Hilti C4/36-350 Charger Issue: Green LED Flashing Every 2s, Battery Not Charging

The slingshot itself fails ..

I sold the Prock from a different charger. Further the same - turning off after 5 seconds.
Has anyone had a problem with a transformer or an operational amplifier?

I know that there was a zener diode that made a short circuit after damage. But I don't remember anymore because it was a long time ago ...

Welcome friends.
I found a short Zener diode DZ16 in this charger, does anyone know its value?
Thank you

If it's the diode at the FET transistor is 15V. Most of the zippers on this board are at 15V.

thanks, the zener anode is at GND of the main capacitor and the cathode connects to the mosfet source

U1 --- (OPEN) L6599AD
J3 --- (OPEN) 0R
D9 --- (SHORT) B4
ZD16 --- (OPEN) ???
Q3.Q4. (OPEN) 12NM50
R51 --- (OPEN) 10R

Does anyone know how to fix this?

Does anyone know about unknown part model?

If the above parts are replaced

Also pay attention to which parts are being measured

I also put the photos together.

Translated from GOOGLE

The text expression may be a bit unsatisfactory

J3 - 0R0 GND jumper
R51 10R
D9 - Schottky at 80%
D16 - Zener Melf - voltage unknown - 15V?

Yo.
J3 - 0R burned
path under J3 to GND burned
R51 10R blown
D9 - Schottky compact
D16 - Zener Melf - compact.
The small converter is excited cyclically reaching 50V (bargraph on the multimeter) and in this rhythm the green diode flashes.
Request hints:
What output voltage does a small converter give?
Is VOUT from a large inverter in ST-BY and if so, what is the VOUT?

Regards Adam

IC1 from what I remember is 12-13V, but I do not remember if it turned off in STBY.
I would suggest removing IC1 and all the short circuits close to it. Make sure the main keying transistors are ok (if not, I would desolder them too) and keep checking.

Hello,
I have been struggling with the repair of such a charger for several days and it finally worked yesterday.

Symptom: steady green light, not charging. After installing the battery, the relay and the fan were turned on for 5 seconds, and then everything returned to the starting point.

After preliminary measurements, damaged:
IC1
Q6
R28
J3
D9
ZD16
R31
R51
Q3
Q4
D16
D17
F3

After replacing these elements and making sure that the power supply of IC1 does not exceed the permissible 17V for it (it has an internal zener diode for this voltage), the main converter started to start but released a voltage at the output significantly exceeding the final charging voltage of the battery. It turned on for a split second with the relay and the fan and everything turned off.

So I looked at the feedback circuit and the PC3 optocoupler turned out to be damaged. It is soldered under the transformer so the access is best after desoldering the transformer. After replacing, everything started and the charger works properly. Maybe someone will find this description useful.

Let me just mention that the R28 was "burned" and only after desoldering and measuring with the technical method it showed damage. It was the same with the R31. D16 and D17 diodes can also be measured only after lifting at least one leg from the board.

Cool.
Congratulates my colleague on your persistence in the fight against this charger.
I gave up, but with this description I will probably come back to check again what hurts her.
Thanks for the detailed description.

I was helped by the replacement of the L6599AD chip

If R42 is burned, J3 is replaced by L6599.
D9, R31, R32, D17, D16, R59 are verified

Hello
I have the same smd elements burned as my colleagues above. Could any of my dear colleagues give me the values of the elements:
D9 (diode marking 94 K)
D16 (I know from 15 V but how much W?)
I have the same symptoms as others, i.e. after connecting to the network, the green LED is on and after inserting the battery - 5 is charging and turns off
For tax purposes, I would like to inform you that after connecting to the network, you can hear a strange noise in the vicinity of this large electrolytic condenser - is it dry?
Thank you in advance for your help

D9= schotky -1A/40v
ZD16= zener 5v1- 0,5w

Thank you for the fast reponse !

Added after 2 [minutes]:

ionel calota wrote:

D9 = schotky -1A / 40v
ZD16 = 5v1 zener- 0.5w

Was it supposed to be 15V and not 5V1?

welcome back
Probably in my system there is a capacitor to be replaced and I have a question: what other / other can I replace it (where I buy components, there are shortages in the warehouses of this capacitor and I can't look for it anywhere else)
link with technical data: https://pl.mouser.com/ProductDetail/EPCOS-TDK/B43305A9397M7?qs=sB%252BYVu%2FGxqHpUcUOLgTgUw==

"Probably defective capacitor" ... Then you don't have any capacitance or ESR meter? From what did you draw such a conclusion? Is it swollen, or did you think the yellow glue next to it was a leak?
If you just assumed it and did not measure it, it is an error. Although you can buy an electrolytic capacitor of similar capacity (voltage 400-450V) and dimensions (so that it will fit), but this one can be measured as well - the meter for diode measurement, you put the plus leads to plus minus to minus, look at its indications and wait until it recharges, then you swap the meter leads and watch it discharge and recharge for a long time. Do this several times and compare it with the charging and reloading time of a new capacitor of similar capacity, e.g. 470uF (voltage irrelevant).
Primitive method, but when there were no capacity meters, I used it successfully. A capacitor that has lost capacity will charge quickly and will recharge just as quickly if the wires are reversed.

You are right that I approach it wrong, but I am already running out of ideas, and I know one hundred percent that there is a logical solution to this problem.
I checked the capacitor by your method. Both processes, i.e. charging, then discharging and recharging, are temporally similar (from 5s to 6s).
I found a 470 capacitor on some IC and its "processes" were 2s longer. I have not found anything with a closer capacity.
Are you able to draw any conclusions from this old method of validating a capacitor?

I assume the capacitor is functional.

It is enough to measure the voltage on it.

Can someone help me? I have lost these elements, some I do not know what to be, please help

NNTFD wrote:

Hello, Do you have a wiring diagram for this charger? I need to read the fuse values.

I have a similar problem with the Hilti C4 / 36-350 charger.
I have already repaired a few such chargers and most often IC1 or transistors were damaged.
I have a case in the workshop that has no damaged transistors, neither IC1 nor IC2 MIP2M2. I checked IC1, there is no short circuit between pin 12 and 10. Moreover, I measured the supply voltage of IC1 during charging and it is 13.7V - ok. I replaced IC1 prophylactically and nothing. 5 seconds after starting charging, the charger turns off. I checked optocouplers and also ok. Any ideas what else could be wrong?

Hello, a few elements of the triac burned me on the back of the board, the bridge three resistors, I also burned the resistor marked R7 and I don't know what value is there, is any of you able to say what is the value on it?

Welcome

I received a damaged charger of the above-mentioned model in a dead condition, the cause of the damage is unknown. After the initial inspection and measurements, a lot of small components were damaged, and you also describe burned tracks. Since the diagram of the charger is still unknown today, and so many elements have been damaged, some of which cannot be identified due to their "evaporation", I decided to do my homework and draw a diagram, and thus correct many mistakes made by the above-mentioned people ... and make repairs easier in the future.

The diagram I present concerns only the primary part of the power supply and only the section that I need to repair; I will add and divide it into two blocks, of which I present the final one today.

The UC1 system is L6599AD Vcc power supply from approx. 9V to max 16V pin 12 and here for correction it is driven by Q5 transistor, and (not Q3) BCP54, there is a R42 resistor between them, and (not R51 because R51 has 2k? and supplies another part block of the power supply) with a value of 10?.

The Q3 and Q4 transistors are SPP12NM50ND and are the keys of the main converter.

The Q6 transistor is the BC817-40 NPN transistor in the SOT-23 package and the 6Ct marking, and (not 6C1 as mentioned by user @ rsv6).

The D9 diode is SS05D in the SOD-123 housing and marked B4, and (no 94 as user @ misqu007 mentions) Schottky diode 40V / 0.5A here I used SS14.

The D16 and D17 diodes in the SOD-328 housing and marked with E are 35V / 0.1mA switching diodes, they can be replaced with the popular IN4148 diode; it is worth noting that the manufacturer used this type of element in the catalog note of the system.

All the values given in the drawing are measured and checked; correct unless it is annotated to an element. I marked the damaged elements and places of burned paths in red.



Questions:
1. What is the voltage of the Zener diode ZD9 and ZD10?
2. What is this PTC1 element, is it a capacitor?
3. Is the substitution of the ZD16 diode as 5.1V confirmed; for me is this diode working?

If there is any error, sorry, and soon the second part of the IC2 diagram, i.e. MIP2M20, the documentation of the system in the appendix.
MIP2M20MS-...asonic.pdf Download (680.28 kB)
I have corrected TONI_2003

welcome back
First, thanks to TONI_2003 for the corrections; it looks much better ...
Next, I promised the second part of the diagram with the MIP2M2 chip (the only version of the MIP2 chip that does not have pin 6 used). See photo

The IC2 system is the main converter that gives power to all electronics, and exactly 13V pin 4. In my case, the ZD17 diode was damaged (I initially put 15V because I had it, i.e. it can be seen in the diagram, but in the final stages I changed it to 13V and it works correctly) and the transistor Q5 which is BCP54. Its short circuit caused the charger to be in a dead condition, even though the MIP2 chip was not damaged, it was cool enough because it is difficult to access and relatively expensive.

It is worth adding that at this stage the charger does not show any sign of life; but the lack of IC1, keys and despite the "blown up" general cargo, if we have IC2, we should have 13V on the C39 capacitor and, which is very important for a quick diagnosis, the LED lights up in green. Behind the Q5 transistor we will not get voltage (despite the working electronics) if the battery is not inserted. The converter on the IC1 chip will start only if the battery is placed and it gives more than 36V. In my case, the transistor Q3 did not completely short-circuit like Q4 because it measured correctly, but it got such a "shot" that after replacing only Q4, the heat sink in the form of a sheet quickly heated up to a very high temperature, and thus it was impossible to touch it after a few minutes of charging and you need to mark the maximum start of the fan at the start, but after the repair, this problem disappeared. Only the replacement of both transistors (in my case without an insulated housing, which also had to be used with additional insulation) brought the correct results.

Finally, I will add that there are two versions of this type of power supply because please pay attention to the photo of the user @ updown5678, and the photos of other power supplies and what I present to you, in my case there is no D14 and R23, R3 or C23 diodes directed to the L3 coil, but it is an additional block of electronics (general cargo) that I did not draw. As for the ZD09 and 10 diodes, I used 15V there and they work properly. Now repairing this model should not be a problem for you at the end of a few photos. The charger is fixed and is doing well.

Another question is what value of the capacitor C8

Hello
I have 13V on pin 4 of IC2, but there is no voltage on pin 12 of IC1 - what could be the reason for this?

I replaced almost everything in this system, diodes, resistors, even mofsets, I was sure that everything would be fine, but after connecting it was a big bummm, I forgot to put the light bulb on the power supply in a row, the board burned down so much that I no longer have the strength to repair again