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Summary of Contents for StarCharge Athena 60kW DC EVSE
- Page 1 Charging Infrastructure Athena 60kW DC EVSE Maintenance Manual...
- Page 2 Legal Statement This document is part of technical file “Charging Infrastructure” and copyrighted. Without any prior written consent, it’s strictly not allowed to use it out of the permission of copyright, which is also applied to copied, translated, video taken and electronic media preserved version. Any party violating this statement is obligated to compensate for the losses!
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Page 3: Table Of Contents
Contents Scope ..........................................1 Range of Application ....................................1 Requirements for Maintenance ................................1 Safety ....................................... 1 Normal Requirements ................................. 2 Responsibility ....................................2 Skill Requirements ..................................2 Preventive Maintenance ..................................3 Site Inspection ....................................3 Appearance Inspection ................................4 Internal Inspection.................................. -
Page 4: Scope
For the great operation and maintenance management of charger, there is a great management system and safety regulations to ensure the safe, stable, and efficient work of charger. Range of Application This document is for Athena 60kW DC EVSE. Requirements for Maintenance 3.1 Safety 1) The engineer should master the knowledge of electrical safety, understand the principle and performance of charger, and know what to do if there is an electric shock or some emergencies. -
Page 5: Normal Requirements
the superior leader, make a record. 12) The power transmission sequence is: high-voltage power supply, low-voltage input and output line side, load (box transformer → distribution cabinet → charger); The power failure sequence is: load, low-voltage input and output line side, high-voltage power supply (charger →... -
Page 6: Preventive Maintenance
Preventive Maintenance 4.1 Site Inspection Illustration: The following inspection items are based on Chinese requirements, as well as the frequency and working hours are based on Chinese experience. The overseas regions can adjust according to local requirements and actual conditions. Requirements: It is necessary to identify the dangerous source of the charging station site, and report the hidden safety hazard to the place for treatment in time. -
Page 7: Appearance Inspection
The name plate is complete, correct and Visually Pass □ Fail □ firm. Cannot open the door after the door is Visually Pass □ Fail □ closed and locked. The cabinet body is placed properly on the foundation, and there are no bolts lost or Visually Pass □... -
Page 8: Internal Inspection
Charging cable is complete without damage. No water or dust in the charging Visual Pass □ Fail □ connector. The insulation cap is complete LED indicators work normally Visual Pass □ Fail □ Emergency stop button should not be Visual/ Manual Pass □... -
Page 9: Insulation Inspection
the input of charging cable and DC- of the input of charging cable There should be no reverse connection in Measurement/ Visual Pass □ Fail □ DC+/DC- of the input/output of charging cable Ensure fireproof material at the bottom is sealed Visual Pass □... -
Page 10: Functional Check
Check Item Content and specification Check Method Conclusion Remark Ensure resistance of output of DC+ relay to PE is Measurement Pass □ Fail □ not less than 1 MΩ and record this value. Insulation Ensure resistance of output of DC- relay to PE is Measurement Pass □... -
Page 11: Cleaning
charge automatically and display a warning at the screen. During charging, move the angle switch board should immediately stop the charge Visual Pass □ Fail □ automatically and display a warning at the screen. Setting the upper temperature threshold to below the ambient temperature will result Visual Pass □... -
Page 12: Charging Test
2) When install the new filter mats, the side without steel wire should be outside; Exhaust Fan: 1) Check the status of fans in advance, if there is damage, replace the fan. 4.7 Charging Test When all the check items have been tested, use the APP to scan the code or swipe the card to start, and the charging time for each charging gun is not less than 10 minutes. -
Page 13: Common Issue
Corrective Maintenance 5.1 Common Issue 5.1.1 Could not Access Web Panel Phenomenon: Could not access web panel (192.168.1.136) successfully. Analysis: 1) Wrong website address; 2) IP address of your PC is not configured correctly; 3) Unstable LAN connection; 4) Hardware issue (A7 core board/A7 board/Router). Solution: 1) Check the IP address setting of your PC;... -
Page 14: No Network Connection
5.1.2 No Network Connection Phenomenon: EVSE is offline on the web panel in “Network State”. Analysis: 1) SIM card is not inserted correctly; 2) Incorrect APN configuration; 3) Unstable 4G signal onsite; 4) SIM card is out of charge 5) Non-supported frequency band; 6) Unstable WIFI signal;... -
Page 15: Evse Is Offline
Solution: If using SIM card: 1) Check whether SIM card is inserted correctly. And SIM card should be inserted when EVSE is powered off. If inserting SIM card when EVSE is powered on, rebooting is necessary. 2) Check whether the SIM card is workable and APN configuration with SIM card operator and confirm the configuration in web panel. -
Page 16: Power Module Communication Fault
Analysis: 1) EVSE is out of power; 2) EVSE is not connected to network successfully; 3) Backend configuration is not set correctly in web panel or backend; 4) 4G communication module or A7 board is broken. Solution: 1) Check whether EVSE is powered on. If not, check whether there is no power. 2) Check the network connection;... - Page 17 2) Main breaker is broken or tripped; 3) AC contactor is broken; 4) Power module address is not set correctly; 5) Configuration in web panel about power module is incorrect. Solution: 1) Check the power module address and configurations about power module in web panel; A01, G01 A02, G02 2) Check whether some of the power modules’...
- Page 18 4) If input power is normal, check whether the main breaker is tripped. If so, turn it on. If not, measure the input and output voltage (DC 400V, AC 230V) of the main breaker. If no output, replace the main breaker.
- Page 19 6) If AC relay is normal, turn AC relay on in web panel. Check the status of power modules in web panel. If the status of one power module is offline still. Plug in this power module one more time or exchange this power module with another one.
- Page 20 7) If not, measure the resistance between CANL and CANH of power module socket, 60Ω normally. If abnormal, remove the J9 port on A7 board (CB01), measure the resistance between CANL and CANH of power module socket, 120Ω normally. If abnormal, replace the 120Ω resistor on the power module socket.
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Page 21: Meter Fault
5.1.5 Meter Fault Phenomenon: “Meter fault” is shown on the display. Analysis: 1) Meter itself is broken; 2) A7 board is broken; 3) The communication line between meter and A7 board is unstable. Solution: 1) Check whether the meter is power on. If not, check the input power. 2) Check the communication line between meter and A7 board. -
Page 22: Input Over-Voltage
Analysis: 1) The input voltage is over 400V-10% 2) Power module is broken. Solution: 1) Measure the input voltage, if abnormal, contact the installation team. 2) Monitor whether there are some power modules error during charging. If so, try to replace it. 5.1.7 Input Over-Voltage Phenomenon:... -
Page 23: Door Sensor Fault
1) Check whether there is water, stone or something inside the charging connector. If so, clean or dry it. 2) Measure the insulation resistance of input power cable and charging connector as the steps during commissioning. Correct the components with issue. 3) Check the wiring of insulation detection module. -
Page 24: Emergency Button Fault
Solution: 1) If the door is open when door sensor is enabled. Close the door or disable door sensor; 2) Check the wiring on the door sensor; 3) Check the wiring on A7 board (CB01); 4) Check the distance between the door sensor and the door when the door is closed. If too far, try to install the door sensor bit outside. -
Page 25: No Output Current During Charging
Solution: 1) Check whether the emergency button is pressed. If so, reset it. 2) Use multimeter to measure whether emergency stop button is operating normally. If not, replace emergency stop button. 3) Use multimeter to check short circuit of emergency button as well as wrong connection. If the circuit is abnormal, change it. - Page 26 relay. If not, replace the A7 board. If there is, test the continuity with multimeter. Replace the broken one. 3) Test the continuity of fuse protector with multimeter. Replace the broken one. 4) Monitor the status of power modules during charging and replace the abnormal one. 5) Find another EV for testing.
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Page 27: No Response After Plug In
5.1.12 No response after plug in Phenomenon: No response after plug in Analysis: 1) Something wrong with the charging connector; 2) Abnormal CP voltage; 3) Abnormal line connection of SECC board; Solution: 1) Check whether there is water, stone or something inside the charging connector. If so, clean or dry it; 2) Measure the voltage between CP and PE when the charging connector is standby, 12V normally. -
Page 28: No Response After Swipe Rfid Card
4) Check the wiring between SECC and M4 board. 5.1.13 No response after swipe RFID card Phenomenon: No response after swipe RFID card Analysis: 1) Wrong configuration; 2) UID of RFID card is not uploaded in backend; 3) Incompatible format 4) Card reader is broken Solution: 1) Check the configuration in web panel;... -
Page 29: No 230V Input
2) If EVSE is set in “Card Authentication” mode, make sure UID of RFID card is uploaded in backend-by- backend supplier; 3) Place the RFID card before card reader area for 2s and then remove it. 4) Replace the RFID card reader. 5) If the issue still, send the log file and the specification of RFID card to Star Charge for analysis. -
Page 30: Display Is Not Working
3) Check whether there is input and output voltage from switch mode power supply. If not, replace the switch mode power supply. 5.1.15 Display is not working Phenomenon: Display is not working. Analysis: 1) No input power; 2) Poor connection; 3) Display is broken. - Page 31 3) Replace the display. Maintenance Manual...
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