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EXICOM POWER SOLUTIONS Harmony Series Troubleshooting Manual
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EXICOM POWER SOLUTIONS Harmony Series Troubleshooting Manual

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Troubleshooting Guide - Harmony series EV Charger
INTRODUCTION
Preface
This document is valid for the Harmony series EV Charger only.
The images used in this document are for illustration and instruction purposes only. The images and
descriptions in this document refer to a representative device design. The devices used by the user may
differ in their appearance and design.
We recommend that the charging station is always kept updated with the latest version of the software (as
per the latest release by the manufacturer), as this will ensure functional enhancements and product
improvements from time to time
.
Purpose of this Guide
The document describes the troubleshooting of Harmony series EV Charger.
*Note: This document includes the latest information available at the time of printing. Exicom Tele-
Systems Ltd. reserves the right to make changes to this manual or product without further notice.
Changes, modifications, or repairs to this product by parties other than an authorized service provider
could void the product warranty.
Introduction to charger
Harmony – Fast charger solution is Exicom's most innovative design till date and a true representation of
interoperability. The system has three connectors - CCS, CHAdeMO & AC TYPE 2: 142kW (DC: 120kW + AC:
22kW).
All guns can be used in Parallel for charging. The charger is equipped with multiple components as shown
below:

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Summary of Contents for EXICOM POWER SOLUTIONS Harmony Series

  • Page 1 INTRODUCTION Preface This document is valid for the Harmony series EV Charger only. The images used in this document are for illustration and instruction purposes only. The images and descriptions in this document refer to a representative device design. The devices used by the user may differ in their appearance and design.
  • Page 2 Housing The Cover Key Operated Lock LEDs LCD Display RFID Reader Emergency Switch Cable Gland Charging Cable Charging Gun Plug [10] SMR’s Cover [11] Ventilation [12] Charging Gun Dummy Socket...

  • Page 3: Ground Protection

    SAFETY MEASURES AND INSTRUCTIONS Harmony series EV Charger complies with IEC 61851 Harmony series EV Charger complies with IEC 61851-1 Safety Standard and uses only certified 1 Safety Standard and uses only certified components. IEC 61851-1 Safety Standard is an International safety standard and Exicom Tele...

  • Page 4: Prohibited Areas

    Prohibited Areas Any unauthorized personnel should not open the cover. It can lead to risk of bodily harm and will result in losing warranty qualification. Safety Precautions  Make sure that the equipment is well-grounded to avoid electric shock before opening the equipment.

  • Page 5: Troubleshooting Approach

    TROUBLESHOOTING APPROACH The basic steps to approach the correct issue and resolve it are given below: STEP 1 – Identify the issue...
  • Page 6 STEP 2 – Check the issue STEP 3 – Locate the issue...
  • Page 7 STEP 4 – Resolve the issue Software:  Update Software  Use the latest Software Faulty Parts:  Replace the faulty item  Use the correct MPN part Other Faults:  Correct wiring,if loose  Take action as per the fault detail.
  • Page 8 CHARGING STOP REASON TROUBLESHOOTING During charging, the vehicle requests for voltage & current and the charger delivers the same by limiting the current as per requested current. However, charging may be stopped/interrupted by various reasons. Charging can be stopped by the charger, the vehicle or by any other means. Charger generates stop reason based on the nature of the cause of why the charging stops.
  • Page 9 Abnormal volt of outside bus Error Code Error Name Abnormal volt outside bus Error Cause The pilot controller voltage measurement has deviation. Error Solution Check wires of 10-J30 connectors for the respective gun. Check if rectifiers are building the voltage. Please check if the backup battery voltage is within range(330V-438V DC) Check if DC contactors of the respective guns are working OK.
  • Page 10 Insulation inspection abnormally Error Code Error Name Insulation inspect abnormally Error Cause Insulation test failed during charging initialization Error Solution 1. Check if rectifiers are building the voltage. 2. Please check if the backup battery voltage is within range(330V-438V DC) 3.
  • Page 11 EV Relay pull-In timeout Error Code Error Name EV Relay pull-In timeout Error Cause EV Contactors are not closed. This error only valid for CHAdeMO & GBT. Error Solution 1. Check battery voltage after contactors (The vehicle end). If no voltage please inform the vehicle manufacturer. 2.
  • Page 12 Ring fail alarm Error Code Error Name Ring fail alarm Error Cause Error Solution This is a reserved alarm. Shall not display on the charger, if observed on-screen please coordinate with the R&D team. Communication with EV failed Error Code Error Name Comm with EV failed Error Cause...
  • Page 13 Plugged gun timeout Error Code Error Name Plugged gun timeout Error Cause This means the connector is not properly connected to EV or EV changed CP voltage. Error Solution 1. Check if the gun is properly connected to the vehicle. 2.
  • Page 14 Door open Error Code Error Name Door open Error Cause The door is open or wiring loose. Error Solution Close door/check wiring at the door sensor. Emergency button pressed Error Code Error Name Error Cause Emergency button pressed or wiring loose. Error Solution Release Emergency button / check wiring at button.
  • Page 15 All Rectifier fail Error Code Error Name AllRectFail Error Cause All rectifiers have failed Error Solution 1. Check SMR CAN wiring. 2. Check if all SMR are inserted properly. 3. Check if AC MCB/DC MCB is ON & AC/DC input voltage is healthy.
  • Page 16 E-Lock Failed Error Code Error Name E-Lock Failed Error Cause Locking of Gun has failed. Error Solution 1. This is only for the GBT connector. 2. Please check the connector e-lock configuration in display. 3. Check 12V pulse for LKA+ & LKA-. 4.
  • Page 17 PWM failure Error Code Error Name PWM has failed for GUN-C Error Cause PWM failed because of GUN-C. Error Solution AC connector PWM connection failure. Please check the AC connector cable. Ground Fault Detected Error Code Error Name Ground Fault Detected Error Cause Earth wire is disconnected Error Solution...
  • Page 18 kWhMeter Comm Fail Error Code Error Name kWhMeter Comm Fail Error Cause kWh meter communication has failed. Error Solution 1. Check if DC energy meters are ON or OFF. 2. Please check the wiring of meters. CCU Comm Fail Error Code Error Name CCU Comm Fail Error Cause...
  • Page 19 Charging stopped/Interrupted by Vehicle S.No Alarm name Alarm code Alarm Cause Alarm Resolution EV Request Alarm is 1. Please change the vehicle and try again Stop reported by charging. Vehicle 2. Inform the user to check at the vehicle end. 3.
  • Page 20 Battery voltage Alarm is 1. Please change the vehicle and try again charging. deviation error reported by 2. Inform the user to check at the vehicle end. Vehicle 3. Please take serial data & CAN1/CAN2 data of PLC module. Also capture SMR data from controller's CAN3 Port.
  • Page 21 PLC High-Level Alarm is 1. At HLC stages, communication fails. Comm Fail reported by 2. Please change the vehicle and try again charging. Vehicle 3. Inform the user to check at the vehicle end. 4. Please take serial data & CAN1/CAN2 data of PLC module.
  • Page 22 Charging stopped/ interrupted – Other reasons S.No Alarm name Alarm code Alarm Cause Alarm Resolution Local Stop Alarm is User Cancelled the charging from display. cause by User Server Stop Alarm is Charging stopped from the OCPP server via the cause by "Remote stop"...

  • Page 23: Alarms Troubleshooting

    ALARMS TROUBLESHOOTING The chargers are equipped with multiple devices such as rectifier’s module, MCBs, energy meters & controllers, etc. These devices communicate with the main controller board. This master control board controls the charger and if anything unusual happens the charger generates the alarm. Various alarms along with their explanations are given below, System-Level Alarms These are system-level alarms,...
  • Page 24 GUN-A Alarms These alarms are related to GUN-A S.No Alarm name Alarm Cause Alarm Resolution E-Lock Failed -Group Locking of Gun-A failed. 1. This is only for the GBT connector. 2. Please check the connector e-lock configuration in display. 3. Check 12V pulse for LKA+ & LKA-. 4.
  • Page 25 GUN-B Alarms These alarms are related to GUN-B S.No Alarm name Alarm Cause Alarm Resolution E-Lock Failed -Group Locking of Gun-B failed. This is only for the GBT connector. Please check the connector e-lock configuration in display.. Check 12V pulse for LKA+ & LKA-. Check gun lock feedback wires.
  • Page 26 PLC board comm fail PLC board communication Check PLC is ON. - Group B failed. Check 12V at the power connector. Check PLC typesetting in display. Check CAN communication wires GUN-C Alarms These alarms are related to GUN-C, S.No Alarm name Alarm Cause Alarm Resolution AC Fail Alarm GUN - C AC input has failed...
  • Page 27 CHARGING RELATED TROUBLESHOOTING EVDC Harmony series charger is an important electric vehicle charging facility used for providing DC charging and AC charging power supply to electric vehicles. This series provides varies DC charging protocols such as GBT, CHAdeMO & CCS and provides AC Charging with Type 2 as per IEC61851 standards.
  • Page 28 Check Average attenuation, it should be below 35. SLAC - Check if SLAC is matching properly Protocol check – Should be ISO or DIN. Cable Check - Check if SMR is making voltage as per Maximum vehicle battery voltage. Pre -Charge - Check if SMR is making pre-charge voltage Check if Current demand packets starts or not...
  • Page 29 CHAdeMO charging issue S.No Steps / Checkpoints Reference Check if any alarm is present Plz refer to the above pages to resolve the alarm issue Check if D1 is ON - Check Voltage between PIN1 & PIN 2, it should be 12V.
  • Page 30 AC Type 2 charging issue S.No Steps / Checkpoints Reference Check if any alarm is present Plz refer to the above pages to resolve the alarm issue. Between 10-J15-1 & 10-J15-2, Check if the voltage between CP-PE is 12Vdc when GUN is not connected Check if the voltage between CP-PE is 9Vdc when GUN is connected Check if all three phases input is...

  • Page 31: System Schematic Diagram

    SYSTEM SCHEMATIC DIAGRAM The system components & wiring arrangements are given below:...