Zerova eSolutions DC Series Troubleshooting And Maintenance Manual

180kw standalone fast charger

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DC Series

DC EVSE 180kW

Standalone Fast Charger

Troubleshooting/Maintenance Manual

Model

Table of Contents

Troubleshooting

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Summary of Contents for Zerova eSolutions DC Series

Page 2: Table Of Contents
3. Maintenance ....................29 3.1 Before Maintenance ..................29 3.2 General Maintenance ..................29 4. Zerova Limited Warranty Agreement (Parts Only) ........32 5. Appendix B - Replacement Kit List ............... 35 6. Appendix C - Preventative Maintenance Worksheet .........36 7. Appendix B - Replacement Kit Lise .............. 37...
Page 3: Revision History
Revision History Author Version Date Description Writer Editor V1.0 2024/01/09 First Issue Clara V2.0 2024/05/15 • Free2Move customized first issue Natalie Julie...
Page 4 Introduction The intent of this manual is to provide a guide for the troubleshooting and maintenance of the Standalone DC Fast Charger. Compliance with the information in this manual does NOT relieve the owner/ operator of their responsibility to comply with all applicable codes and safety standards.
Page 5: Specifications And Features
1. Specifications and Features 1.1 Device User Interface Antenna for Wi-Fi & 3G/4G LED Indication 7" Information Screen • Charging Status • Alarm information • User Authorization Right Button & Left Button RFID Capable Credit Card Payment System (If equipped) Emergency Stop Left DC Charging Plug...
Page 6: Troubleshooting
2. Troubleshooting Follow the troubleshooting guide when errors occur during the charging process.Make sure the EVSE is connected to the Internet, then contact the EVSE owner/operator for further instructions. Note: The EVSE must be connect to the Internet for remote diagnostics and upgrades.
Page 7 1. Please make sure the correct charging cable is selected. 2. Please make sure the charging cable has been plugged in completely with a “clicking” sound, and the charging plug button cannot be pressed. The Indication page returns from 3. Please check the charge port indicator or meter whether the charge function has failed.
Page 8: Troubleshooting - (011-Xxx) Error Codes
2.2 Troubleshooting - (011-XXX) Error Codes 011-XXX codes are related to EVSE parts or connector faults. 1. Unplug the DC plug. 2. Turn the power off. 3. Install the issued part. 4. Turn the power on. If the same error code is displayed, the EVSE must be serviced by a qualified technician.
Page 9: Troubleshooting - (013-Xxx) Codes
1. Make sure the Ethernet cable connection Communication between cabinets is reliable. error between 2. If there is no green light solid on the power 012304 power and cabinet, please reset it. charging plug 3. Please contact your dealer for further cabinet.
Page 10 Status Conditions Troubleshooting Methods Code 1. Unplug the charging cable, release the EV side charging limit, and try again. 023758 Procedure Error. 2. Follow steps 1~7 for troubleshooting. 1. Charging cable is not locked by EV side, please unplug, and plug the charging The charger missed the cable in completely until you hear a 023809...
Page 11: Troubleshooting - (033-Xxx) Codes
2.6 Troubleshooting - (033-XXX) Codes 033-XXX codes are related to the charger control server. The charger control server is running intelligent remote control. Use the troubleshooting methods that follow or contact the Owner/Operator. Status Conditions Troubleshooting Methods Code 1. Code scanning and app authorization are unavailable for the moment, change to RFID or other authorization.
Page 12: Status Codes
2.7 Status Codes Status Code Description 11001 CHAdeMO output fuse blew 11002 CCS output fuse blew 11003 GB output fuse blew 11004 RCD/CCID self-test fail 11005 AC input contactor 1 welding 11006 AC input contactor 1 driving fault 11007 AC input contactor 2 welding 11008 AC input contactor 2 driving fault 11009...
Page 13 Status Code Description 11031 PSU module broken 11032 RCD/CCID module broken 11033 Maximum Output Current setup error 11034 Shutter fault 11035 Ble module broken 11036 Rotary switch fault 11037 CCS liquid chiller water level fault 11038 Chiller temperature sensor broken 11039 Parallel relay welding 11040...
Page 14 Status Code Description 12222 System GB output OCP 12223 System ambient/inlet OTP 12224 System critical point OTP 12225 PSU ambient/inlet OTP 12226 PSU critical point OTP 12227 Aux. power module OTP 12228 Relay board/smart box OTP 12229 CHAdeMO connector OTP 12230 CCS connector OTP 12231...
Page 15 Status Code Description 12254 Fail to create share memory 12255 CSU initialization failed 12256 AC Ground Fault 12257 MCU self-test Fault 12258 Relay self-test Fault 12259 CHAdeMO groundfault detection timeout (GFD) 12260 CCS groundfault detection timeout (GFD) 12261 GB groundfault detection timeout (GFD) 12262 System AC L1 output Circuit Short 12263...
Page 16 Status Code Description 12286 Self test Failed due to communication of PSU failure 12287 Self test Failed due to Model name is none match 12288 CCS output UVP 12289 Chademo output UVP 12290 GBT output UVP 12291 Self test Failed due to communication of GBTboard failure 12292 Self test Failed due to communication of AC failure 12293...
Page 17 Status Code Description 12318 PSU Fault : Pfc Eeprom Fault 12319 PSU Dcdc Over Voltage 12320 System CHAdeMO output UCP 12321 System CCS output UCP 12322 System GBT output UCP 12323 System Chiller output OTP 12324 Connector 1 detects abnormal voltage on the output line 12325 Connector 2 detects abnormal voltage on the output line 12326...
Page 18 Status Code Description 13603 Reach to CHAdeMO max. plugging times. 13604 Reach to CCS max. plugging times. 13605 Reach to GB max. plugging times. 13606 Reach to AC max. plugging times. 13607 CSU fimrware update fail 13608 CHAdeMO Module fimrware update fail 13609 CCS Module fimrware update fail 13610...
Page 19 Status Code Description 23705 CHAdeMO: no charging permission 23706 CHAdeMO: battery incompatibility 23707 CHAdeMO: battery OVP 23708 CHAdeMO: battery UVP 23709 CHAdeMO: battery OTP 23710 CHAdeMO: battery current difference 23711 CHAdeMO: battery voltage difference 23712 CHAdeMO: shift position 23713 CHAdeMO: battery other fault 23714 CHAdeMO: charging system error 23715...
Page 20 Status Code Description 23737 CCS_EVCC_EVErrorCode_FAILED_RESSTemperatureInhibit 23738 CCS_EVCC_EVErrorCode_FAILED_EVShiftPosition 23739 CCS_EVCC_EVErrorCode_FAILED_ChargerConnectorLockFault 23740 CCS_EVCC_EVErrorCode_FAILED_EVRESSMalfunction 23741 CCS_EVCC_EVErrorCode_FAILED_ChargingCurrentdifferential 23742 CCS_EVCC_EVErrorCode_FAILED_ChargingVoltageOutOfRange 23743 CCS_EVCC_EVErrorCode_FAILED_ChargingSystemIncompatibility 23744 CCS_EVCC_EVErrorCode_FAILED_EmergencyEvent 23745 CCS_EVCC_EVErrorCode_FAILED_Breaker 23746 CCS_EVCC_EVErrorCode_FAILED_NoData 23747 CCS_EVCC_EVErrorCode_FAILED_reserved_by_DIN_A 23748 CCS_EVCC_EVErrorCode_FAILED_reserved_by_DIN_B 23749 CCS_EVCC_EVErrorCode_FAILED_reserved_by_DIN_C 23750 CCS_EVCC_EVErrorCode_FAILED_reserved_by_ISO_1 23751 CCS_EVCC_EVErrorCode_FAILED_reserved_by_ISO_2 23752 CCS_EVCC_EVErrorCode_FAILED_reserved_by_ISO_3 23753 CCS_EVCC_EVErrorCode_FAILED_reserved_by_OEM_1 23754 CCS_EVCC_EVErrorCode_FAILED_reserved_by_OEM_2 23755 CCS_EVCC_EVErrorCode_FAILED_reserved_by_OEM_3 23756 CCS_EVCC_EVErrorCode_FAILED_reserved_by_OEM_4...
Page 21 Status Code Description 23769 CCS_SECC_ResponseCode_FAILED_CertChainError 23770 CCS_SECC_ResponseCode_FAILED_CertValidationError 23771 CCS_SECC_ResponseCode_FAILED_CertVerificationError 23772 CCS_SECC_ResponseCode_FAILED_ContractCanceled 23773 CCS_SECC_ResponseCode_FAILED_ChallengeInvalid 23774 CCS_SECC_ResponseCode_FAILED_WrongEnergyTransferMode 23775 CCS_SECC_ResponseCode_FAILED_WrongChargeParameter 23776 CCS_SECC_ResponseCode_FAILED_ChargingProfileInvalid 23777 CCS_SECC_ResponseCode_FAILED_TariffSelectionInvalid 23778 CCS_SECC_ResponseCode_FAILED_EVSEPresentVoltageToLow 23779 CCS_SECC_ResponseCode_FAILED_PowerDeliveryNotApplied 23780 CCS_SECC_ResponseCode_FAILED_MeteringSignatureNotValid 23781 CCS_SECC_ResponseCode_FAILED_NoChargeServiceSelected 23782 CCS_SECC_ResponseCode_FAILED_ContactorError CCS_SECC_ResponseCode_FAILED_ 23783 CertificateNotAllowedAtThisEVSE 23784 CCS_SECC_ResponseCode_FAILED_GAChargeStop 23785 CCS_SECC_ResponseCode_FAILED_AlignmentError 23786 CCS_SECC_ResponseCode_FAILED_ACDError 23787 CCS_SECC_ResponseCode_FAILED_AssociationError 23788...
Page 22 Status Code Description CCS_SECC_ResponseCode_FAILED_MO_SubCA1_ 23797 CertificateRevoked CCS_SECC_ResponseCode_FAILED_MO_SubCA2_ 23798 CertificateRevoked CCS_SECC_ResponseCode_FAILED_MO_RootCA_ 23799 CertificateRevoked 23800 CCS_SECC_ResponseCode_FAILED_CPS_Prov_CertificateRevoked CCS_SECC_ResponseCode_FAILED_CPS_SubCA1_ 23801 CertificateRevoked CCS_SECC_ResponseCode_FAILED_CPS_SubCA2_ 23802 CertificateRevoked CCS_SECC_ResponseCode_FAILED_CPS_RootCA_ 23803 CertificateRevoked 23804 CCS_SECC_ResponseCode_FAILED_reserved_1 23805 CCS_SECC_ResponseCode_FAILED_reserved_2 23806 CCS_SECC_ResponseCode_FAILED_reserved_3 23807 CCS_SECC_ResponseCode_FAILED_reserved_4 23808 CCS_SECC_ResponseCode_FAILED_reserved_5 23809 CCS_SECC_TIMEOUT_SLAC_TT_EVSE_SLAC_init 23810 CCS_SECC_TIMEOUT_SLAC_TP_match_response 23811 CCS_SECC_TIMEOUT_CM_START_ATTEN_CHAR_IND 23812 CCS_SECC_TIMEOUT_SLAC_TT_EVSE_match_MNBC 23813 CCS_SECC_TIMEOUT_SLAC_TP_EVSE_avg_atten_calc...
Page 23 Status Code Description 23823 CCS_SECC_TIMEOUT_SLACC_SDP_UDP_TT_match_join 23824 CCS_SECC_TIMEOUT_SLACC_SDP_TCP_TT_match_join 23825 CCS_SECC_TIMEOUT_SLACC_SDP_TP_amp_map_exchange 23826 CCS_SECC_TIMEOUT_SLACC_SDP_TP_link_ready_notification 23827 CCS_SECC_TIMEOUT_SLACC_SDP_reserved_1 23828 CCS_SECC_TIMEOUT_SLACC_SDP_reserved_2 23829 CCS_SECC_TIMEOUT_SLACC_SDP_reserved_3 23830 CCS_SECC_TIMEOUT_SLACC_SDP_reserved_4 23831 CCS_SECC_TIMEOUT_SLACC_SDP_reserved_5 CCS_SECC_TIMEOUT_V2G_Msg_Performance_Time_ 23832 SupportedAppProtocolRes CCS_SECC_TIMEOUT_V2G_Msg_Performance_Time_ 23833 SessionSetupRes CCS_SECC_TIMEOUT_V2G_Msg_Performance_Time_ 23834 ServiceDiscoveryRes CCS_SECC_TIMEOUT_V2G_Msg_Performance_Time_ 23835 ServicePaymentSelectionRes CCS_SECC_TIMEOUT_V2G_Msg_Performance_Time_ 23836 ContractAuthenticationRes CCS_SECC_TIMEOUT_V2G_Msg_Performance_Time_ 23837 ChargeParameterDiscoveryRes CCS_SECC_TIMEOUT_V2G_Msg_Performance_Time_ 23838 PowerDeliveryRes CCS_SECC_TIMEOUT_V2G_Msg_Performance_Time_...
Page 24 Status Code Description CCS_SECC_TIMEOUT_V2G_CommunicationSetup_Performance_ 23846 Time CCS_SECC_TIMEOUT_V2G_CableCheck_Performance_Time 23847 (Output short circuit) 23848 CCS_SECC_TIMEOUT_V2G_CPState_Detection_Time 23849 CCS_SECC_TIMEOUT_V2G_CPOscillator_Retain_Time 23850 CCS_SECC_TIMEOUT_V2G_PreCharge_Performace_Time 23851 CCS_SECC_TIMEOUT_V2G_reserved_2 23852 CCS_SECC_TIMEOUT_V2G_reserved_3 23853 CCS_SECC_TIMEOUT_V2G_reserved_4 23854 CCS_SECC_TIMEOUT_V2G_reserved_5 23855 CCS_CAN_TIMEOUT_TP_GET_EV_TARGET_INFO 23856 CCS_CAN_TIMEOUT_TT_GET_EV_TARGET_INFO 23857 CCS_CAN_TIMEOUT_TP_GET_EV_BATTERY_INFO 23858 CCS_CAN_TIMEOUT_TT_GET_EV_BATTERY_INFO 23859 CCS_CAN_TIMEOUT_TP_EV_STOP_EVENT 23860 CCS_CAN_TIMEOUT_TT_EV_STOP_EVENT 23861 CCS_CAN_TIMEOUT_TP_EVSE_STOP_EVENT 23862 CCS_CAN_TIMEOUT_TT_EVSE_STOP_EVENT 23863 CCS_CAN_TIMEOUT_TP_GET_MISC_INFO...
Page 25 Status Code Description 23876 CCS_CAN_TIMEOUT_TT_CONNECTOR_INFO 23877 CCS_CAN_TIMEOUT_TT_RTC_INFO 23878 CCS_CAN_TIMEOUT_TP_RTC_INFO 23879 CCS_CAN_TIMEOUT_TP_EVSE_PRECHARGE_INFO 23880 CCS_CAN_TIMEOUT_TT_EVSE_PRECHARGE_INFO 23881 CCS_CAN_TIMEOUT_MSG_Sequence 23882 CCS_CAN_MSG_Unrecognized_CMD_ID 23883 CCS_SECC_DIN_Msg_Decode_Error 23884 CCS_SECC_DIN_Msg_Encode_Error 23885 CCS_SECC_ISO1_Msg_Decode_Error 23886 CCS_SECC_ISO1_Msg_Encode_Error 23887 CCS_SECC_ISO2_Msg_Decode_Error 23888 CCS_SECC_ISO2_Msg_Encode_Error 23889 CCS_SECC_CP_State_Error 23890 CCS_SECC_Unexpected_60V_Before_Charing_Error 23891 CCS_SECC_Not_Ready_For_Charging CCS_SECC_TIMEOUT_QCA7000_COMM (The firmware code of 23892 QCA7000 may not be installed, yet).
Page 26 Status Code Description 23913 GBT_ISOLATION_RESULT_FAIL 23914 GBT_MOTHER_BOARD_MISS_LINK 23915 GBT_OUTPUT_VOLTAGE_MORE_THAN_LIMIT 23916 GBT_REQ_CURRENT_MORE_THAN_LIMIT 23917 GBT_OUTPUT_VOLTAGE_MORE_THAN_10_PERCENT 23918 GBT_OUTPUT_VOLTAGE_DIFF_BCS_5_PERCENT 23919 GBT_STOP_ADC_MORE_THAN_10V 23920 ERROR_CODE_GBT_BMS_BROAA_NO_VOLTAGE_TIMEOUT 23921 ERROR_CODE_GBT_BMS_BROAA_TO_BRO00_ERROR 23930 GBT_CEM_BHM_TIMEOUT 23931 GBT_CEM_BRM_TIMEOUT 23932 GBT_CEM_BCP_TIMEOUT 23933 GBT_CEM_BRO_TIMEOUT 23934 GBT_CEM_BCL_TIMEOUT 23935 GBT_CEM_BCS_TIMEOUT 23936 GBT_CEM_BSM_TIMEOUT 23937 GBT_CEM_BST_TIMEOUT 23938 GBT_CEM_BSD_TIMEOUT 23939 GBT_CEM_BEM_OTHER_TIMEOUT 23940 GBT_BEM_CRM_TIMEOUT...
Page 27 Status Code Description 23955 GBT_BST_OUTPUT_CONNECTOR_OTP 23956 GBT_BST_COMPONEN 23957 GBT_BST_CHARGE_CONNECTOR 23958 GBT_BST_OTP 23959 GBT_BST_OTHER 23960 GBT_BST_HIGH_V 23961 GBT_BST_CC2 23962 GBT_BST_CURRENT 23963 GBT_BST_VOLTAGE 23964 GBT_GET_BST_NO_REASON 23970 GBT_BSM_CELL_OVER_VOLTAGE 23971 GBT_BSM_CELL_UNDER_VOLTAGE 23972 GBT_BSM_OVER_SOC 23973 GBT_BSM_UNDER_SOC 23974 GBT_BSM_CURRENT 23975 GBT_BSM_TEMPERATURE 23976 GBT_BSM_ISOLATE 23977 GBT_BSM_OUTPUT_CONNECTOR 23979 CCS_EV full charging 23980 ERROR_CODE_CHADEMO_BMS_CHARGE_ALLOW_ERROR...
Page 28 Status Code Description 41005 AC input contactor 1 welding 41006 AC input contactor 1 driving fault 41007 AC input contactor 2 welding 41008 AC input contactor 2 driving fault 41009 AC output relay welding 41010 AC output relay driving fault 41017 AC connector temperature sensor broken 41021...
Page 29 Status Code Description 42223 System ambient/inlet OTP 42224 System critical point OTP 42225 PSU ambient/inlet OTP 42226 PSU critical point OTP 42227 Auxiliary power module OTP 42228 Relay board/smart box OTP 42232 AC connector OTP 42233 RCD/CCID trip 42237 SPD trip 42238 Main power breaker trip 42239...
Page 30 Status Code Description 42270 PSU Input UVP 42271 PSU Input OVP 42272 PSU WalkIn State 42273 PSU Fault : Power Limited State 42274 PSU Fault : Id Repeat 42275 PSU Fault : Severe Uneven Current 42276 PSU Three Phase Input Inadequate 42277 PSU Three Phase Onput Imbalance 42278...
Page 31 Status Code Description 42309 PSU Bus Voltage Unbalance 42310 PSU Bus Over Voltage 42311 PSU Bus Voltage Abnormal 42312 PSU Bus Under Voltage 42313 PSU Input Phase Loss 42314 PSU Fan Full Speed 42315 PSU Temperature Power Limit 42316 PSU Ac Power Limit 42317 PSU Dcdc Eeprom Fault 42318...
Page 32: Maintenance
Status Code Description 43626 Disconnected from APN through 3G/4G 43627 WiFi disabled (separated charger only) 43628 4G disabled (separated charger only) 43629 PSU quantity not match Table 5. Status Codes 3. Maintenance 3.1 Before Maintenance To meet NFPA-70E, OSHA 1910.333 and other Health/safety/security codes, adhwere to the notice and get the permit needed in advance as below: •...
Page 33 WARNING Danger of electrical shock or injury. Disconnect power to the charger before performing any maintenance. Failure to do so may cause physical injury or damage to the charger. WARNING After power to the charger has been removed and the maintenance door is open, the charger is still hazardous.
Page 34 Clean the air filters regularly. Replace the air filters every 6 to 12 months. The following limited warranty covers all Zerova EV Chargers sold to authorized Zerova Reseller Partners. DC EVSE Standalone DC Fast Charger 31...
Page 35: Zerova Limited Warranty Agreement (Parts Only)
4. Zerova Limited Warranty Agreement (Parts Only) Warranty Coverage: • The warranty period for all Zerova EV chargers is two years (parts only) from the invoice date. A two- month grace period is provided for all shipments direct from Asia to the location designated by the reseller.
Page 36 Except as expressly stated in this warranty or in the written sales agreement between Zerova and its direct customer, no other warranties, expressed or implied will be applicable. In no event shall Zerova be liable for loss of profit or benefits, indirect, special, consequential, or other similar damages arising out of any breach of warranty or otherwise.
Page 37 2. A copy of the original purchase order or other proof of purchase and defect report must accompany the return. 3. EV chargers or parts returned to Zerova that are determined to be misused, altered, or modified from the original manufactured release will be returned to the client freight collect.
Page 38: Appendix A - Replacement Kit List
5. Appendix A - Replacement Kit List Item Description year year year year year year Preventive maintenance Appearance Appearance visual inspection inspection Fan clean and spinning 3 System fan smoothly check Air filter, air inlet and 4 Air filter outlet clean 5 Charging cable Appearance clean 6 PCBA Visible section clean...
Page 39: Appendix B - Preventative Maintenance Worksheet
6. Appendix B - Preventative Maintenance Worksheet Note: Tear out this page and make copies before use. Item Status Remark Appearance visual Appearance inspection inspection Fan clean and spinning System fan smoothly check Air filter, air inlet and outlet Air filter clean Charging cable Appearance clean...
Page 40: Appendix C - Torque Requirements Table
7. Appendix C - Torque Requirements Table Steel Steel Steel Aluminum Aluminum Metric Size Type lbf-in Kg-cm Kgf-cm M2*0.4 Machine 3~4.77 3.5~5.5 0.34~0.54 3~4.5 0.34~0.44 M2.5*0.45 Machine 3~4.77 3.5~5.5 0.34~0.54 3~4.5 0.34~0.44 M3*0.5 Machine 5.5~9 6.5~10.5 0.64~1.04 5.2~8.4 0.51~0.82 M3.5*0.6 Machine 8.5~13 10~15...
Page 41 NOTE 38 DC EVSE Standalone DC Fast Charger...
Page 42 NOTE DC EVSE Standalone DC Fast Charger 39...
Page 43 NOTE 40 DC EVSE Standalone DC Fast Charger...
Page 44 Manufacturer Contact Info Sticker 41 DC EVSE Standalone DC Fast Charger DC EVSE Standalone DC Fast Charger 41...

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