Volkswagen Flexible fast charging station Maintenance Instruction
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Volkswagen Flexible fast charging station Maintenance Instruction

Volkswagen Flexible fast charging station Maintenance Instruction

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Service
Flexible fast charging station
 
Maintenance instructions
Edition 06.2023
Service Department. Technical Information
3

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  • Page 1 Service Flexible fast charging station   Maintenance instructions Edition 06.2023 Service Department. Technical Information...
  • Page 2 Links to other workshop manuals must be followed. The listed and approved special tools must be used for every repair. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2023 Volkswagen AG, Wolfsburg Printed in Germany...

  • Page 3: Table Of Contents

    Maintenance instructions 06.2023 Contents Technical data 00 - ..................Revision history .
  • Page 4   Maintenance instructions 06.2023 7.5.2 Change of location without fixed connection, in accordance with DIN VDE 0100-600 (2017:06) ..................7.5.3 Change of location with fixed connection, in accordance with DIN VDE 0100-600 (2017:06)
  • Page 5 Maintenance instructions 06.2023 9.18.1 Checking devices in operation ..............9.18.2 Special testing equipment or testing software .
  • Page 6   Maintenance instructions 06.2023 Contents...

  • Page 7: Technical Data

    Maintenance instructions 06.2023 00 - Technical data Revision history V1.3_20230718_EN_GB Revision history Issue/date Changes/amendments ⇒  “ Query of energy quantity of the AC meas- First edition October 2021 added uring device, models without remote emergency stop function” on page 77 ⇒ ...

  • Page 8: Preface

      Maintenance instructions 06.2023 Preface Preface This document is intended for trained technicians and con- tains information on maintaining the mobile charging sta- tion. This documentation about the mobile charging station is based around the product’s life cycle. The individual life cycles are described in a range of additional documents.

  • Page 9: Qualification Of Maintenance Staff

      Maintenance instructions 06.2023 checked. The operator or the instructed personnel are re- sponsible for secure operation of the flexible charging sta- tion. When work is carried out on the flexible quick charging sta- tion within the network operator’s area of authority, the re- quirements of DIN VDE 0105-100 (EN 50110-1) “Operation of electrical installations”...
  • Page 10 ◆ The Volkswagen dealership must contact the nearest high- voltage service centre or importer as a matter of urgency. ◆ The mobile charging station must be marked with the warn- ing sign 'Danger: High voltage'.
  • Page 11   Maintenance instructions 06.2023 Concept for setting up a quarantine area 1 -  -VAS 6786;Warnschild "Warnung vor Gefahren durch Batterien- 2 -  -VAS 6649;Warnschild "Warnung vor gefährlicher elektrischer Spannung"- 3 - -VAS 6882;Verbotsschild "Kein Feuer"- 4 - -VAS 6881;Verbotsschild "Betreten Verboten- 5 - Parking area incl. hazard marking 6 - Outer safety zone 7 - Suitable open area (e.g.

  • Page 12: Safety Measures When Working On Charging Stations That Use High-Voltage Systems

      Maintenance instructions 06.2023 a) For “Caution: Danger!”, take the following action: Keep a safe distance and observe the mobile charging station/high-voltage batteries. Be prepared to extinguish fires, and call the fire service immediately if there is any indication that a fire may occur.

  • Page 13: Safety Precautions When Working In The Vicinity Of High-Voltage Components

      Maintenance instructions 06.2023 ◆ Never support body weight on high-voltage cables or high- voltage connectors. ◆ Never rest any tools on high-voltage cables or high-voltage connectors. ◆ Never kink or severely bend high-voltage cables. ◆ Always observe the coding when connecting high-voltage connectors.

  • Page 14: Safety Precautions When Using Air Conditioner Service Stations

      Maintenance instructions 06.2023 Risk of asphyxiation and poisoning due to refrigerant Refrigerant fumes can cause dry coughing and nausea or even asphyxiation and poisoning. ◆ Never breathe in refrigerant fumes. ◆ Only work on the refrigerant circuit and store refrigerant tanks in well ventilated rooms.

  • Page 15: Safety Precautions When Working With Chemical Substances

      Maintenance instructions 06.2023 the measuring beaker supplied, ensure that it is filled back into a sealable tank as the oil contains a small amount of re- frigerant. Do not allow refrigerant to escape into the environ- ment. ● When the air conditioner service station is parked, it must be secured to prevent it rolling away.

  • Page 16: Legal Texts And Regulations, Air Conditioning Systems

      Maintenance instructions 06.2023 Observe the five safety rules: 3. Verify that the installation is de-energised at all Use a suitable measuring device to verify de-energi- poles sation at all poles. To do this, you must use a two- pole voltage measuring device (e.g. Duspol, Fluke). 4.
  • Page 17   Maintenance instructions 06.2023 ple, came into force in the Federal Republic of Germany on 1 August 2008 in order to define European legislation more pre- cisely. In the European Community, various regulations and directives on the handling of refrigerants have been adopted, such as: ◆...

  • Page 18: Charging Refrigerant Circuit With Different Refrigerants

      Maintenance instructions 06.2023 ◆ Maintenance work and the decommissioning of goods con- taining refrigerants specified in the regulations referred to and the withdrawal of the substances and preparations refer- red to in these regulations may only be carried out by per- sons with the necessary skills (expertise) and technical equipment.
  • Page 19   Maintenance instructions 06.2023 A risk assessment of the storage location is essential. ⇒  A fire safety concept/accident concept must be developed “Handling critical high-voltage batteries” on page Condition ● If present: The packaging must have openings in the area of the ventilation grilles to prevent a flammable atmosphere in- side the system.

  • Page 20: Storing The Mobile Charging Station

      Maintenance instructions 06.2023 Storing the mobile charging station Carrying out maintenance after three months of storage is recommended. The limit for the required check is six months.  - Observe the general safety rules. ⇒  “ General q See: safety rules” on page 12  - The high-voltage bat- teries should have a...

  • Page 21: Checking, Storing And Charging The Mobile Charging Station

      Maintenance instructions 06.2023 Checking, storing and charging the mobile charging station The following section describes how to perform maintenance on the stored charging station (high- voltage batteries and 12-V backup battery, BAT). Carrying out maintenance after three months of storage is recommended.

  • Page 22: Maintenance Tables

      Maintenance instructions 06.2023 In addition, some components have their own life cycle and therefore need to be checked regularly and, if their condition makes it necessary, replaced: this applies in particular to the batteries, the cooling system and, in some cases, to electronic components.

  • Page 23: Service Intervals

      Maintenance instructions 06.2023 Service intervals Service event Interval Visual inspection at the site At least twice by the sixth month Once after six months; Once after initial commissioning/after re-commis- the scope of maintenance corresponds to the annu- sioning al maintenance After 12 months;...
  • Page 24   Maintenance instructions 06.2023 Interior checks Recurring checks according to time interval in accordance with DIN VDE 0105-100 (2015:10) not OK Comments ⇒  “ Visual in- General degree of soiling □ □ spection for leaks and damage on the interior” on page 73 ⇒ ...

  • Page 25: Measurement Tests, Carried Out Once A Year

      Maintenance instructions 06.2023 Interior checks Recurring checks according to time interval in accordance with DIN VDE 0105-100 (2015:10) not OK Comments ⇒  “ Query of energy quantity of the AC □ □ measuring device, models without re- mote emergency stop function” on page 77 ⇒ ...

  • Page 26: Environment-Specific Servicing Work

      Maintenance instructions 06.2023 Check Individual Limit value Measured Comments measure- value ments Fault loop impedance L1-PE Zs ≤ U □ OK □ not U0 = voltage be- tween outer conduc- L2-PE □ OK □ not tor and neutral con- ductor L3-PE □...
  • Page 27   Maintenance instructions 06.2023 Exterior checks Recurring checks according to time interval in accordance with DIN VDE 0105-100 (2015:10) not OK Comments ⇒  “ Visual inspection State of housing □ □ for damage and contamination on the exterior” on page 73 ⇒ ...

  • Page 28: Event-Related Servicing Work

      Maintenance instructions 06.2023 Interior checks Recurring checks according to time interval in accordance with DIN VDE 0105-100 (2015:10) not OK Comments Adhesive seal on measuring device A □ □ ⇒  “ Visual inspection (left) undamaged of adhesive seal, calibration-law-com- pliant measuring device”...
  • Page 29   Maintenance instructions 06.2023 Exterior checks Initial commissioning in accordance with DIN VDE 0100-600 (2017:06) not OK Comments HMI display panels, advertising □ □ ⇒  “ Visual inspection for dam- screen age and contamination on the exteri- or” on page 73 ⇒ ...

  • Page 30: Change Of Location Without Fixed Connection, In Accordance With Din Vde 0100-600 (2017:06)

      Maintenance instructions 06.2023 Interior checks Initial commissioning in accordance with DIN VDE 0100-600 (2017:06) not OK Comments ⇒  “ Query of energy quantity of the AC □ □ measuring device, models without re- mote emergency stop function” on page 77 ⇒  “ Query of energy quantity of the AC measuring device, models with remote emergency stop function”...
  • Page 31   Maintenance instructions 06.2023 Interior checks Change of location without fixed connection, in accordance with DIN VDE 0100-600 (2017:06) not OK Comments Components (RCD, contactor, MCB □ □ ⇒  “ High-voltage components and etc.) high-voltage cables” on page 61 ⇒  “ High-voltage components Cabling □...

  • Page 32: Change Of Location With Fixed Connection, In Accordance With Din Vde 0100-600 (2017:06)

      Maintenance instructions 06.2023 7.5.3 Change of location with fixed connection, in accordance with DIN VDE 0100-600 (2017:06) Exterior checks Change of location with fixed connection, in accordance with DIN VDE 0100-600 (2017:06) not OK Comments ⇒  “ Visual inspection State of housing □...

  • Page 33: Maintenance Table For Measuring Equipment Compliant With Calibration Law

    A bro- □ Smith 21 Nov 2020 □ □ □ □ □ □ □ □ Review of electrical safety Test report Test object: Flexible fast charging station AFC SN - Test date: 7 Maintenance tables...
  • Page 34   Maintenance instructions 06.2023 Test: Results: Visual inspection □ OK □ not OK Check PE continuity □ OK □ not OK Checking the insulation resistance □ OK □ not OK Electric strength □ OK □ not OK Checking insulation resistance after checking elec- □...
  • Page 35   Maintenance instructions 06.2023 2. Revision history Date Version Changes 15 December 2020 ◆ Ref. docu. specification over- voltage protection added ◆ Reduction of test time from 60 to 15 s in the event of insula- tion resistance measurement and electric strength test acc. to EOL test spec V1.2 20 January 2021 ◆...
  • Page 36   Maintenance instructions 06.2023 5. Measuring equipment Designation Manufacturer Type Serial number Milliohmmeter GMC-I Messtechnik METRAHIT H+E CJ5828730007 GmbH Installation tester GMC-I Messtechnik Metroiso Prime+ M5000 V001 A01 GmbH C01 E01 Electric strength Sefelec SXS 506 1425722 tester 6. Measuring point Condition ●...
  • Page 37   Maintenance instructions 06.2023 -2- Top hat rail on the main fuse carrier -3- Housing of battery 1 -4- Housing of battery 2 -5- Housing of battery 3 -6- Housing of battery 4 7 Maintenance tables...
  • Page 38   Maintenance instructions 06.2023 -7- Rear door -8- PE on CEE -9- PE on the holder of the electricity meter for delivered energy Repair Group 00 - Technical data...
  • Page 39   Maintenance instructions 06.2023 -10- on the housing of the mobile charging station -11- PE bus bar A 7 Maintenance tables...
  • Page 40   Maintenance instructions 06.2023 -12- Front door -13- DC+ socket for battery pack A -14- DC- socket for battery pack A -15- DC+ socket for battery pack B -16- DC- socket for battery pack B Repair Group 00 - Technical data...
  • Page 41   Maintenance instructions 06.2023 -17- DC/DC G4 -18- DC/DC G3 -19- DC/DC G6 -20- DC/DC G5 -21- AC/DC G2 -22- AC/DC G1 -23- PE charging gun A / B 7 Maintenance tables...
  • Page 42   Maintenance instructions 06.2023 -24- PE bus bar B -25- PE charging gun -26- DC- charging gun -27- DC+ charging gun -8- PE CEE -28- N CEE -29- L1 CEE -30- L2 CEE -31- L3 CEE Repair Group 00 - Technical data...
  • Page 43   Maintenance instructions 06.2023 7. Visual inspection Test point Comment Inspector Ref. docu- Passed criteri- Test result ments Visual inspec- Corresponds to □ OK tion the circuit dia- □ not OK gram Visual inspec- Corresponds to □ OK tion the circuit dia- □...
  • Page 44   Maintenance instructions 06.2023 7. Visual inspection Test point Comment Inspector Ref. docu- Passed criteri- Test result ments Check BMS Tensile strength Check that the □ OK connector test BMS connector □ not OK (to the battery) is properly con- nected and se- curely engaged Protection...
  • Page 45   Maintenance instructions 06.2023 8. Check PE continuity Condition ● OK criterion: R < 100 mΩ (applies to all measurements) Descrip- Measure- Inspector Measuring Necessary Measure- Measure- Result of tion of the ment re- instrument conditions ment point ment point check measure- sult in mΩ...
  • Page 46   Maintenance instructions 06.2023 8. Check PE continuity Condition ● OK criterion: R < 100 mΩ (applies to all measurements) Descrip- Measure- Inspector Measuring Necessary Measure- Measure- Result of tion of the ment re- instrument conditions ment point ment point check measure- sult in mΩ...
  • Page 47   Maintenance instructions 06.2023 8. Check PE continuity Condition ● OK criterion: R < 100 mΩ (applies to all measurements) Descrip- Measure- Inspector Measuring Necessary Measure- Measure- Result of tion of the ment re- instrument conditions ment point ment point check measure- sult in mΩ...
  • Page 48   Maintenance instructions 06.2023 10. Checking the insulation resistance Condition ● Testing period: 15 s ● OK criterion: R > 7 MΩ (applies to all measurements) Descrip- Measure- Inspector Measuring Necessary Measure- Measure- Test result tion of the ment re- instrument conditions ment point...
  • Page 49   Maintenance instructions 06.2023 10. Checking the insulation resistance Condition ● Testing period: 15 s ● OK criterion: R > 7 MΩ (applies to all measurements) Descrip- Measure- Inspector Measuring Necessary Measure- Measure- Test result tion of the ment re- instrument conditions ment point...
  • Page 50   Maintenance instructions 06.2023 10. Checking the insulation resistance Condition ● Testing period: 15 s ● OK criterion: R > 7 MΩ (applies to all measurements) Descrip- Measure- Inspector Measuring Necessary Measure- Measure- Test result tion of the ment re- instrument conditions ment point...
  • Page 51   Maintenance instructions 06.2023 11. Electric strength Condition ● The test object (AFC) must not be touched during this test! Danger of electrocution! ● Measuring time: 15 s / rise time: 1 s ● OK criterion: leakage current I < 10 mA (applies to all measurements) Descrip- Measure- Inspector...
  • Page 52   Maintenance instructions 06.2023 DC+ (con- Measure- □ OK nector A) ment volt- □ not OK against L3 age: 2500 on CEE V DC DC+ (con- Measure- □ OK nector A) ment volt- □ not OK against N age: 2500 on CEE V DC DC+ (con-...
  • Page 53   Maintenance instructions 06.2023 DC- (con- Measure- □ OK nector B) ment volt- □ not OK against PE age: 2500 on CEE V DC DC- (con- Measure- □ OK nector B) ment volt- □ not OK against L1 age: 2500 on CEE V DC DC- (con-...
  • Page 54   Maintenance instructions 06.2023 12. Checking insulation resistance after checking electric strength Condition ● Testing period: 15 s ● OK criterion: R > 7 MΩ (applies to all measurements) Descrip- Measure- Inspector Measuring Necessary Measure- Measure- Test result tion of the ment re- instrument conditions...
  • Page 55   Maintenance instructions 06.2023 12. Checking insulation resistance after checking electric strength Condition ● Testing period: 15 s ● OK criterion: R > 7 MΩ (applies to all measurements) Descrip- Measure- Inspector Measuring Necessary Measure- Measure- Test result tion of the ment re- instrument conditions...

  • Page 56: General Information

      Maintenance instructions 06.2023 12. Checking insulation resistance after checking electric strength Condition ● Testing period: 15 s ● OK criterion: R > 7 MΩ (applies to all measurements) Descrip- Measure- Inspector Measuring Necessary Measure- Measure- Test result tion of the ment re- instrument conditions...

  • Page 57: Harsh Operating Conditions

      Maintenance instructions 06.2023 ● For this reason, it is essential to document every replace- ment of these components in the digital service schedule/ service schedule. ● This also applies to components that were replaced before the regular change interval elapsed. Harsh operating conditions In the case of harsher operating conditions, certain tasks may need to be carried out before the next service is due or between...

  • Page 58: Dusty Countries

      Maintenance instructions 06.2023 Cameroon Western Sahara Qatar Central African Republic Dusty countries ◆ High dust content in the air due to road conditions and envi- ronmental conditions. ◆ Dust is divided according to particle size or according to dust type (organic and inorganic material), such as pollen, bacte- ria, fungal spores or rock dusts, mineral fibres.

  • Page 59: Work Descriptions

    ◆ ⇒  “ Safety measures when working on charging stations that use high-voltage systems” on page You must always switch off the flexible fast charging station when performing maintenance work! Condition ● Only trained specialists in accordance with IEC 60050 may perform work inside the charging station while the door is open.
  • Page 60   Maintenance instructions 06.2023 ◆ 192.168.1.101 IP address ◆ 255.255.255.0 Gateway – Open the service flap -1- of the rear door. – Use a cable to connect the laptop to the LAN port (-arrow-) on the mobile charging station. – Enter the login details for the web configuration interface as shown in the table or as indicated by the operator.
  • Page 61   Maintenance instructions 06.2023 Depending on its status, the system will require different amounts of time to end all functions once it has been shut down. – Open the rear door using the door handle -1-. CAUTION Risk of injury from unsecured doors –...

  • Page 62: Switching On The Mobile Charging Station After Maintenance Work

      Maintenance instructions 06.2023 – Switch off the circuit breaker of the 12-V backup battery, main switch CB2 -1-. Switching on the mobile charging sta- tion after maintenance work – Before switching on the device, carefully check that it is con- nected correctly.

  • Page 63: Cleaning And Maintaining The Flexible Charging Station

      Maintenance instructions 06.2023 Cleaning and maintaining the flexible charging station 9.3.1 Cleaning Condition ● Cleaning with high-pressure cleaners is not permitted. Even with protection class IP 54, water can penetrate and cause damage in an unfavourable case. ● Permitted cleaning agents are water and soapy water. If flowing water (garden hose) is used, the maximum standard water pressure of approx.

  • Page 64: Checking The Water Sensor, Sj

      Maintenance instructions 06.2023 Checking the water sensor, SJ 9.4.1 Assembly overview for the water sensor, SJ 1 - Front door 2 - Water sensor, SJ ⇒  “ Checking the mounting of the wa- ter sensor, SJ” on page 58 3 - Electrical connection 4 - Screws q Qty. 5 q 1.5 Nm 9.4.2 Checking the mounting of the water sen- sor, SJ...

  • Page 65: Checking The 12-V Backup Battery, Bat

      Maintenance instructions 06.2023 – Perform visual inspection of water sensor, SJ -1-, and the securing bolts -2-. Specified torques ◆ ⇒  “ Assembly overview for the water sensor, SJ” on page 58 Checking the 12-V backup battery, BAT WARNING High voltage on the high-voltage system of the quick- charging station.
  • Page 66   Maintenance instructions 06.2023 – Switch off the circuit breakers, CB1 -1- and QF1 -2- on the main fuse carrier. – The test connector -1- is located next to the main switch, CB2 -2-. – Use the digital multimeter on the test connector -1- to meas- ure the voltage (charge level).

  • Page 67: High-Voltage Components And High-Voltage Cables

      Maintenance instructions 06.2023 High-voltage components and high-voltage cables WARNING High voltage on the high-voltage system of the fast charging station. Danger of electric shock! Before start- ing work, perform a visual inspection of the high-voltage components in the work area. Observe the safety instruc- tions.

  • Page 68: Visual Inspection For Corrosion

      Maintenance instructions 06.2023 Operation is not permitted when defects have been identified. If damage is detected, block the charging station immediately and inform the operator! – The rectification of the defect must be documented in writing in the service schedule. Condition ●...
  • Page 69   Maintenance instructions 06.2023 Using other “unsuitable” coolants can cause undesirable reac- tions which might impair the function of the cooling system and cause significant damage from overheating. Secondary damage caused by cleaning the cooling system af- ter the use of non-approved coolant is very expensive and is not covered by the warranty.

  • Page 70: Renewing The Coolant

      Maintenance instructions 06.2023 CAUTION When the charging station is at operating temperature, the cooling system is under excess pressure. Hot steam/hot coolant can escape – risk of scalding. Skin and other parts of the body may be scalded. – Wear protective gloves. –...
  • Page 71   Maintenance instructions 06.2023 – Remove the bolts -3- and the cover -2-. – Remove the screws (-arrows-) and the thermal management unit cover -1-. Draining CAUTION When the charging station is at operating temperature, the cooling system is under excess pressure. Hot steam/hot coolant can escape –...
  • Page 72   Maintenance instructions 06.2023 – Working at the shut-off taps -1-, connect two hoses with a di- ameter of “1 inch” -arrows- and hold the ends in the drip tray for the workshop hoist -VAS 6208-. – Open the shut-off taps -1- and allow the coolant system to drain.
  • Page 73   Maintenance instructions 06.2023 Anti-freeze protection must be guaranteed down to -25°C as a minimum and, in countries with arctic conditions, down to ap- prox. -36°C. Increasing the anti-freeze protection is permissible only if climatic conditions require stronger anti-freeze protection. It may, however, be increased only to a maximum of -48°C.
  • Page 74   Maintenance instructions 06.2023 – Close shut-off taps -1-. Note: The system can also be filled with coolant manually and bled manually without special tools. To do this, fill the system and switch on the quick-charging station. Check the coolant level and refill over a period of 45 minutes; see ⇒ ...
  • Page 75   Maintenance instructions 06.2023 – Open valve -B-; turn lever in direction of flow to do this. Condition ● Vacuum is generated in the cooling system. The indicator pointer should move to the green zone. – In addition, open valve -A- briefly by turning the lever in the flow direction so that the hose of the coolant expansion tank -VAS 6096/1- fills with coolant.

  • Page 76: Checking The Filling Quantities For Refrigerant R1234Yf

      Maintenance instructions 06.2023 – Fill coolant up to the MAX mark. – Tighten the sealing cap -1- on the coolant expansion tank -2 -. – Check coolant level. ⇒  “ Switching on the – Switch on the quick-charging station mobile charging station after maintenance work”...

  • Page 77: Renewing The Advertising Screen Fan Filter, Ad-Hmi

      Maintenance instructions 06.2023 9.10 Renewing the advertising screen fan fil- ter, AD-HMI Observe the safety information. ◆ ⇒  “ Safety precautions when working in the vicinity of high- voltage components” on page 7 Removing – Open the front door⇒  “ Opening the doors for servicing work” on page –...

  • Page 78: Checking Threaded Connections For Foundation/Charging Station

      Maintenance instructions 06.2023 Installing – Install in reverse order of removal, observing the following: – Switch on the charging station, ⇒  see: Initial commissioning. Specified torques ◆ Torque: nut = 0.6 Nm ◆ Torque: screw = 0.3 Nm 9.11 Checking threaded connections for foundation/charging station Removing –...

  • Page 79: Visual Inspection For Leaks And Damage On The Interior

      Maintenance instructions 06.2023 9.12 Visual inspection for leaks and damage on the interior WARNING High voltage on the high-voltage system of the quick- charging station. Danger of electric shock! Before start- ing work, perform a visual inspection of the high-voltage components in the work area.

  • Page 80: Checking Warning Stickers

      Maintenance instructions 06.2023 ◆ Check for sharp edges, dents, bumps, scratches or other damage. ◆ Check for visible soiling such as graffiti and smears. ◆ Condition of the meter display panels, control system, infor- mation screen and the type plate. ◆...
  • Page 81   Maintenance instructions 06.2023 ● Only warning stickers within the visible area are checked during the inspection! ● Missing warning labels on high-voltage components must be replaced! ⇒  “ Opening the doors for servicing – Open and secure doors work” on page Warning stickers must be fitted on following assembly groups: –...
  • Page 82   Maintenance instructions 06.2023 – High-voltage warning label on the high-voltage batteries – High-voltage warning label on the EMS and BMS control unit – High-voltage warning label on the internal high-voltage as- sembly group – High-voltage warning label on connection terminal –...

  • Page 83: Query Of The Energy Level Of Ac Measuring Equipment

      Maintenance instructions 06.2023 – Reference to the operating manual 9.15 Query of the energy level of AC measur- ing equipment 9.15.1 Query of energy quantity of the AC meas- uring device, models without remote emer- gency stop function Special tools and workshop equipment required ◆...

  • Page 84: Query Of Energy Quantity Of The Ac Measuring Device, Models With Remote Emergency Stop Function

      Maintenance instructions 06.2023 – The AC measuring device -1- is located on the main fuse carrier. The device’s accuracy exceeds class 1 (class B). The calcula- ted values may deviate by +/- 1 % from the actual values. – Use the buttons on the AC measuring device as follows to call up the energy usage.
  • Page 85   Maintenance instructions 06.2023 The five safety rules must be observed when working on the ⇒  “ The five safety rules” on page system – Switch off the ready-to-operate mobile charging station. See⇒  : Initial commissioning – The AC measuring device -1- is located on the main fuse carrier.

  • Page 86: Calling Up The Log For All Systems

      Maintenance instructions 06.2023 – Use the “OK” -arrow- button to select the “kWh” tab (the val- ue is displayed after the sigma. Info: The current consumption in this example is ∑ = 741.2 kW/h. 9.16 Calling up the log for all systems –...
  • Page 87   Maintenance instructions 06.2023 a. Quality checks b. Functional tests including accuracy tests a. Quality checks The device must be checked for agreement with the BMP: ◆ Physical design of the charging unit ◆ Meters/measurement capsules used ◆ Type plate markings ◆...

  • Page 88: Special Testing Equipment Or Testing Software

      Maintenance instructions 06.2023 It is assumed that the accuracy of the measurement of the en- ergy emitted via the charging point is essentially determined by the electricity meters in conformity with calibration law and the corresponding declaration of conformity from the meter manu- facturer.

  • Page 89: Identification

      Maintenance instructions 06.2023 2. An electric-vehicle simulating cable adapter inserted at the delivery point of the charging station. 3. A normal energy meter connected between the adapters re- ferred to in point 2 and the test load referred to in point 1. The normal energy meter must be connected to the metrological check within the meaning of §...
  • Page 90   Maintenance instructions 06.2023 ● For calibration-law-compliant market launch, these seals are designed as manufacturer seals with a brand-protected im- age for the manufacturer. ● The seals must ensure tamper-proofness, durability and non-transferability. During regular maintenance, check that the adhesive seals (sealing tags) are intact for the measuring equipment that is compliant with calibration law.

  • Page 91: Querying Plug Cycle Counter

      Maintenance instructions 06.2023 – Check: caps on the data lines at bottom sealed with adhe- sive seal – Check: caps on the sensor unit, SU2, and charging cable on the left (charging socket B) sealed with adhesive seal – Check: caps on the sensor unit, SU1, and charging cable on the right (charging socket A) sealed with adhesive seal 9.19 Querying plug cycle counter Plug cycle counter as a display for replacing contacts on...

  • Page 92: Technical Data

      Maintenance instructions 06.2023 For information on the plug cycle counter, see the ⇒  Diagnostic Manual Technical data 10.1 Technical data of the mobile charging station Technical specifications Certification Protection IP 54 system IP67 battery Mechanical protection IK 08 Dimensions (H x W x D) 2,260 mm x 1,340 mm x 1,100 mm Weight 2,650 kg...
  • Page 93   Maintenance instructions 06.2023 Output DC charging point #1 DC output interface CCS Type 2 Combo DC metering compliant with MessEG Yes (German variant) DC metering compliant with MID Yes (EU – non-German variants) Vehicle PLC communication ISO 15118 , DIN 70121 IEC 61000-6-2, EN 55011 EMC emissions When connected to grid with 400 V/63 A, max.

  • Page 94: Displays And Controls, Electricity Meters For Delivered Energy

      Maintenance instructions 06.2023 Battery /SoC 5%/95% min. max. 2x20 kW to battery Max. recharge power 1x40 kW (DPD ) to vehicle See warranty agreement When connected to grid with 400 V/63 A, max. system output power 250 kW Dynamic Power Distribution User interface 10"...

  • Page 95: Type Plate

      Maintenance instructions 06.2023 10.3 Type plate The type plate is located on the rear door. Condition ● The type plate must be clearly visible from the outside and must not be covered or damaged. Type plate Explanation Rated input voltage Required / permissible mains input voltage Frequency Required / permissible mains frequency...

  • Page 96: Glossary

      Maintenance instructions 06.2023 Condition ● Refrigerant compressor oil: G 055 535 M2 Quantity of refrigerant 31 March 2022 ► Condition ● Refrigerant compressor oil: G 055 535 M2 Heat Control Unit-EU 530100000778A5 Part No. 27000 DP02-2 Product Model Refrigerant Volume Refrigerant R1234yf 830±20g...

  • Page 97: Legal Information

      Maintenance instructions 06.2023 Legal information 12.1 Legal information The safety-relevant descriptions and the legal requirements for creating technical documentation have been observed. The manufacturer is responsible for compliance with all regula- tions and testing and certification requirements within the EU. Technical documentation, owner’s manuals and other user in- formation fulfil a central function for the safety of products and are a prerequisite for free movement of goods within the Euro-...

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