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StarCharge Jupiter V3 Maintenance Manual

Charging infrastructure
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Charging Infrastructure
Jupiter V3 Maintenance Manual
Wanbang Digital Energy Co. Ltd.

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Summary of Contents for StarCharge Jupiter V3

  • Page 1 Charging Infrastructure Jupiter V3 Maintenance Manual Wanbang Digital Energy Co. Ltd.
  • Page 2 Legal Notice Wanbang Digital Energy Co. Ltd. No,39 Longhui Road, Wujin, Changzhou, Jiangsu, China www.starcharge.com Wanbang Digital Energy Co. Ltd. All rights reserved. This document is an integral part of the technical documentation regarding the "Charging Infrastructure" and is protected by copyright. Any use outside of the strict limits of copyright law without written consent is prohibited.
  • Page 3 Contents 1 Scope ........................................... 1 2 Range of Application ......................................1 3 Requirements for Maintenance ..................................1 3.1 Safety ........................................1 3.2 Normal Requirements..................................2 3.3 Responsibility ......................................2 3.4 Skill Requirements ....................................2 4 Preventive Maintenance....................................3 4.1 Site Inspection ...................................... 3 4.2 Appearance Inspection ..................................
  • Page 4 5.1.21 Charger input overvoltage ............................29 5.1.22 Charger input under voltage ............................30...
  • Page 5 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 Jupiter V3. 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 6 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 7 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 8 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 Visually Pass □...
  • Page 9 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 10 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 Visual Pass □...
  • Page 11 Frequency: every six month 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 12 charge automatically and display a warning at the screen. During charging, move the tilt sensor should immediately stop the charge automatically and display a warning at the screen. Setting the upper temperature threshold to below the ambient temperature will result Visual Pass □...
  • Page 13 Pass □ Fail □ Pass □ Fail □ Pass □ Fail □ Pass □ Fail □ Maintenance Manual Wanbang Digital Energy Co. Ltd...
  • Page 14 Corrective Maintenance 5.1 Common Problem 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 15 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 16 2) Check whether the SIM card is workable and APN configuration with SIM card operator and confirm the configuration in web panel. 3) Check “Strength of 4G” in web panel. (If CSQ<18, the site signal is not stable) If using WIFI/Ethernet: 4) Connect your phone or you PC with this WIFI or LAN cable to check whether it is connected to network.
  • Page 17 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 18 1) Power module or power module socket itself is broken; 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;...
  • Page 19 4) If main breaker is normal, connect AC relay in web panel (disable door sensor and open AC relay). Measure the input and output voltage (AC 230V) of AC relay. If no output, measure whether there is 230V to AC relay. If so, replace the AC relay. If not, replace the environment monitor board or A7 board. 5) If AC relay is normal, turn AC relay on in web panel.
  • Page 20 6) 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.
  • Page 21 5.1.5 Meter Fault Phenomenon: “Meter fault” is shown on the display. Analysis: 1) Meter itself is broken; 2) M4 board is broken; 3) The communication line between meter and M4 board is unstable. Solution: 1) Check whether the meter is power on. If not, check the input power. 2) Measure WH1-21/22/23 to pins 5/6/4 of J8 terminal of M4 mainboard using the multimeter buzzer.
  • Page 22 “Input under voltage” is shown on the display. 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 Solution: 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 Solution: 1) Check whether there is water, stone or something inside the charging connector. If so, clean or dry it. 2) Check the wiring of precharge board; 3) Enable pre-precharge function in web panel; 4) Send log file to Star Charge for analysis. 5.1.10 Door Sensor Fault Phenomenon: “Door is open”...
  • Page 25 Analysis: 1) Output relay is broken; 2) The circuit is abnormal; 3) Fuse protector is broken; 4) Power module is broken; 5) EV issue. Solution: 1) Check the wiring on the output relays. 2) Connect output replay in web panel manually. Measure whether there is 12V to control the output relay.
  • Page 26 4) Monitor the status of power modules during charging and replace the abnormal one. 5) Find another EV for testing. 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;...
  • Page 27 3) Measure the resistance between PP and PE, 1.45kΩ normally. If abnormal, replace the charging connector. 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;...
  • Page 28 1) Check the configuration in web panel; 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.
  • Page 29 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; Maintenance Manual Wanbang Digital Energy Co.
  • Page 30 3) Display is broken. Solution: 1) Follow steps in “No 230V input” to check whether is input power for display. 2) Replace the communication cable; 3) Replace the display. 5.1.16 RCCB Trip Fault Phenomenon: RCCB fails to close or trips during frequent charging. Analysis: 1) The aging sensitivity of the circuit breaker fails;...
  • Page 31 3) For the case of charging current exceeding the maximum upper limit and tripping, it is necessary to replace the air switch with a larger range. If there is no belt at that time, it can temporarily reduce the power to the customer to ensure the normal use of the customer; 5.1.17 AC charging socket lock failure Phenomenon: After the charging gun is connected to the vehicle, the gun seat on the charger side is not actively locked.
  • Page 32 5.1.18 220V/380Vpower supply is normal, the indicator light is off Phenomenon: AC charger panel indicator light is off Analysis: 1) The power supply of the external air switch is normal, and the power cord to the main board is not connected tightly or the circuit is broken;...
  • Page 33 Solution： 1) Measure whether the DC12V output of the switching power supply is normal. If the DC12V output is normal, check the power supply circuit from the output to the motherboard; otherwise, replace the switching power supply; 2) Replace the main control board. 5.1.20 Card cannot be activated Phenomenon: 1) There is no response when the indicator light of the charging pile is swiped;...
  • Page 34 Analysis: The AC input voltage is too high, and the AC stake requires an input voltage range of 230V±10% solution: Check whether the power distribution system is normal, the incoming line voltage is higher than the 253V overvoltage value, and you need to contact the local power grid company for rectification. 5.1.22 Charger input under voltage Phenomenon: Charger input under voltage...