Hitachi UC 18YML2 Technical Data And Service Manual

Hitachi
Brand
Hitachi
Model
UC 18YML2
Category
Cool boxes
Type
Technical Data And Service Manual
CHARGER
UC 18YML2
UC 18YML2
Jul. 2010
LIST No.: H872
MODEL
U
CONTENTS
Page
1. PRODUCT NAME ---------------------------------------------------------------------------------------------- 1
2. MARKETING OBJECTIVE ---------------------------------------------------------------------------------- 1
3. APPLICATIONS ------------------------------------------------------------------------------------------------ 1
4. SELLING POINTS --------------------------------------------------------------------------------------------- 2
4-1. Selling Point Descriptions ---------------------------------------------------------------------------------------- 3
5. SPECIFICATIONS --------------------------------------------------------------------------------------------- 6
5-1. Specifications ---------------------------------------------------------------------------------------------------- 6
6. PRECAUTIONS ON SALES PROMOTION ------------------------------------------------------------- 7
6-1. Safety Instructions ------------------------------------------------------------------------------------------------- 7
6-2.
Extra Precautions on Sales Promotion ----------------------------------------------------------------------- 8
7. QUESTIONS AND ANSWERS ON MODEL UC 18YML2 ------------------------------------------- 9
8. GENERAL PRECAUTIONS---------------------------------------------------------------------------------- 10
8-1. Model UC 18YML2 ---------------------------------------------------------------------------------------------10
8-2. Pilot Lamp Indications ------------------------------------------------------------------------------------------10
9. PRECAUTIONS ON DISASSEMBLY AND REASSEMBLY ----------------------------------------- 11
9-1. Disassembly ------------------------------------------------------------------------------------------------------11
9-2. Reassembly -------------------------------------------------------------------------------------------------------11
9-3. Confirmation after Reassembly ------------------------------------------------------------------------------13
10. TROUBLESHOOTING GUIDE----------------------------------------------------------------------------- 14
10-1. Troubleshooting Based on Pilot Lamp Indications ----------------------------------------------------14
10-2. Troubleshooting and Repair Procedures-----------------------------------------------------------------14
11. STANDARD REPAIR TIME (UNIT) SCHEDULES --------------------------------------------------- 18
Assembly Diagram for UC 18YML2
-1-
1. PRODUCT NAME
Hitachi Charger, Model UC 18YML2
2. MARKETING OBJECTIVE
The new Model UC 18YML2 is a general-purpose slide-in/out type of charger capable of
recharging 14.4 V to 18 V lithium-ion batteries only.
3. APPLICATIONS
Recharging of Hitachi batteries
Applicable batteries:
Li-ion batteries BSL 1415 [14.4 V, 1.5 Ah]
BSL 1415X [14.4 V, 1.5 Ah]
BSL 1430 [14.4 V, 3.0 Ah]
BSL 1815X [18 V, 1.5 Ah]
BSL 1830 [18 V, 3.0 Ah]
-2-
4. SELLING POINTS
(1) Operable from an AC power supply or DC 12 V power supply equipped in a vehicle.
(2) Rapidly charges Hitachi BSL 14 and BSL 18 Series Batteries.
Charging time (AC power supply / DC 12 V power supply):
BSL 1415/BSL 1415X/BSL 1815X ------------------ 22/60 minutes
BSL 1430/BSL 1830 ------------------------------------ 45/120 minutes
NOTE: The recharging time may vary according to ambient temperature.
In particular, the recharging time when using a DC12 V in-car power supply
may take longer under a high-temperature environment.
For example, the recharging time at 40°C is approx. 170 to 180 min. (3.0 Ah)
(3) Hitachi original charge control mechanism for longer battery life
Fig. 1
BSL 1430
BSL 1415
BSL 1415X
BSL 1815X
BSL 1830
Line
General-purpose charger capable of
recharging 14.4 V to 18 V Li-ion batteries
Capable of recharging batteries with internal temperatures as high as 55°C
Recharging/discharging cycles of battery
(Ambient temperature range between 10°C and 30°C)
•
Li-ion (BSL 1415/BSL 1415X/BSL 1430/BSL 1815X/BSL 1830): about 1,500 times
3-way overcharging
protection systems
for longer battery
and charger life
Easy-to-read visual display of charging
status through constant lighting or
flashing of red pilot lamp
-3-
4-1. Selling Point Descriptions
4-1-1. Operable from an AC power supply or DC 12 V power supply equipped in a vehicle
The Model UC 18YML2 can run on either an AC power supply or a DC 12 V power supply
equipped in a vehicle by means of an AC adapter or cigarette lighter cord, in order to charge Type
BSL 1415/BSL 1415X/BSL 1430/BSL 1815X/BSL 1830 Li-ion Batteries.
4-1-2. Battery recharging/discharging cycles (ambient temperature range from 10°C to 30°C)
• Li-ion (BSL 1415/BSL 1415X/BSL 1430/BSL 1815X/BSL 1830): about 1,500 times
Detecting any decrease in charging current (stop current) and then automatically stopping
recharging can dramatically extend battery recharging/discharging cycles.
4-1-3. Capable of recharging batteries with internal temperatures as high as 55°C
Each Li-ion battery shown in Fig. 2 incorporates a thermistor. The Model UC 18YML2 can
continue recharging these batteries until the battery temperature reaches 55°C.
NOTE 1:
• Wiring diagrams for batteries are shown below.
• The thermistor is an element to detect battery temperature.
• The thermal protector incorporated in each 14.4 V/18 V battery interrupts the
recharging circuit.
• Because lithium-ion (Li-ion) batteries are heated to high temperatures during
recharging, this charger operates within the range of a 5°C temperature
difference in maximum battery temperature when starting recharging (50°C)
and the temperature when stopping recharging (55°C).
Fig. 2 Li-ion batteries (14.4 V, 18 V)
Terminal
p
osition
Thermal
p
rotecto
r
-4-
Battery voltage
Charging output current
Battery temperature
Battery internal gas pressure
Battery
voltage
Charging output current
Battery
temperature
Overcharge
range
Battery temperature
(55°C thermistor)
Battery temperature
(Thermal protector)
Sto
p
current: 1 A
240 minute time
r
Batter
y
internal
g
as
p
ressure
Charging time
4-1-4. 3-way overcharge protection system
A stop current detection system, a built-in battery temperature sensor (thermistor), and a timer
ensure overcharge protection.
Fig. 3 Relations of time, voltage, temperature and gas pressure while charging
(A)
• Stop current detection: This detects a drop in battery current at the end of charging and
suspends charging.
(B)
• Built-in battery temperature sensor: In the event the stop current detection system fails to
detect the completion of recharging, recharging stops automatically when the battery
temperature reaches 55°C.
(C)
• Timer: Should both the stop current detection system and the temperature sensor fail, the
timer automatically stops charging within 240 minutes from the beginning of charging.
NOTE 2: As shown in Fig. 3, the pressure of gas generated after fully charging a battery
rises rapidly to cause high temperature and high gas pressure that adversely
affect the battery’s effectiveness. If charging is allowed to continue, the gas
pressure will activate the safety valve in the battery, and the electrolyte will begin
leaking.
-5-
4-1-5. Easy-to-read visual display of charging status through constant lighting or flashing
of red and green pilot lamp
Indications of the pilot lamp
Before
charging
Blinks
(Red)
0.5 sec. ON 0.5 sec. OFF
During
charging
Lights
(Red)
Stays ON continuously
Charging
completed
Blinks
(Red)
0.5 sec. ON 0.5 sec. OFF
Charge
status lamp
(Red)
Charging
impossible
Flickers
(Red)
0.1 sec. ON 0.1 sec. OFF
Battery or charger is
faulty.
Overheat
lamp
(Green)
Overheat
standby
Lights
(Green)
Stays ON continuously
Battery is overheated.
Unable to charge.
(Charging will
commence when the
battery is cooled.)
DC charge
status lamp
(Green)
Charging
impossible
Blinks
(Green)
0.5 sec. ON 0.5 sec. OFF
DC 12 V supply is
faulty.
NOTE: When in standby for cooling a battery, the UC 18YML2 cools the overheated
battery by cooling fan. (During DC charging, the cooling fan does not rotate.)
• Rechargeable battery temperature range
The table below shows the rechargeable battery temperature range. Overheated batteries should be
cooled to the specified temperature before recharging.
Rechargeable battery temperature range
32°F to 122°F (0°C to 50°C)
-6-
5. SPECIFICATIONS
5-1. Specifications
Model
Item
UC 18YML2
Power source
AC single-phase,
50 Hz or 60 Hz
DC 12 V power supply
equipped in a vehicle
Power input 90 W 42 W
Charging system Constant current and voltage control
Overcharging protection
system
(1) Stop current detection
(2) Battery surface temperature detection (thermistor)
(3) 240 minute timer
Charging voltage 14.4 V to 18 V
Charging current 3.5 A 1.5 A
BSL 1415
BSL 1415X
BSL 1815X
Approx. 22 min. Approx. 60 min.
Charging time
BSL 1430
BSL 1830
Approx. 45 min. Approx. 120 min.
External dimensions
(length x width x height)
135 x 185 x 77.5 mm
Product weight 0.7 kg
Operating ambient
temperature range
0°C to 40°C
-7-
6. PRECAUTIONS ON SALES PROMOTION
6-1. Safety Instructions
In the interest of promoting the safest and most efficient use of the Model UC 18YML2 Charger by
all of our customers, it is very important when concluding a sale that the salesperson carefully
ensure that the buyer seriously recognizes the importance of the Handling Instructions.
6-1-1. Handling instructions
Salespersons must be thoroughly familiar with the Handling Instructions in order to give pertinent
advice to the customer.
(1) Connect the charger to an AC power outlet or a DC 12 V power supply equipped in a vehicle.
Using any other power source (DC outlet, fuel-powered generator, etc.) will cause the charger
to overheat and burn out.
(2) Do not use any voltage-increasing equipment (e.g., transformer, voltage regulator) between
the power source and the charger.
Using the charger at voltage exceeding that indicated on the unit will result in malfunction.
(3) Conduct battery charging in an ambient temperature range of 0°C to 40°C.
At ambient temperature is below 0°C, charging is not possible or overcharging will occur due
to a malfunctioning recharging control circuit. At ambient temperature above 40°C, charging
stops before fully charging the battery due to a rise in temperature caused by the small
difference between the upper limit of rechargeable battery temperature (55°C) and the
ambient temperature.
(4) Do not use the charger for successive charging.
Charging multiple batteries in succession at high ambient temperature will cause the charger
to become very hot and possibly fail. Therefore, instruct the customer to wait at least 15
minutes before charging the next battery. Particular care is necessary in summer or tropical
countries when the power source voltage is low.
(5) Do not insert foreign objects into the air vents on the charger.
The charger case is equipped with air vents to protect the internal electronic components from
overheating. Caution the customer not to allow foreign materials, such as metallic or
inflammable objects, to be dropped or inserted into the air vents. This could cause electrical
shock, fire or other serious hazards.
(6) Do not attempt to disassemble the charger.
Incorrect parts replacement and/or wiring will cause malfunctions that could result in fire or
other hazards. Instruct the customer to bring the charger to an authorized service center in the
event repair or replacement is necessary.
(7) Use the battery charger correctly.
Do not use the battery charger other than with a DC 12V in-car power source. The battery
charger is solely for use on minus-grounded vehicles. Make sure that the minus pole of the car
battery is connected to the car body.
-8-
(8) Keep your attention focused on driving the car.
If you use the battery charger while driving, fasten the battery charger in place so that it does
not move inadvertently and distract your attention from driving. Do not place the battery
charger or battery under the driver’s seat, irrespective of whether it is charging or not, as it
may get under the brake pedal or the cable may get wrapped around the driver’s feet and
cause an accident.
(9) Do not manipulate the battery charger or battery while driving as this may cause an accident.
(10) Do not leave the battery charger or battery within reach of children as this may result in an
accident.
(11) Be sure to use the cable provided.
Using a different cable could result in a fire or accident due to overheating.
(12) Do not place the battery charger on a blanket-type car seat cover or car mat during charging
as this may result in a fire or accident due to overheating.
(13) Do no expose the battery charger to direct sunlight during charging as this may result in a
fire.
(14) Do not leave the vehicle unattended during charging.
6-2. Extra Precautions on Sales Promotion
The following points must be given during sales promotion.
6-2-1. Charging may not be possible at high battery temperature
Charging may not be possible at high battery temperature after the battery has been exposed to
direct sunlight for a long time or immediately after it has been used.
The customer should be advised in such a case to place the battery in a shaded area with good
airflow, and allow it to sufficiently cool down before recharging. This phenomenon is common to
all existing batteries and chargers that employ temperature-sensitive overcharge protection
devices. The cooling time required before recharging varies from a few minutes to about 30
minutes, depending on the load, duration of use and ambient temperature.
-9-
7. QUESTIONS AND ANSWERS ON THE MODEL UC 18YML2
Q1 What are typical charging methods?
A1 The most recent electronic charging methods are outlined below.
Q2 The battery charger is supposed to be used within an ambient temperature range
of 0 to 40°C.
What happens if the charger is used at below 0°C or above 40°C?
A2 At ambient temperature below 0°C, charging is either not possible or overcharging will
occur due to a malfunctioning recharging control circuit. At ambient temperature above
40°C, charging stops before fully charging the battery due to a rise in temperature
caused by the small difference between the upper limit of rechargeable battery
temperature (55°C) and the ambient temperature.
Q3 What is the relation between the chargeable battery temperature range at the start
of charging and the upper limit of chargeable battery temperature?
A3 The table below shows said relation.
Chargeable battery temperature range at start of
charging
0°C to 50°C
Upper limit of chargeable battery temperature 55°C
The Model UC 18YML2
automatically stops recharging
upon the detection of stop current
only when recharging a lithium-ion
battery.
Charger output voltage
Charger output current
Current
Charging time
Stop current
detection
Voltage
-10-
8. GENERAL PRECAUTIONS
8-1. Model UC 18YML2
(1) The outer frame consists of Case (A) and Case (B). A prism for pilot lamps is built into Case
(A). The printed circuit board ass'y can be found inside the frame.
(2) The printed circuit board ass'y consists of a high-frequency power transformer, microcomputer,
and other electronic devices to permit rapid charging and protect against overcharging.
Fig. 4
8-2. Pilot Lamp Indications
See 4-1-5 for details.
Case (A) [2]
Case (B) [11] Printed Circuit Board Ass'y [19]
Tapping Screw (W/Flange) D3 x 18 [12]
Case Rubber [13]
Prism [15]
-11-
9. PRECAUTIONS ON DISASSEMBLY AND REASSEMBLY
[Bold] numbers in the descriptions below correspond to item numbers in the Parts List and
exploded assembly diagram for the Model UC 18YML2.
9-1. Disassembly
(1) Remove Case (A) [2] after removing the four Case Rubber [13] and the four Tapping Screw
(W/Flange) D3 x 18 [12].
(2) Remove the Fan [21] after removing the two Tapping Screw (W/Flange) D3 x 25 [20], and
then remove the connector of the Fan [21] from the Printed Circuit Board Ass'y [19].
(3) Remove Fin (A) [8] and Fin (B) [10] from the Printed Circuit Board Ass'y [19] after removing
the three Machine Screw (W/Washers) M3 x 12 [9], three Nut M3 [6] and four TP Tapping
Screw D3 x 8 [4].
(4) Remove Insulator (A) [7] and Insulator (A) [7] from the Printed Circuit Board Ass'y [19].
(5) Remove the Terminal Holder [16] after removing the three TP Tapping Screw D3 x 8 [4] and
the connector of the Terminal Holder [16] from the Printed Circuit Board Ass'y [19], and then
use a soldering iron to melt the soldered connections of the red and black lead wires of the
Terminal Holder [16], and finally remove the wires.
(6) Remove the Cord [18] from the Printed Circuit Board Ass'y [19] after melting the soldered
connections with a soldering iron.
(7) The Prism [15] for pilot lamps is built into Case (A) [2] and the filter is stuck on Case (A) [2].
NOTE:
• Ideally, the soldered portions should be freed with a solder absorber. If it is
necessary to use a soldering iron, use one with rated power of 35 W.
• As excessive heat may damage the material of the printed circuit board, use of the
soldering iron should be limited to less than three seconds at one time.
9-2. Reassembly
Conduct reassembly by reversing the disassembly procedures; however, special attention should
be given to ensure that lamps, cord armor and charging terminals are properly installed in the
prescribed grooves.
(1) Screw tightening torque
• Machine Screw (W/Washers) M3 x 12 [9]---------------- 0.4 to 0.7 N·m (4.0 to 7.0 kgf·cm)
• TP Tapping Screw D3 x 8 [4] -------------------------------- 0.6 to 1.0 N·m (6.0 to 10.0 kgf·cm)
• Tapping Screw (W/Flange) D3 x 18 [12]------------------ 0.6 to 1.0 N·m (6.0 to 10.0 kgf·cm)
• Tapping Screw (W/Flange) D3 x 25 [20]------------------ 0.6 to 1.0 N·m (6.0 to 10.0 kgf·cm)
-12-
Cord [18]
Case (B) [11] Printed Circuit Board Ass'y [19]
Tapping Screw (W/Flange)
D3 x 25 [20]
Fan [21]
Insulator (B) [22]
Fin (B) [10]
Case (A) [2]
Fuse (250 V - 3.15 A)
[5]
Insulator (A) [7]
Machine Screw
(W/Washers) M3 x 12
[9]
Nut M3 [6]
Fin (A) [8]
Machine Screw
(W/Washers) M3 x 12
[9]
Prism [15]
Fig. 5
-13-
9-3. Confirmation after Reassembly
(1) Confirm the following after reassembly. The red pilot lamp on the charger lights up when
charging is started.
• When charging the BSL 1430/BSL 1830 Batteries, confirm that the red pilot lamp flashes at
one-second intervals about 45 minutes after the start of charging.
(2) Measure the insulation resistance and conduct a dielectric strength test.
• Insulation resistance: 10 M or more between the plug blade of the cord and the nameplate
or case fastening screws, with a DC 500 V megohm tester.
• Dielectric strength test:
(a) Between the plug blade of the cord and the charging terminal blade
(b) Between the plug blade of the cord and the nameplate or fastening screws on the case
Conduct a dielectric strength test based on the voltage listed on the nameplate.
Voltage on the nameplate Test voltage
120 V AC 1,240 V (1 minute)
220 V to 240 V AC 3,750 V (1 minute)
CAUTION: Without fail, insulation resistance must be measured between the plug blade of
the cord and the nameplate or fastening screws, and a dielectric strength test
must be conducted between the plug blade of the cord and the charging
terminal blade or between the plug blade of the cord and the nameplate or
fastening screws on the case. Under no circumstances should testing be
conducted between both blades of the plug or those of the charging terminal.
Doing so may cause the charger to burn out.
-14-
10. TROUBLESHOOTING GUIDE
10-1. Troubleshooting Based on Pilot Lamp Indications
Phenomenon Typical cause Check procedure
Pilot lamp fails to light or flash. (1)
Faulty AC cord or cigarette lighter cord
(2) Blown fuse (3.15 A) on primary side
Refer to trouble mode (A).
Red pilot lamp does not stay lit
(continues to flicker) after battery
has been connected.
(1) Poor connection of (T) or (LS)
terminal
(2) Faulty battery (open circuit)
(3) Faulty PCB
Refer to trouble mode (B).
Pilot lamp remains green (red
fails to light) after battery has
been connected.
(1) Poor connection of (T) or (LS)
terminal
(2) Faulty PCB
Refer to trouble mode (C).
Pilot lamp indicates abnormality
by flashing red rapidly (at 0.2
second intervals.)
(1) Faulty battery
(short-circuit, or open circuit)
(2) Faulty PCB
Refer to trouble mode (D).
10-2. Troubleshooting and Repair Procedures
(1) Trouble mode (A)
Is rated voltage
applied to the plug?
Is there continuity
between blades of
the AC cord plug or
the cigarette lighter
cord?
Faulty internal circuit
Replace the PCB.
Apply rated voltage.
Is there an open
circuit in the AC cord
or cigarette lighter
cord?
Replace the AC
cord or cigarette
lighter cord.
Is the fuse on the
primary side blown?
Replace the fuse.
Faulty internal circuit
Replace the PCB.
Pilot lamp fails to light or flash.
Check with tester.
YES
YES
NO
NO
YES
NO
NO
YES
-15-
(2) Trouble mode (B)
NO
YES
Check with tester.
NO
YES
Red pilot lamp does not stay li
t
(continues to flash) after battery
has been connected.
Are the connection terminals of the
charger or battery dirty, deformed,
or otherwise abnormal?
Remove dirt o
r
correct abnormality.
Replace the battery.
Is the resistance between
(LS) and (
-
) terminals
2 K to 100 K?
Faulty internal circuits
Replace the PCB.
-16-
(3) Trouble mode (C)
NO
NO
NO
NO
YES
YES
YES
YES
YES
0ºC to 40ºC
Charging cannot be accomplished if
battery temperature is above 50ºC.
Pilot lamp remains green
(red fails to light) after battery has been
connected.
Is ambient temperature
within designated range
(between 0
º
C and 40
º
C)?
Is the battery very hot?
Are the connection
terminals of the charger o
r
battery dirty or deformed?
Is the resistance between
(LS) and (
-
) terminals
2 K to 100 K?
Faulty internal circuits
Replace the PCB.
Conduct charging within
designated temperature range.
llow battery to cool prior to
charging.
Clean or repair deformed
terminals.
Replace the battery.
-17-
YES
NO
NO
YES
YES
YES
NO
Pilot lamp flickers red,
indicating abnormality.
Is the batter
y
properl
y
connected?
Is there an
y
conductive
foreign matter in the hole
where the battery is
inserted?
Is the battery short-circuited
or open?
Faulty internal circuit
Replace the PCB.
Properly insert the battery.
Remove the foreign matter.
Replace the battery.
(4) Trouble mode (D)
-18-
11. STANDARD REPAIR TIME (UNIT) SCHEDULES
MODEL
Variable
Fixed
10 20 30 40 50 60 min.
Work Flow
UC 18YML2
General Assembly
Case (A)
Case (B)
Fuse
Prism
Terminal Holder
Printed Circuit
Board Ass'y
Fan
Insulator (A)
Fin (A)
Insulator (B)
Fin (B)
Cord
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Hitachi UC 18YML2 Technical Data And Service Manual

Hitachi
Brand
Hitachi
Model
UC 18YML2
Category
Cool boxes
Type
Technical Data And Service Manual
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