Download
Share
Print this page
  1. Manuals
  2. Brands
  3. EVBox Manuals
  4. Battery Charger
  5. Iqon
  6. Maintenance manual

EVBox Iqon Maintenance Manual

Hide thumbs Also See for Iqon:

Advertisement

Quick Links

Download this manual
EVBox Iqon
Maintenance�0%18%/
UL version
1

Advertisement

loading
Need help?

Need help?

Do you have a question about the Iqon and is the answer not in the manual?

Questions and answers

Related Manuals for EVBox Iqon

Summary of Contents for EVBox Iqon

  • Page 1 EVBox Iqon Maintenance�0%18%/ UL version...
  • Page 3 EVBox Iqon Maintenance�0%18%/ UL version...

  • Page 5: Table Of Contents

    Contents 1. Introduction 1.1. Periodical servicing schedule 2. IMPORTANT SAFETY INSTRUCTIONS 2.1. INSTRUCTIONS PERTAINING TO RISK OF FIRE OR ELECTRIC SHOCK 2.2. GENERAL SAFETY INSTRUCTIONS 3. PREPARATION 3.1. Description 3.2. Tools and material 3.3. Prepare the work area 3.4. Open the charging station 4.
  • Page 6 7.1. Commission the charging station 7.2. Test the charging station 8. Disclaimer...

  • Page 7: Introduction

    1. Introduction 1. Introduction This Maintenance Manual tells you how to service and maintain the charging station. You must carefully read and obey the safety information before you start. The owner of the charging station is responsible for the condition of the charging station, whereby both the law regarding the safety of persons, animals, and property must be observed, as well as the installation regulations in force in the country of use.

  • Page 8: Important Safety Instructions

    2. IMPORTANT SAFETY INSTRUCTIONS 2. IMPORTANT SAFETY INSTRUCTIONS Read these instructions before you service or maintain this product. SAVE THESE INSTRUCTIONS. WARNING: When using electric products, basic precautions should always be followed, including the following: 2.1. INSTRUCTIONS PERTAINING TO RISK OF FIRE OR ELECTRIC SHOCK DANGER: Not following the installation and user instructions given in this manual will result in the risk of...
  • Page 9 2. IMPORTANT SAFETY INSTRUCTIONS DANGER: Some electric vehicles release hazardous or explosive gasses when charging which will result in the risk of explosion, which will cause severe injury or death. • Refer to your vehicle user manual to check if your vehicle releases hazardous or explosive gases when charging.

  • Page 10: General Safety Instructions

    2. IMPORTANT SAFETY INSTRUCTIONS station specifications in the charging station installation manual for details. • Refer to your vehicle user manual to check if your vehicle is compatible. WARNING: Exposure of the charging station or the charging cable to heat or flammable substances can result in damage to the charging station, which will cause injury or death.
  • Page 11 2. IMPORTANT SAFETY INSTRUCTIONS • Take the necessary precautions against ESD before touching electronic components. CAUTION: Improper usage of the charging station may result in damage to the charging station, which may cause injury or death. • Read and understand this manual before installing or using the charging station. •...

  • Page 12: Preparation

    3. PREPARATION 3. PREPARATION 3.1. Description Top cover. Lifting eyes. Display. Side panel. Bottom cover. 10. Holder for charging cable plug. Charging cable. 11. Installer box. LED ring. 12. Spare part: Torx T25 screw (2x). Charging cable locking mechanism. 13. Spare part: Thumbnut (2x). Charger box.

  • Page 13: Tools And Material

    Wire cutter. Screwdriver, flat blade, 8 mm. Marker pen, black indelible ink. Tools - optional EVBox Dual Socket Test Box, article number 462323 (or equivalent electrical vehicle test box CCS1). Materials - locally-sourced Cable ties, UL-approved (US only), various sizes.

  • Page 14: Prepare The Work Area

    3. PREPARATION 3.3. Prepare the work area DANGER: Working on electric installations without proper precautions will result in the risk of electric shock, which will cause severe injury or death. • Read and obey the safety precautions at the beginning of this manual before you install, repair, service or use this charging station.
  • Page 15 3. PREPARATION 4. Unlock the top and bottom covers using the key, then remove the covers. Put the covers front side up in a place where they will not be damaged. 5. Open the side covers as follows: Loosen two Torx screws that secure the side panels at the top.
  • Page 16 3. PREPARATION Fully extend the charging cables and insert the safety pin. Install a flanged Torx T25 M5 x 10 mm screw to secure the safety pin.
  • Page 17 3. PREPARATION Loosen two Torx screws that secure the side panels at the bottom. Remove the eight thumbnuts.
  • Page 18 3. PREPARATION Carefully slide open each side panel.

  • Page 19: Maintenance Instructions

    4. MAINTENANCE INSTRUCTIONS 4. MAINTENANCE INSTRUCTIONS DANGER: Working on electric installations without proper precautions will result in the risk of electric shock, which will cause severe injury or death. • Switch off input power before working on the charging station. •...
  • Page 20 4. MAINTENANCE INSTRUCTIONS Loosen six Phillips PH2 screws and remove the installer box cover. Disconnect the power wires from the terminal blocks.
  • Page 21 4. MAINTENANCE INSTRUCTIONS Disconnect the RS485 wires from the terminal blocks. Note: Carefully record which RS485 wiring connects to the charging station. The RS485 wiring depends on the configuration: The Smart Charging connection is optional, and is only found on the Hub station. ◦...
  • Page 22 4. MAINTENANCE INSTRUCTIONS and rubber seals from the conduit fittings and cable glands. 3. Disconnect the charging cables: Remove four Torx T25 screws and the service hatch from the charger box.
  • Page 23 4. MAINTENANCE INSTRUCTIONS Disconnect the following two sets of wires from the charger box: Note: The terminals on the left are for the left charging cable and brake solenoid. The terminals on the right are for the right charging cable and brake solenoid. Wire Terminal Signal (red)
  • Page 24 4. MAINTENANCE INSTRUCTIONS Cut and discard four cable ties that secure two ferrite beads to each PE/G wire. Remove and keep two ferrite beads from each PE/G wire. Unscrew the four cable glands.
  • Page 25 4. MAINTENANCE INSTRUCTIONS Pull the two charging cables and two solenoid cables through the four cable glands. Remove and keep the nuts and rubber seals from the cable glands. 4. Remove the installer box and charger box: Remove four Torx screws that secure the installer box to the charging station.

  • Page 26: Install The Charger Box And Installer Box

    4. MAINTENANCE INSTRUCTIONS Hold the charger box in place, then remove four Torx screws that secure the charger box to the charging station. Remove the charger box and the installer box as one assembly from the charging station. CAUTION: The charger box and installer box assembly weighs approximately 9.3 kg. 5.
  • Page 27 4. MAINTENANCE INSTRUCTIONS Loosen six Phillips PH2 screws and remove the installer box cover. Secure the installer box with four Torx screws. 2. Connect the charging cables:...
  • Page 28 4. MAINTENANCE INSTRUCTIONS Remove four Torx T25 screws and the service hatch from the charger box. Install the cable gland nuts and rubber seals on the solenoid cables and charging cables. Guide the cables through the four cable glands. Make sure that the cables use the correct glands and that the cable routing is correct.
  • Page 29 4. MAINTENANCE INSTRUCTIONS Tighten the four cable glands. Install two ferrite beads on each PE/G wire and secure them in position using a UL-approved cable tie. Note: Position the ferrite beads on the PE/G wire so the wire will fit in the charger box without touching the ferrite beads on the other PE/G wire.
  • Page 30 4. MAINTENANCE INSTRUCTIONS In the charger box, route the cables to their applicable terminals. Connect the following two sets of wires to the charger box: Note: The terminals on the left are for the left charging cable and front brake solenoid. The terminals on the right are for the right charging cable and rear brake solenoid.
  • Page 31 4. MAINTENANCE INSTRUCTIONS Pull on each wire to make sure it is correctly connected. The indicators on the terminal blocks must be in the locked position. Make sure that the ferrite beads on one PE/G wire do not touch the ferrite beads on the other PE/G wire.
  • Page 32 4. MAINTENANCE INSTRUCTIONS To ensure the station IP rating and the security of cables, make sure that the cable glands on the top of the charger box are tight: Check the four cable gland sealing nuts on the outside of the charger box. ◦...
  • Page 33 4. MAINTENANCE INSTRUCTIONS Feed the power cables and RS485 cables through the conduit fittings into the installer box. Push the ferrules on the RS485 network cable wires fully into the terminal blocks. Note: Connect the RS485 wiring in the same configuration that you recorded during removal. The RS485 wiring depends on the configuration: The Smart Charging connection is optional, and is only found on the Hub station.
  • Page 34 4. MAINTENANCE INSTRUCTIONS must be in the locked position. Connect the power wires to the terminal blocks and tighten the screws.
  • Page 35 4. MAINTENANCE INSTRUCTIONS Install the installer box cover then tighten the six screws. Install the installer box frame using four Torx screws. 4. Apply the new charging station stickers as follows: Note: The new charger box has a unique registration number. This number is on a sticker that needs to be added to the charging station.

  • Page 36: Replace A Kwh Meter

    4. MAINTENANCE INSTRUCTIONS Clean the area on the bottom right side of the charging station where the sticker will be placed. CAUTION: Do not use aggressive chemical cleaners or solvents. Place the sticker on the right side of the charging station. On the existing sticker on the left side of the charging station, use a black indelible marker to hide the old EVB-P registration number.
  • Page 37 4. MAINTENANCE INSTRUCTIONS 2. Remove four Torx screws and the frame from the installer box. 3. Remove six Torx PH2 screws and the installer box cover.
  • Page 38 4. MAINTENANCE INSTRUCTIONS 4. Loosen the screws that secure the two terminal covers to the kWh meter, then remove the terminal covers. 5. Disconnect the following wires from the kWh meter: Wire Terminal Signal (solid color) Signal (white/color) Current transformer (CT) 1 (white) Current transformer (CT) 1 (black) Current transformer (CT) 2 (white) Current transformer (CT) 2 (black)

  • Page 39: Install The Kwh Meter

    4. MAINTENANCE INSTRUCTIONS 6. Release the kWh meter from the DIN rail, then remove the kWh meter from the installer box. 4.2.2. Install the kWh meter 1. Place the kWh meter on the DIN rail, pull down the lock then push the kWh meter on to the DIN rail.
  • Page 40 4. MAINTENANCE INSTRUCTIONS 2. Connect the following wires to the kWh meter: Wire Terminal Signal (solid color) Signal (white/color) Current transformer (CT) 1 (white) Current transformer (CT) 1 (black) Current transformer (CT) 2 (white) Current transformer (CT) 2 (black) Power phase L1 Power phase L2 Note: The varistor is crimped to the power phase L1 and L2 wires.

  • Page 41: Replace A Charging Cable

    4. MAINTENANCE INSTRUCTIONS 4. Install the installer box cover then tighten the six PH2 screws. 5. Install the installer box frame using four Torx screws. 6. Close the charging station (see Close-up after maintenance on page 55). 7. Test the charging station (see Test the charging station on page 60).
  • Page 42 4. MAINTENANCE INSTRUCTIONS Remove four Torx T25 screws and the service hatch. Disconnect the following set of wires for the charging cable that you are replacing: Note: The terminals on the left side are for the left charging cable. The terminals on the right side are for the right charging cable.
  • Page 43 4. MAINTENANCE INSTRUCTIONS keep two ferrite beads from the PE/G wire. Unscrew the cable gland.
  • Page 44 4. MAINTENANCE INSTRUCTIONS Pull the charging cable through the cable gland. Remove and keep the nut and rubber seal from the cable gland. 3. Remove the charging cable: Remove the cable ties that secure the charging cable to the charging station. Note: The right charging cable has two cable ties.
  • Page 45 4. MAINTENANCE INSTRUCTIONS Push and pull the charging cable out of the charging cable locking mechanism to access the strain relief. Remove and discard the strain relief.

  • Page 46: Install The Charging Cable

    4. MAINTENANCE INSTRUCTIONS Pull the charging cable out of the charging station. 4.3.2. Install the charging cable 1. Install the charging cable: Place a protective mat on the ground and place the charging cable and plug on the mat. Remove and retain the strain relief from the new charging cable. Note the crimp mark on the charging cable where the strain relief was installed.
  • Page 47 4. MAINTENANCE INSTRUCTIONS Push the brake down to open the charging cable locking mechanism then insert the charging cable. Guide the charging cable around the counterweight and feed it through the strain relief hole at the top. Pull the charging cable out 1 m (40 in).
  • Page 48 4. MAINTENANCE INSTRUCTIONS Install the strain relief on the charging cable at the crimp mark (730 mm (28 ¾ in) from the beginning of the black insulation). Pull the charging cable back until the strain relief reaches the charging cable locking mechanism.
  • Page 49 4. MAINTENANCE INSTRUCTIONS Secure the charging cable to the charging cable support using new cable ties. Note: The right charging cable has two cable ties. The left charging cable has one cable tie. L = Left, R = Right Remove the protection cap from the end of the charging cable.
  • Page 50 4. MAINTENANCE INSTRUCTIONS Install the cable gland nut and rubber seal on the charging cable. Guide the charging cable through the cable gland then tighten the cable gland. 2. Connect the charging cable: Install two ferrite beads on the charging cable PE/G wire. Secure the ferrite beads in position using one UL-approved cable tie.
  • Page 51 4. MAINTENANCE INSTRUCTIONS Connect the following set of wires for the charging cable that you are replacing: Note: The terminals on the left side are for the left charging cable. The terminals on the right side are for the right charging cable. Wire Terminal Signal (red)
  • Page 52 4. MAINTENANCE INSTRUCTIONS Make sure that the ferrite beads on one PE/G wire do not touch the ferrite beads on the other PE/G wire. To ensure the station IP rating and the security of cables, make sure that the cable glands on the top of the charger box are tight: Check the four cable gland sealing nuts on the outside of the charger box.

  • Page 53: Replace A Led Ring

    4. MAINTENANCE INSTRUCTIONS Install the service hatch using four Torx T25 screws. 3. Close the charging station (see Close-up after maintenance on page 55). 4. Test the charging station (see Test the charging station on page 60). 4.4. Replace a LED ring Two LED rings are installed.

  • Page 54: Install The Led Ring

    4. MAINTENANCE INSTRUCTIONS 4.4.2. Install the LED ring 1. Make sure the pin contacts on the charging station are clean. 2. Align the two pins on the LED ring with the holes in the charging station and push the LED ring into position.
  • Page 55 4. MAINTENANCE INSTRUCTIONS 3. Install two screws to secure the LED ring. 4. Close the charging station (see Close-up after maintenance on page 55). 5. Test the charging station (see Test the charging station on page 60).

  • Page 56: Servicing Instructions

    5. SERVICING INSTRUCTIONS 5. SERVICING INSTRUCTIONS Refer to Periodical servicing schedule on page 3 for the recommended servicing schedule. CAUTION: Do not use a hose or a high pressure spray to clean the charging station. CAUTION: Do not use aggressive chemical cleaners or solvents to clean the charging station. 5.1.
  • Page 57 5. SERVICING INSTRUCTIONS 4. Fully extend the charging cables and insert the safety pin. 5. Clean the external surfaces of the charging cables and plugs using a soft damp cloth and mild detergent. 6. Check the charging plug for damage and for foreign matter. Clean if necessary. 7.
  • Page 58 5. SERVICING INSTRUCTIONS 9. Retract the charging cables by pushing down the levers in the cable locking mechanism. 10. Install the top cover (see Close-up after maintenance on page 55).

  • Page 59: Close-Up After Maintenance

    6. Close-up after maintenance 6. Close-up after maintenance 6.1. Close the charging station Note: Spare thumbnuts and Torx M5 T25 screws are installed near the charging cable brake mechanism (see Description on page 1. Close the side covers as follows: Slide the side panels closed.
  • Page 60 6. Close-up after maintenance Tighten two Torx screws that secure the side panels at the bottom. Remove the flanged Torx T25 M5 x 10 mm screw that secures the safety pin. Note: Do not install the safety pin screw when the safety pin has been removed. The screw can catch on the charging cable mechanism.
  • Page 61 6. Close-up after maintenance Remove the safety pin and place it back into its holder. Retract the charging cables by pushing down the levers in the cable locking mechanism.
  • Page 62 6. Close-up after maintenance Tighten two Torx screws that secure the side panels at the top. 2. Install the bottom cover.
  • Page 63 6. Close-up after maintenance 3. Install the top cover. 4. Place the charging cable plugs in the holders. Make sure the cables are fully retracted.

  • Page 64: Testing And Commissioning

    7.1. Commission the charging station After replacing a charger box in an Iqon Hub, use the EVBox Connect App to connect the Hub to the charging management system of the CPO. Then contact the support channel of the CPO to re-register the new EVB-P registration number of the Hub charging station with the CPO, and request that the CPO configures the Iqon Hub for use.
  • Page 65 The present document is drawn up by way of information only and does not constitute an offer binding upon EVBox ("EVBox"). EVBox has compiled the contents of this document to the best of its knowledge. No express or implied warranty is given for the completeness, accuracy, reliability or fitness for particular purpose of its content and the products and services presented therein.
  • Page 66 8. Disclaimer...
  • Page 68 UL EVBIM_102021 © EVBox Manufacturing B.V.