VESTEL EVC04-AC Series Service Manual
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VESTEL EVC04-AC Series Service Manual

Electric vehicle ac charger
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EVC04 AC22-AC7.4
SERVICE MANUAL
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Summary of Contents for VESTEL EVC04-AC Series

  • Page 1 EVC04 AC22-AC7.4 SERVICE MANUAL Page 1 of 64...
  • Page 2 Revision History: First Version Uğur Korcan İçten Second Version Overcurrent and under voltage values Third Version Smart Model extension Fourth Version Fifth Version Sixth Version Seven Version Eight Version Page 2 of 64...

  • Page 3: Table Of Contents

    Changing Cosmetic Frame .......................38 RCCB AND DC6mA........................39 CABLE GLAND NUT ........................43 SOFTWARE UPDATE GUIDE WITH VESLINK ..................44 Software Update Procedure .....................44 8 GETTING LOG WITH EVC TESTER AND MOBILE APPLICATION............50 9 DETAILS OF VESTEL EVC TESTER ....................60 10 TROUBLESHOOTING........................62 Page 3 of 64...
  • Page 4 Notes, Cautions, and Warnings Signs used in this manual Some words and phrases are written in a different format to get your attention. Note: It is being used to put emphasis on useful information and critical points regarding the product. WARNING: CAUTION: Disconnect product from the power supply before attempting any operation on it.

  • Page 5: System Specification

    SYSTEM SPECIFICATION General Specification MODEL DESCRIPTION: EVC04-AC**-* EVC04 : Electric Vehicle AC Charger (Mechanical Cabinet 04) 1st Asterisk (*) : Rated Power 7 : 7.4 kW (1Phase Supply Equipment) (3Phase Supply Equipment) 22 : 22 kW (3Phase Supply Equipment) 2nd Asterisk (*) can include combinations of the following communication module options.

  • Page 6: Technical Specification

    Technical Specification This product is compliant to IEC61851-1 (Ed3.0) standard for Mode 3 use. Model EVC04-AC22 Series EVC04-AC11 Series IEC Protection class Class - I Class - I Socket Model Socket TYPE 2 (IEC 62196) Socket TYPE 2 (IEC 62196) Vehicle 5 m Cable with TYPE 2 ( IEC 5 m Cable with TYPE 2 ( IEC...

  • Page 7: System Block Diagram

    MECHANIC SPECIFICATIONS Material Plastic Size 315 mm (Width) x 460 mm (Height) x 135 mm (Depth) Dimensions (Package) 405 mm (Width) x 530 mm (Height) x 325 mm (Depth) Weight (Product) 5 kg for socket equipped model, 6,8kg attached cable model Weight with package 7,1 kg for socket equipped model, 8,9kg attached cable model For 22 kW version Ø...

  • Page 8: Board Layout

    BOARD LAYOUT Main Board Top View Figure 2.1 COMPONENT COMPONENT Relay input terminal (L3) HMI connection socket Relay input terminal (L2) Rotary switch Relay input terminal (L1) Dip switch Relay input terminal (N) LED socket Interlock connection socket Power Input Veslink connection socket Protective Earth LOG connection socket...

  • Page 9: Rfid Module

    RFID Module Top View COMPONENT RFID Connection Socket Table 2-3 Page 9 of 64...

  • Page 10: Led Board

    LED Board Top View Back View COMPONENT LED Connection Socket Page 10 of 64...

  • Page 11: Hmi Board (Smart Model)

    HMI Board (Smart Model) Top View COMPONENT Protective Earth Cable ACPW-HMI Power Board Connection Socket Micro SD Card Socket Wifi Module Socket External RS485 Connection Socket USB Connector Micro USB Connector PLC Module GSM/WCDMA/LTE Module Socket GSM/WCDMA/LTE Module Power Socket RFID Module Socket MID RS485 Connection Socket Dip Switch...

  • Page 12: Lte Board (Smart Model)

    LTE Board (Smart Model) Top View COMPONENT HMI Socket Power-In Socket (HMI) Main Antenna SMA Connector Diversity Antenna SMA Connector SIM Card Connector Page 12 of 64...

  • Page 13: Wi-Fi Board (Smart Model)

    Wi-Fi Board (Smart Model) Top View COMPONENT HMI Socket Page 13 of 64...

  • Page 14: Product Behavior

    PRODUCT BEHAVIOR LED Behavior VESTEL Electric Vehicle Charger (EVC) is designed to charge plug-in hybrid electric vehicles (PHEV) and battery electric vehicles (BEV) on charging station side. LED Light Color Indications Ready : No Light Charging : Blue Glowing Waiting For Authorization: Blinking Blue...
  • Page 15 EVC. If the LED is steady Red, please check troubleshooting section in user manual and service manual. Do not connect any charging plug to the VESTEL EVC. Page 15 of 64...

  • Page 16: Disassembling Of Evc04

    DISASSEMBLING OF EVC04 Maintenance and troubleshooting procedure: The list of equipment in order to use for parts replacement: Required Tools for Installation (1x) Drilling Machine (1x) Drill bit Ø8mm (1x) Hammer (for Screw Anchor) (1x) Torque T25 (Security) Screwdriver (1x) Torque T20 Screwdriver (1x) Allen Screwdriver (4) (1x) Allen Screwdriver (3) (1x) Phillips PH2/PH3/P4/P5/P6 Screwdriver...

  • Page 17: Changing Main Board

    Changing Main Board General Information and Warnings Please make sure to be complete following operations before starting any repair or disassembly. Shut down AC mains energy supply from MCB and RCCB. Important! If EVC is energized, do not disassemble the device for part replacement. Use grounding wrist strap.
  • Page 18 Step 1. Unscrew the back cover and open front cover. Step 2. Unscrew and remove RCD housing. Step 3. Unlock and remove RCD cover on the left side of the charging station. Step 4. Remove isolation sheet from the mainboard. Step 5.
  • Page 19 Step 2: Unscrew and remove RCD housing: Unscrew the RCD HOUSING using “SCREW P C ZN RYSB 3.5*10*Ø8 ROH” with PH2 bit 1Nm Tork. Step 3: Unlock and remove RCD cover on the left side of the charging station: Place and push the triangle key on the side cover lock then rotate the key 90 degree counter-clockwise.
  • Page 20 Important! Earth Protection Cable is Safety critical component. It must be connected properly to the mainboard. See “2- Board Layout, section “2.1- Mainboard”  Two protective earth cable connected on output terminals (21 and 22).  If it is a smart EVC04 model and there is HMI board then, one (HMI) protective earth cable connected on the mainboard (30) Page 20 of 64...
  • Page 21 Step 4: Remove isolation sheet from the mainboard: Remove the isolation sheet on the mainboard as shown in figure i1 in the previous section. Make sure that the isolation sheets are mounted as in figures i1 and i2 before the installation is finished.
  • Page 22 Step 6: Disconnect the cables connected on the mainboard “ACPW”: Disconnect AC Mains input cables (1, 2, 3, 4), output cables (23, 24, 25, 26) and protective earth cables (21, 22), board power input cable (20), LED cable (19), RFID cable (15), Earth and data cables between ACPW and HMI (only for Smart models: 16, 30), RCD DC 6mA cable (10), CP-PP cable (9), Interlock cable (5) and data cables (11, 12, 13, 14) from the main board.
  • Page 23 Step 7: Unscrew the main board: Unscrew the 4 screws from the main board from the metal bracket. (PH2 type 1Nm torque) 90 degree between HMI protective earth cable terminal and the board Figure 4-6 Step 8: Remove main board: Remove main board from the bracket.
  • Page 24 Please also check: If you unscrew the metal plate (screws in circles in C1), check figures between previous steps 3 and 4 for isolation sheets. Check cable clamps are mounted in figures C1 and C2. Also check figures “Back Cover” and “Front Cover” below. Check the hinge bracket is mounted properly in figure C2 40077389 CABLE_CLAMP_C...

  • Page 25: Changing Hmi Board (Smart Model)

    Changing HMI Board (Smart Model) Before changing the board see “General Information and Warnings” in the beginning of the section “4.2 Changing Main Board” Step 1. Unscrew the back cover and open front cover. Step 2. Disconnect the cables connected on the HMI Board Step 3.
  • Page 26 ETHERNET SOCKET EARTH EARTH SOCKET Step 4. Remove the HMI board. Step 5. Change the board. Step 6. Place and screw the new board. Screw the top left corner of the board with earth connection coming from the main board as shown in the figure “H2”...

  • Page 27: Changing Display (Smart Model)

    Changing Display (Smart Model) Before changing the display see “General Information and Warnings” in the beginning of the section “4.2 Changing Main Board” To change the display, first, remove the LCD Housing as shown in figure below. Unscrew HMI Board as shown in the previous section “Changing HMI Board”. Two double sided tapes are mounted as shown the left side of the figure below.

  • Page 28: Changing Rfid Board

    RFID card can be mounted with double sided tape “TAPE_DOUBLE_SIDE 40X50X1 VESTEL RFID”, such that the socket on the board stays above as shown in the figure R1. For Base model (No HMI Board), RFID board is connected to the main board ACPW (See “2-Board Layout”...
  • Page 29 For Smart models (models with HMI Board), RFID Board is connected to HMI Board as shown in figure below. Page 29 of 64...

  • Page 30: Changing Led Board

    Changing LED Board Before changing the board see “General Information and Warnings” in the beginning of the section “4.2 Changing Main Board” To demount LED board, first you need to demount interlock and output socket. See next sections “Changing Interlock” and “Changing Output Socket”. “21EVCL01”...
  • Page 31 Led cable is mounted as shown in the figure passing through the cable clamps (2-3) and then tied with cable ties (4-5) marked by circles. The ferrite on the ACPW-Led cable on ACPW side, is attached to the metal plate (5-6) as shown in the figure below.

  • Page 32: Changing Wifi Board

    Changing WiFi Board Before changing the board see “General Information and Warnings” in the beginning of the section “4.2 Changing Main Board” Mount double sided tapes on the WiFi Board as shown in figure “W1” below. Mount the WiFi Board as shown in the figure “W2” below. Connect HMI to WiFi cable as shown in the figure below.

  • Page 33: Changing Lte Board

    Changing LTE Board Before changing the board see “General Information and Warnings” in the beginning of the section “4.2 Changing Main Board” Disconnect the cables connected to LTE Board as shown in the figure “L1” below. 10P/90(1,25MM) AWG28 GSM-HMI cable is connected to CN4 on LTE Board and CN4 on HMI Board.

  • Page 34: Changing Interlock

    Changing Interlock If you need to change Interlock, see “General Information and Warnings” in the beginning of the section “4.2 Changing Main Board”, then refer to pictures below. Unscrew and remove the interlock first. Connect the interlock cable back to the interlock and to the interlock socket (Board Layout: 5) on mainboard.

  • Page 35: Changing Output Socket

    Changing Output Socket First, see “General Information and Warnings” in the beginning of the section “4.2 Changing Main Board”, then follow Figure 1, 2 and 3 to change a broken socket. After demounting Interlock as shown in previous section “Changing Interlock”, unscrew the line output cables pointed by arrows in figure 1 with 3mm allen key (1Nm torque).

  • Page 36: Changing Electric Terminals

    Short-distance Short-distance Changing Electric Terminals First, see “General Information and Warnings” in the beginning of the section “4.2 Changing Main Board” before any disassembly or repair. Screw (PH1) 1x terminal rail “RAIL CONNECTOR KLEMENS EVC04” on the back cover and mount the 5 terminals “KLEMENS RAIL TYPE W/SCRW DC10-01P-11-00A” as in figure ET1.
  • Page 37 N, L1, L2 and L3 cables (2,3,4 and 5) are passing through two ferrit cores “a” shown by the arrow in the figure ET5 following the path: a -> b -> c -> d. Protective earth cable is passing outside the ferrite cores (NOT inside) following the path: b ->...

  • Page 38: Changing Cosmetic Frame

    Changing Cosmetic Frame To demount cosmetic frame, first you need to demount interlock and output socket. See previous sections “Changing Interlock” and “Changing Output Socket”. Cosmetic frame is screwed on the front cover as shown in figure CF1 below with PH2 bit 0.5Nm torque.

  • Page 39: Rccb And Dc6Ma

    RCCB AND DC6mA First, see “General Information and Warnings” in the beginning of the section “4.2 Changing Main Board”. 5.1. “RAIL_CONNECTOR_EVC04 R2” is fixed to the METAL PLATE and mounted with two screws (PH2 tip 1Nm torque) as shown in figure 5.1.1. “FUSE SAFE RCCB 40A 4P TYPE AI 30mA”...
  • Page 40 5.2. DC6mA sensor connector is mounted to the socket “CN5” on the mainboard. 5.3. The line input cables coming from the side of the RCCB side or terminal side are passed through the DC6mA sensor and goes through the mainboard as shown in the figüre “DC6a”.
  • Page 41 5.4. The cables from the side of the terminal (N-L1-L2-L3) are mounted to the RCCB fuse in the order shown in figure below. Cable order top to bottom: Blue-brown-black-gray (top: neutral/blue) Neutral 5.4.1 5.5. The gasket “GASKET_SIDE_COVER_EVC04” (left in the figure below) is mounted on the RCCB as shown in the middle in figure below.
  • Page 42 figure “RCD-3”, the gap must be on upper left on rear side of “LOCK BOLT WIDE EVC04 R1”. To demount that part use triangle key on part “RCD-2” to hold the material tight, and use a PH2-type screw driver on “RCD-4” RCD-3 RCD-2 RCD-5...

  • Page 43: Cable Gland Nut

    CABLE GLAND NUT First, see “General Information and Warnings” in the beginning of the section “4.2 Changing Main Board”. For models with sockets (without cable) you can see the gland nuts and blind caps/flanges in figure 6.1 for wall installation. For stand installation, 1 and 2 will be replaced.

  • Page 44: Software Update Guide With Veslink

    IC 4. WG-VESTA Veslink device 6.1.2 Installing Software to Veslink Step1: Download VESTEL Veslink Programmer to a PC. Select update at the beginning of downloading program. Open Driver.exe file and download Veslink programmer to PC. Figure 5-1 Step 2. Make the connection between WG-VESTA Veslink device and PC via USB cable.
  • Page 45 Step 3. Open the programmer and select TI MSP430F67X51AIPZ as microcontroller for main control software update. Figure 5-3 Step 4. Select open and choose your SW based on .hex file which you want to download your main control IC. Then, select “Open”. Figure 5-4 Page 45 of 64...
  • Page 46 Step 5. Select Veslink Program on PC interface to download selected SW to Veslink device. In this step, energize to Veslink Device with 12V adapter or PC with USB cable Figure 5-5 Veslink screen is changed with name of your SW hex file name as shown in Figure 5.6 after downloading.
  • Page 47 Figure 5-8 Step 7. To download SW to main board press the PROG button on Veslink device or select “Hedef Program” on Veslink PC interface. Figure 5-9 Figure 5-10 1. PROG Button: This button is downloading SW to main board MCU. If the SW is downloaded in Veslink before, you can direct to start Step 7 to download SW to main board without PC.
  • Page 48 Figure 5-11 Step 8.Programming process is shown on the Veslink screen in Figure 5.12 and when it completes the screen is shown as Figure 5.13. Figure 5-12 Figure 5-13 If the SW is installed in WG-VESTA Veslink device once, use only Step 7 to download SW to the microcontroller without PC.
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  • Page 50: Getting Log With Evc Tester And Mobile Application

    GETTING LOG WITH EVC TESTER AND MOBILE APPLICATION Figure 7-1 Veslink device and required cables/tools to get log “Vestel EVC Configurator” mobile application must be downloaded from play store for android mobile phones. Mobile phone must have OTG support. Page 50 of 64...
  • Page 51 Step 1. Please make following connections between mobile phone, EVC Tester and EVC. Figure 7-2 Cable connections between EVC tester, EVC main board and mobile phone Step 2. Open “Vestel EVC Configurator” application on your mobile phone and go to home page. Page 51 of 64...
  • Page 52 Figure 7-3 Step 3. Energize the EVC and press Connect button on mobile application to get logs. Figure 7-4 State of the EVC is displayed with “S:” prefix. Possible states are as follows; A1: Pilot State Unplugged – No Cable A2: Pilot State Unplugged PWM B1: Pilot State Plugged in –...
  • Page 53 D1- D2: Pilot State Ventilation required If any error occurs in EVC then error number is printed into the log with “ERROR: ” prefix. Error numbers are as follows; Error Timeout to Limit to enter error Recover case Recover enter error Timeout Contactor Welded 3 sec.
  • Page 54 Interlock Permanent 1 sec. If interlock error Interlock state Immediately Error occurs 3 times changed sequentially then permanent error occurs Overcurrent Permanent 1 sec. If overcurrent A1 state Immediately Error error occurs 3 times sequentially then permanent error occurs Power Optimizer Phase 1 In 1 Phase Communication Auto...
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  • Page 60: Details Of Vestel Evc Tester

    DETAILS OF VESTEL EVC TESTER Follow the steps below for testing a repaired charger. Step 1.a: Connect your AC power cable to EV charger input terminal. Be sure to connect L1, L2, L3, N and Earth correctly. Three-phase: Single Phase Three Phase Figure 8.1...
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  • Page 62: Troubleshooting

    TROUBLESHOOTING Follow the Steps below in Case of Error Situations for Electric Vehicle Charging Station If the charger does not start charging, Step 1: Make sure that the electric cables of product are connected correctly for input. Step 2: If the charging process does not start although the LED color is correct according to LED behavior section, check the states of switches on EVC tester to make sure that they are correct.
  • Page 63 • When the charge cable is removed from the electric vehicle, the charging station opens the lock on its own socket and allows the user to remove the cable from the charging station. • This error occurs when interlock cannot open lock properly. When this error is seen, interlock is at lock position and does not allow user to remove cable.
  • Page 64 Error Number ERROR: 13, ERROR: 14, ERROR: 15, ERROR: 20 • These errors occur when the current drawn by the EV exceeds the current offered by the EVC with a percentage of nearly 20%. Each phase is checked separately. EVC stops charging and retries thrice to make sure that overcurrent failure occurs.

This manual is also suitable for:

Evc04-ac22 seriesEvc04-ac11 seriesEvc04-ac7.4 series

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