire+ or wire- on side of battery.

• Position a digital voltmeter on 2Z2 and 3Z2 (on SP1 ) and check at a voltage of approx.
366 V. (battery voltage is calibrated using R71 on SP2)

NOTE
This gives a max voltage of 366 ± 2.5 V (when the batteries are connected with charger on)

Battery voltage frequency check

Position oscilloscope probe or a frequency meter probe between TP6 (0 V) and TP5 (on SP2)

• Check the frequency is 10 kHz ± 0.5%. (frequency is calibrated using R116)

Note: This calibration must only be carried out after the BATT. V max is calibrated.
• Connect the fastener wire + (or wire -) on side of battery.

6.2. TEST POINTS

NOTE
Use an instrument which has an input impedance >10 MΩ (a small change in the oscillator
frequency may be heard, but this is not a problem for the charger and does not affect the
accuracy of the results)

TP2 The output frequency value is a function of the elapsed overcharge time.
This signal is the same on pin 11P2 on SP2.

Time, min 30 45 60 90 120 150 180

KHz, Tp2 1,5/1,8 2,3/2,7 3,15/3,45 4,7/5,3 6,3/6,9 8,0/8,6 9,7/10,1

TP3 The output frequency value is a function of the charge current whose value is taken at
TP1 where 100 mV = 100 mA.
The signal on Tp3 is the same on pin 4P2 on SP2; it is regulated by R118.

mA, Tp1 25±10 50±10 100±10 150±10 250±10 350±10 450±5

kHz, Tp3 0.440/0.660 0.880/1.320 1.950/2.650 2.900/4.000 5.150/6.350 7.800/8.600 9.950/10.05

4522 129 05272/10318000 (00.1) 21

(Gil document code 64840201-Z1687) Energy Storage Unit

TP5 The output frequency value is a function of the battery voltage, this voltage is scaled by
a resistor ladder on SP1. On TP4 one can measure the charger voltage output that is
equal to the battery voltage reduced by 1 V.
The signal on TP5 is the same on pin 3P2 on SP2; it is regulated by R116.

Batt. Volt 260±1 270±1 290±1 310±1 330±1 350±1 365±1

freq.kHz Tp5 1.50/2.10 2.20/2.95 3.70/4.55 5.10/6.25 6.65/7.75 8.30/9.20 9.90/10.10
V, Tp4 4,49/4,95 4,84/5,34 5,18/5,67 5,66/6,00 6,06/6,34 6,47/6,64 6,75/6,91

TP7 On this test point one can measure the switching frequency of the SP1 power switches
Q1 and Q2.
The frequency depending on the battery pack charge can vary from less than 1 kHz,
when the battery pack is fully charged till about 65 kHz when completely discharged.

4522 129 05272/10318000 (00.1) 22

(Gil document code 64840201-Z1687) Energy Storage Unit

7. SPARE PARTS LIST

The Energy Storage Unit is defined as a single spare part:

Philips: 4522 129 05272 (Gilardoni: 10318000)

4522 129 05272/10318000 (00.0) 23

(Gil document code 64840201-Z1687) Energy Storage Unit

4522 129 05272/10318000 (00.0) Z1-1

(Gil document code 64840201-Z1687) Energy Storage Unit

4522 129 05272/10318000 (00.0) Z1-2

(Gil document code 64840201-Z1687) Energy Storage Unit

4522 129 05272/10318000 (00.0) Z3-1

(Gil document code 64840201-Z1687) Energy Storage Unit

4522 129 05272/10318000 (00.0) Z3-1

(Gil document code 64840201-Z1687) Energy Storage Unit

4522 129 05272/10318000 (00.0) Z3-2