ELECTRIC FENCE ENERGIZER MODEL 950 SERVICE MANUAL Service Manual for OLLI 950 Page 1/16 Date 20.10.2014
Table of Contents...1 1. IMPORTANT SAFETY INSTRUCTIONS...2 2. SPECIFICATIONS...3 3. CONSTRUCTION...4 4. ERROR CODES...6 5. OPENING THE UNIT...7 6. FENCE CONNECTOR (DIS)ASSEMBLY...8 7. COMPONENT BOARD...10 8. OPERATION WITH OPEN DEVICE...14 9. CLOSING THE UNIT...14 10. TESTING...14 11. TROUBLESHOOTING...15 1. IMPORTANT SAFETY INSTRUCTIONS DANGER, HIGH VOLTAGE CAUTION: This device uses high voltages and currents. Only a qualified electrician may open this device! To reduce risk of electric shock, disconnect mains cord before attempting any maintenance or repair. Even after the mains cord is disconnected, capacitors inside the device may be remain charged to a high voltage. Refer to Chapter 5. OPENING THE UNIT before opening the device. CAUTION: This device is a highly powerful electric fence energizer. When working as intended, it outputs high energy, high voltage pulses from its fence terminals. Even though these pulses are not considered harmful for healthy adults, unnecessary contact with the fence terminals should be avoided. Service Manual for OLLI 950 Page 2/16 Date 20.10.2014
2. SPECIFICATIONS Supply voltage: Rated power input: Pulse repetition rate: Charged energy range: Maximum output energy: Output voltage, no load: Output, 500 Ω load: 230 VAC 50 Hz 10 W 1,38 s 5,5 J to 8,7 J 4,8 J (234 Ω load) 10 200 V 4,7 J / 4800 V Output adjusted automatically according to fence load. Visual fence fault alarm. Internal self-check with error code display. Complies with the European electrical safety standard EN 60335-2-76:2005/A1:2006+A11:2008+A12:2010. Service Manual for OLLI 950 Page 3/16 Date 20.10.2014
3. CONSTRUCTION 3 1 4 2 5 7 8 6 9 10 12 11 13 14 15 Figure 1. Exploded view Service Manual for OLLI 950 Page 4/16 Date 20.10.2014
16 Table 1: Part list Ref. Part name Spare part includes Qty. Order code 1 Cover sticker 1 6400141 2 Cover 3,4,5,6,7,8 1 6400110 3 Fence connector button (red) 1 6400121 4 Ground connector button (black) 1 6400124 5 Fence connector (complete) 2 6400120 (1pcs) 6 Lightning protector plate 1 6400150 7 Seal 1 6400157 8 Head gasket 1 6400155 9 Led bracket Red LED + cable 1 6400305 10 Board A 1 6400950 11 Pulse transformer 1 6400190 12 Pulse capacitor 30uF 1 6400182 13 Choke coil 1 6400177 14 Separation wall 1 6400161 15 Chassis 1 6400100 16 Rubber padding * 1 6400158 * It's highly recommend to add rubber padding to the every opened unit where padding is not originally attached. Service Manual for OLLI 950 Page 5/16 Date 20.10.2014
4. ERROR CODES Olli 950 processor (part 11 in figure 7) constantly monitors safe operation of the energizer. When malfunction is detected, an error code is stored in non-volatile memory of the processor. Additionally, the operation of the energizer may be suspended or charge energy may be lowered due to the fault in order to stay within safe operating parameters. During the next power-on, newly stored the error code is indicated by a special sequence flashing the red indicator LED. After the LED flash sequence, normal energizer operation starts. An error is only indicated by this sequence once, at the first power-on after the fault was detected. If an error flash sequence appears often or always during power-on, there is a fault that must be repaired. Note that a faulty energizer will often operate in the triple blink alert mode to attract attention. This mode looks just like normal energizer operation, but pulse led is quickly flashed 3 times after each energizer pulse. On a healthy energizer this means that the fence voltage is too low, but in that case it is due to a short circuit in the fence. Power-on error sequence code (flashing the red indicator LED): Sequence starts with a long 2 second flash. It is followed by one or more short 0,05 second flashes. There is a 0,25 second delay between each flash. Error code equals the number of short flashes. A minimum 2 second pause after the last blink before energizer operation starts. Example, error code = 3: start flash 1 2 3 pause energizer operation xxxxxxxxxxxxxxx x x x x x x See chapter 11. TROUBLESHOOTING for explanation of error codes. Service Manual for OLLI 950 Page 6/16 Date 20.10.2014
5. OPENING THE UNIT 1. Disconnect device from mains supply. 2. Make sure you read the safety instructions in chapter 1. IMPORTANT SAFETY INSTRUCTIONS. 3. Open all six screws on the bottom of the device (figure 2-1) and turn the device around. 4. Carefully raise the cover off (figure 2-2) and turn it like shown in figure (figure 2-3). Disconnect pulse transformer cables from cover. 1 Figure 2. Opening the unit. 5. The pulse capacitor (part 12 in chapter 3. CONSTRUCTION, figure 1) must be discharged after opening the device. It s voltage may be up to 800 VDC, measured between board A connectors J10 (or J11) [+] and J12 (or J13) [-]. There are two alternative methods for discharging the pulse capacitor: Wait for at least one hour after disconnecting mains supply. The capacitor slowly self-discharges. Measure voltage before touching circuit board or connectors. This method may not work if Board A electronics have failed. Carefully connect a suitable resistor between J10 and J11 and wait for capacitor to discharge. A suitable resistor is for example two 10 kohm, 2 W power metal film resistors connected in series. Discharge for a few seconds and measure the voltage. Service Manual for OLLI 950 Page 7/16 Date 20.10.2014
6. FENCE CONNECTOR (DIS)ASSEMBLY Fence connector test Push and hold button down, push stripped end of a wire into the connector and release the button. Test by pulling the wire lightly. If the connector doesn t hold the wire, the connector must be replaced or cleaned. Fence connector Disassembly 1. Pull push button off by lifting from top edge as shown in figure 3. Figure 3. 2. Open connector screw inside the cover. Figure 4. Figure 4. Service Manual for OLLI 950 Page 8/16 Date 20.10.2014
Assembly 1. Bend the spring so that screw holes meet each other. 2. Put the screw back. 3. Push the button back to it s place. Note the correct direction. Fence connector spring (dis)assembly 1. Pull the fixing plate out. 2. Turn spring downwards and pull it away from the frame. 3. Assemble in reverse order. Figure 5. Service Manual for OLLI 950 Page 9/16 Date 20.10.2014
7. COMPONENT BOARD Remember to handle all component boards with ESD safety! Foreword The energizer has 1 component board and 4 discrete components which are connected to the board using wires with quick connect terminals. In general the device can be repaired by replacing these 5 components/board. Additionally, Board A has components which can be delivered as spare parts on request. Board A has two fuses which may blow due to mains over voltage. If replacement fuses blow, board A is defected. For clarity, not all components are viewed on component board images on the following pages. Wiring list for discrete components Table 2: Wiring Ref. Part to component board connector 9 LED bracket J2. Note! red wire to pin 1 11 Pulse transformer primary coil Secondary coil Black insulated wires: Red to J8 (T+) and black to J5 (T-) Red insulated wires: Red to red fence connector and black to black fence connector 12 Pulse capacitor J12 or J13 (C+) and J10 or J11 (C-) 13 Choke coil J14 (L+) and J7 (L-) Service Manual for OLLI 950 Page 10/16 Date 20.10.2014
Component board A Refer to troubleshooting list in chapter 11 to find a fault. Replace only listed parts. If other components are broken, it is advisable to replace board A entirely. See figure 7. Some boards have a power limiting jumper assembled on connector J3 (pin 3-4). Jumper is installed to ensure fence output energy stays within standard limits (5,0J) on units whose pulse transformer is in a higher tolerance range causing higher than average output at certain fence conditions. To make sure the energizer does not exceed the energy limit after service, this jumper (if missing) must be installed if the pulse transformer is replaced. Install jumper as shown in following figure below and fix it permanently with hot melt glue. Alternatively, you may solder connector J3 pins 3 and 4 together. Hot melt glue! Figure 6. Service Manual for OLLI 950 Page 11/16 Date 20.10.2014
Figure 7. Main board (component board A). Replacement parts are listed on next page.
Table 3: Part list for component board A Ref. Part name Spare part order code includes Qty. Order code 1 Varistor (VDR) 275VAC 20A 3 6400340 2 Fuse 2 6400245 (10 pcs) 3 Choke coil 1 6400341 4 Diode 1N4007 4 6400230 (4 pcs) 5 Flyback transformer 1 6400342 6 Diode R2000F / SF4007 2 6400231 (2 pcs) 7 Diode P600M 4 6400232 (4 pcs) 8 Capacitor 220nF / 1600VDC 1 6400343 9 Thyristor 40TPS12 1 6400238 10 IC UCC2802N See 6400223 1 11 Processor PIC16F684 latest firmware 1 6400330 12 MOSFET IRFBE30 See 6400223 1 13 FET 2N7000 1 6400361 14 Resistors R17 (1,8Ω), R18 (1kΩ), R20 (100Ω) see 6400223 15 Capacitor C10 (470pF) see 6400223 16 Resistors R1-3 (1,2MΩ), R14 (9,09kΩ) see 6400322 17 Diode D7 (BZX55C5V1) see 6400322 18 Diode D8 (1N4148) see 6400322 Switching power supply repair kit Fence measurement repair kit Resistors R17 (1,8Ω), R18 (1kΩ), R20 (100Ω) Capacitor C10 (470pF) MOSFET Q5 (IRFBE30) IC U1 (UCC2802N) Resistors R1-3 (1,2MΩ), R14 (9,09kΩ) Diode D7 (BZX55C5V1) Diode D8 (1N4148) IC U3 (TVL274IN) 6400223 6400322 Service Manual for OLLI 950 Page 13/16 Date 20.10.2014
8. OPERATION WITH OPEN DEVICE WARNING! With cover opened, unfused mains voltage, capacitor charge up to ~760 V (8,7 J) and peak voltages up to 1300 V are exposed to the touch in addition to the high fence output voltages! See Chapter 1 for important safety information! PULSE CAPACITOR VOLTAGE If device outputs error code #2, #3, #4 or #5, measure pulse capacitor peak voltage during operation (do not connect anything to fence output terminals during this test). Approximate charging voltage is 607V. 9. CLOSING THE UNIT The device is closed in reverse order to opening, but the following must be noted: Check that seals are placed correctly on the cover (Figure 1, items 7 and 8). Ensure that pulse transformer cables don't get stuck between energizer cover and bottom part. 10. TESTING Test device function after repair in order to verify correct operation. Check that device does not give an error code pulse repetition rate is 1,33s ±0,15 (pulse led indicator blinking) device give output power according to table below. Output voltage, no load Output voltage, 500 Ω load 10 000 V Approximately 4 700 V* *When switching 500 ohm load, it takes three pulses before peak voltage is reached. Note that output voltage may vary depending on mains supply voltage, production tolerances and measuring device. We recommend to use Olli digitester or oscilloscope with high voltage probe. Service Manual for OLLI 950 Page 14/16 Date 20.10.2014
11. TROUBLESHOOTING See chapter 4. ERROR CODES for instructions on how to read error codes. Table 4: Troubleshooting Situation Problem Error code Possible causes and fixes: Quick checks Disconnect device from mains supply. Any Any Any or none - Measure resistance between the red and black fence terminals (fence and ground). This is the pulse transformer (part 11 in Chapter 3) secondary coil resistance. It should be about 8,4 ohm, never below 7,5 ohm. - Check all quick connect terminals inside of the device. Check that connections are tight and that sparking residue cannot be found (see Chapter 5 for instructions and precautions for opening the unit!). Tighten and/or clean connectors if faulty. - Check mains cord and fuses. Replace if faulty. - Measure pulse transformer primary coil resistance. It should be about 0,12 ohm. - Replace transformer if found faulty. The unit powers on when connected to 230 VAC 50 Hz mains voltage Unit charges and discharges, but output voltage is abnormally low Unit outputs an error code #1: Pulse transformer primary coil voltage measurement failure #2: Charging failure #3: Premature triggering 1. Disconnect device from mains supply. 2. Measure resistance between the red and black fence terminals (fence and ground). This is the pulse transformer (part 11 in Chapter 3) secondary coil resistance. It should be about 8,4 ohm, never below 7,5 ohm. Replace transformer if found faulty (see Chapter 5 for instructions and precautions for opening the unit!). 3. Check pulse capacitor (part 12 in figure 1). Replace if found faulty. 1. Disconnect device from mains supply 2. Check components U3, D7-8,C7-8, R11-14, R21, R23 on component board A. Replacement parts are available in spare part kit 6400322. 1. Check components D1-6, Q5, U1, R17 from component board A (see Chapter 5 for instructions and precautions for opening the unit!). If one of D1,D2, D3 or D4 is faulty -> replace all D1-4. If Q5, U1 or R17 is faulty, replace all parts of spare part kit 6400223. 1. Disconnect device from mains supply 2. Check component board A in case of breakthrough. Especially near by thyristor SCR1 (see Chapter 5 for instructions and precautions for opening the unit!). Clean circuit board if dirt causes voltage breakdown. Service Manual for OLLI 950 Page 15/16 Date 20.10.2014
#4: Unsuccessful triggering 1. Disconnect device from mains supply 2. Check Q1-2, R14, R34 and traces from component board A (see Chapter 5 for instructions and precautions for opening the unit!). #5: Over charging Device thinks it has charged too much energy to the pulse capacitor. This is not a common fault. This is most likely a sign of a pulse capacitor voltage measurement problem, not excessive charge. 1. Disconnect device from mains supply 2. Open unit and measure charge voltage during operation (see Chapters 5 and 8 for instructions and precautions for opening the unit!). 3. If voltage is too high, replace board A. 4. If voltage is too low, follow instructions given for error code #2 (charging failure). #6: Clock frequency fail 1. Disconnect device from mains supply 2. Check solder joints and PCB traces for board A components U2, R24 and C14. The device does not power on when connected to 230 VAC 50 Hz mains voltage. Unit charges and discharges normally but info LED does not blink. 1. Disconnect device from mains supply. 2. Open the unit (see chapter 5 for instructions and precautions for opening the unit!) 3. Check info LED condition and wiring 4. Check solder joints and PCB traces for board A components Q3, J2, R22, R34, C15, U2 5. Replace LED bracket 1. Disconnect device from mains supply 2. Check mains cord 3. Open the unit (see chapter 5 for instructions and precautions for opening the unit!). 4. Check for loose connections. 5. Check for overvoltage induced damage, especially on circuit board A and the lightning protector plate (figure 1, part 6). 6. Check fuses F1 and F2 on circuit board A. 7. Check choke coil L1 and diodes D10-13. Service Manual for OLLI 950 Page 16/16 Date 20.10.2014