Page 1 Flexpole Workshop Manual Edition 01.2025...
Page 2 The following information regarding repairs and the use of the documentation must be observed: Model-related information does not necessarily reflect current charging status data. Repair work may only be carried out on the charging station by specialist personnel who have been trained in advance.
Page 3: Table Of Contents
Workshop Manual 01.2025 Contents Technical data 00 - ..................Revision history .
Page 4 Workshop Manual 01.2025 Removing and installing the 12-V back-up battery, BAT ........Removing and installing the battery tray for the 12-V back-up battery, BAT .
Page 5 ......... . . Assembly overview of components/control units in the front area of the Flexpole .
Page 6 ....................Removing the mains connecting cable of the CEE connector, Flexpole with mains con- nection block .
Page 7 Workshop Manual 01.2025 6.10 Removing and installing the sensor unit SU1/2 for the electricity meters for delivered en- ergy ....................Voltage converter .
Page 8 Workshop Manual 01.2025 viii Contents...
Page 9: Technical Data
IM30” on page 80 ⇒ “ Notes on replacing and addressing volt- 04/2024 added age converters” on page 189 ⇒ “ Switching off the Flexpole” on page 133 03/2024 revised ⇒ “ Notes on replacing high-voltage batteries” 03/2024 added on page 109 ⇒ ...
Page 10: Safety Information
Assembly overview – switching contactor for charg- ⇒ “ Assembly overview – charg- ing function added ing unit for high-voltage battery charging” on page 139 ⇒ “ Switching off the Flexpole” on page 133 02/2023 revised ⇒ “ Removing and installing the water sensor, 02/2023 added SJ”...
Page 11: Protective Clothing
During servicing work, additional protection may be required when handling coolant and refrigerant. Condition ● Comply with safety data sheets! See: ⇒ https://www.elli.eco/de/downloads ● Observe the safety instructions and warnings. Safety measures when working on charging stations that use high-volt-...
Page 12: Safety Precautions When Working In The Vicinity Of High-Voltage Components
Workshop Manual 01.2025 ◆ Have the high-voltage system de-energised by a high-voltage technician (HVT) or a high-voltage expert (HVE). Danger to life due to electrical and magnetic fields Electrical and magnetic fields can arise at the high-voltage system. Death or severe bodily injury due to mal- function of active implants (e.g.
Page 13: Safety Precautions When Working On Air Conditioning Systems
Workshop Manual 01.2025 Safety precautions when working on air conditioning systems Risk of fatal injury and explosions due to ignition sources Risk of fatal injury and explosions due to ignition sources near air conditioning systems and refrigerant tanks. Escaping refrigerant can ignite and cause explosions. Risk of severe or fatal injury from explosions. ◆...
Page 14: The Five Safety Rules
Workshop Manual 01.2025 ● Before connecting the filling system to the air conditioning system, ensure that all shut-off valves present are closed. ● Before the air conditioner service station is disconnected from the air conditioning system, make sure that the process is completed so that as little refrigerant as is technically feasible enters the atmosphere.
Page 15: Repair Notes
Workshop Manual 01.2025 Observe the five safety rules: 4. Earth and short-circuit Earthing and short-circuiting provides a last safety resort if the system is re-energised despite all the other measures. This step also prevents residual voltages from being discharged via your body if you touch the installation.
Page 16: Refrigerant And Refrigerant Oil
Workshop Manual 01.2025 Refrigerant and refrigerant oil Repair instructions for refrigerant Condition ● No refrigerant R134a may be filled into an air conditioning system for refrigerant R1234yf. ● An information sign is affixed to the thermal management unit that indicates the refrigerant used. Condition ●...
Page 17: Handling Refrigerants
Workshop Manual 01.2025 ● Prevent container from falling over! Upright bottles should be prevented from falling, and bottles placed flat should be secured against rolling away. Condition ● Do not throw containers! On impact, the container could be deformed in shape so much that it could split. Refrigerant would vaporise very suddenly, thereby releasing very high pressures.
Page 18: Handling Critical High-Voltage Batteries
◆ The Volkswagen dealership must contact the nearest high-voltage service centre or importer as a matter of urgency. ◆ The Flexpole must be marked with the warning sign “Danger: High voltage”. Additional labels must be af- fixed if quarantine is required.
Page 19 7 - Suitable open area (e.g. car park) Next steps Condition ● Cordon off the outer safety zone! ● Immediately report the issue to the technical support team of the Flexpole importer. ● Inspect the damaged Flexpole carefully and assess the following criteria. Evaluation criteria Meaning Is there any indication of a fire? If a question is answered with “YES”, then exercise...
Page 20: Contact Corrosion
Cordon off a wide area around the battery and notify the responsible electrically skilled person (EFK) or the importer. b) If the damaged Flexpole can be classified as non-hazardous on the basis of the evaluation crite- ria, perform the following actions: Perform classification/condition assessment of the high-voltage lithium iron phosphate batteries via “Diag-...
Page 21 Workshop Manual 01.2025 ◆ Only install clean parts. ◆ Replacement parts must be removed from their packaging only immediately before their installation. ◆ Do not use parts that have been stored without packaging (e.g. in toolkits etc.). ◆ Any transport and protective packaging and caps present may only be removed immediately prior to in- stallation.
Page 22: Cooling
– Remove maintenance covers page CAUTION When the Flexpole 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 23: Discharging The Cooling System
– Open the front door CAUTION When the Flexpole 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 scal- ded.
Page 24: Checking The Filling Quality
Installing Install in reverse order of removal, observing the following: ⇒ “ Filling cooling system” on page – ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆ ⇒ “ Assembly overview – thermal management unit, TMS” on page 50 ◆...
Page 25: Filling Cooling System
Distilled water must be used when mixing coolant concentrate, as the contents of tap water may vary by country and region. Only use coolant additives approved for the Flexpole ⇒ Electronic parts catalogue. The use of other coolant additives can significantly impair the anti-corrosion effect. The resulting damage could lead to loss of coolant and subsequent severe damage.
Page 26 Workshop Manual 01.2025 The temperature reading on the refractometer corresponds to the “ice flocculation point”. Flakes of ice may start forming in the coolant below this temperature. Do not reuse old coolant. Use only a water/coolant additive mixture as lubricant for coolant hoses. Filling –...
Page 27: Checking The Coolant Level And Topping It Up
– Remove maintenance covers page CAUTION When the Flexpole 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 28 Workshop Manual 01.2025 – Allow the cooling system to cool down and open the cap -1- of the coolant expansion tank -2-. – Add coolant up to the “max. marking” -3- of the coolant ex- pansion tank -2-. Installing Install in reverse order of removal, observing the following: Specified torques ◆...
Page 29: Coolant Pipes
Workshop Manual 01.2025 Coolant pipes Assembly overview – coolant pipes 1 - Coolant pipes q for voltage convert- ⇒ “ Removing and installing coolant pipes” on page 21 2 - Hose clips 3 - 2-way coolant valve 4 - Shut-off valves q 4 pcs. 5 - Hose clips 6 - Bolt q 2 Nm 7 - Coolant pipes q Supply and return...
Page 30 Workshop Manual 01.2025 Remove the coolant line from the component concerned, to do – Release the securing clip -1- -arrow A-. – Pull the coolant pipe -2- off the component -arrow B-. Installing – Place the safety clasp back in its original position. Attach the coolant pipe to the component. A clicking noise indicates that it has locked in place correctly.
Page 31: Starter, Current Supply, Ccs
Workshop Manual 01.2025 27 - Starter, current supply, CCS 12-V back-up battery, BAT Assembly overview – 12-V back-up battery, BAT 1 - Bolt q for black negative battery terminal connection q M5 x 8 cross-head screw incl. spring lock washer q 2.5 Nm 2 - Bolt q for red positive bat- tery terminal con-...
Page 32: Removing And Installing The Battery Tray For The 12-V Back-Up Battery, Bat
⇒ “ Assembly overview – 12-V back-up battery, BAT” on page 23 ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 Removing and installing the battery tray for the 12-V back-up battery, Observe the safety information.
Page 33: Checking The 12-V Backup Battery, Bat
Installing Install in reverse order of removal, observing the following: Condition ● Return all cable positions and their fasteners to the delivery condition in order to avoid damage! ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆...
Page 34 If there are no measured values when switch CB2 is switched on, check fuse FU7, see ⇒ circuit diagram!. During the charging process, the Flexpole is switched on but does not start up! (Door contact switch active) – Determine the charge level using the table.
Page 35 Result of voltage test Action Measurement result: voltage > 12 V “OK” Switch off main switch, CB2 -2-. Switch on the Flexpole and, if necessary, clear the error. Measurement result: voltage 11 V–12 V Connect the battery charger to the test connector and charge for 15 minutes.
Page 36: Front Doors, Door Components, Central Locking
1 - Front door ⇒ “ Removing and installing the door” on page 29 2 - Door hinge q 4 pcs. 3 - Door wiring harness 4 - Flexpole 5 - Door seal ⇒ “ Removing and installing the inner door seal” on page 28 6 - Bolt q for door hinge q 3 pcs.
Page 37: Removing And Installing The Door
Install in reverse order of removal, observing the following: – Align the vulcanisation point -3-. – Start installing the inner door seal -1- at the vulcanisation point -3-. ⇒ “ Switching on the Flexpole” on page – 137. Removing and installing the door Special tools and workshop equipment required ◆...
Page 38: Opening The Door
⇒ “ Assembly overview – front door” on page 28 Opening the door WARNING Never carry out electrical work on the Flexpole while standing on a ladder. There is a risk of fall- ing. Observe the safety information. Repair Group 57 - Front doors, door components, central locking...
Page 39 ● Warning signs “Danger: high voltage” and “Do not switch on” must be affixed. The five safety rules must be observed when working on the system⇒ “ The five safety rules” on page 6 ⇒ “ Switching off the Flexpole” on page – Switch off the Flexpole 133.
Page 40: Door Components
Workshop Manual 01.2025 Door components Assembly overview – door handle and door lock 1 - Guide q for door lock 2 - Nut 3 - Door locking mecha- nism 4 - Striker 5 - Bolt q for striker pin 6 - Bolt 7 - Retaining ring 8 - Washer 9 - Nut 10 - Door lock 11 - Bolt q for door fitting 12 - Door fitting q with lock cylinder ⇒ ...
Page 41: Tightening Torques
– In the correct position, the lock cylinder -3- can be pulled out, -arrow-. Installing Install in reverse order of removal, observing the following: ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆ Screw = 2 Nm...
Page 42: Rear Doors/Door Components
1 - Mains connections q for mains connec- tion using CEE con- nector ⇒ “ Removing the mains connecting cable of the CEE connector, Flexpole with mains connec- tion block” on page 132 2 - Door dampers q 16 Nm 3 - Rear door ⇒ “ Removing and installing the door”...
Page 43: Removing And Installing The Inner Door Seal
Observe the safety information. ◆ ⇒ “ Safety precautions when working in the vicinity of high-voltage components” on page 4 Removing ⇒ “ Switching off the Flexpole” on – Switch off the Flexpole page 133. Condition ● The LED status indicators -1- are off.
Page 44 Workshop Manual 01.2025 Flexpole with 4-pole load transfer switch, QS – Unscrew the screws -7- and disconnect the wires from the 4- pole load transfer switch, QS -1- to -4-. – Unscrew the screw -6- and removed the PE conductor -5-.
Page 45 Workshop Manual 01.2025 – Move the mains connecting cable -1- clear from the CEE connector. – Seal the ends of the mains connector cable -2- with heat- shrinkable end caps to protect against accidental contact. – Position the mains connector cable -1- as shown in the illus- tration.
Page 46: Opening The Door
⇒ “ Assembly overview – main fuse carrier” on page 199 Opening the door WARNING Never carry out electrical work on the Flexpole while standing on a ladder. There is a risk of fall- ing. Observe the safety information. ◆...
Page 47 ● Warning signs “Danger: high voltage” and “Do not switch on” must be affixed. The five safety rules must be observed when working on the system⇒ “ The five safety rules” on page 6 ⇒ “ Switching off the Flexpole” on page – Switch off the Flexpole 133.
Page 48: Door Components
Workshop Manual 01.2025 Door components Assembly overview – door handle and door lock 1 - Striker 2 - Bolt q for striker pin 3 - Door locking mecha- nism 4 - Nut 5 - Guide q for door lock 6 - Nut 7 - Door fitting q with lock cylinder ⇒ “ Removing and installing lock cylin- der”...
Page 49: Assembly Overview - Door Handle And Door Lock, Service Door
Workshop Manual 01.2025 Assembly overview – door handle and door lock, service door 1 - Nut 2 - Top section of guide q for door lock 3 - Door lock at top 4 - Lower section of guide q for door lock 5 - Service door 6 - Washer 7 - Bolt 8 - Retaining ring 9 - Door fitting q with lock cylinder ⇒ ...
Page 50 Workshop Manual 01.2025 Installing Install in reverse order of removal, observing the following: ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆ Screw = 2 Nm Repair Group 58 - Rear doors/door components...
Page 51: Exterior Equipment
Workshop Manual 01.2025 66 - Exterior equipment Covers/panels/trim Assembly overview – housing cover 1 - Housing cover ⇒ “ Removing and installing the hous- ing cover” on page 45 2 - Aerial connections, Fakra system q for combined aerial, q for combined aerial, 3 - Nut q 4 pcs.
Page 52: Assembly Overview - Covers And Trim
Workshop Manual 01.2025 Assembly overview – covers and trim 1 - Cover q for the advertising screen, AD-HMI ⇒ “ Removing and installing the adver- tising screen, AD- HMI” on page 74 2 - Bolt q 8 pcs. 3 - Seal 4 - Cover q for maintenance ac- cess ⇒ ...
Page 53: Assembly Overview - Water Drain Hoses
Workshop Manual 01.2025 Assembly overview – water drain hoses 1 - Support q for voltage convert- er; G1 – G6 2 - Thermal management system 3 - Hose clip q 2 pcs. 4 - Water drain hose q for thermal manage- ment system ⇒ “ Cleaning the wa- ter drain hoses”...
Page 54 Workshop Manual 01.2025 Removing ⇒ “ Switching off the Flexpole” on – Switch off the Flexpole page 133. Condition ● The LED status indicators -1- are off. The images shown here may differ depending on the retrofit/ conversion status of the Flexpole! –...
Page 55: Removing And Installing The Covers For Maintenance Access
⇒ “ Assembly overview – thermal management unit, TMS” on page 50 Removing and installing the covers for maintenance access Removing ⇒ “ Switching off the Flexpole” on page 133 – – Remove the bolts -3- and the cover -2-.
Page 56: Removing And Installing The Base Trim
-1-. Installing Install in reverse order of removal, observing the following: Condition ● Check the seals that are installed for damage and replace them if necessary. ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆...
Page 57: Cleaning The Water Drain Hoses
Workshop Manual 01.2025 Cleaning the water drain hoses Special tools and workshop equipment required ◆ Cleaning and insertion aid Observe the safety information. ◆ ⇒ “ Safety precautions when working in the vicinity of high-voltage components” on page 4 ⇒ ...
Page 58: Air Conditioning System
Workshop Manual 01.2025 87 - Air conditioning system Thermal management unit, TMS Assembly overview – thermal management unit, TMS 1 - Seal q 2 pcs. 2 - Thermal management unit, TMS ⇒ “ Removing and installing the ther- mal management unit, TMS” on page 50 3 - Bolt q 8 pcs.
Page 59 ⇒ “ Safety precautions when working on the cooling system” on page ◆ ⇒ “ Safety precautions when working with chemical substances” on page Removing ⇒ “ Switching off the Flexpole” on – Switch off the Flexpole page 133. Condition ●...
Page 60 Workshop Manual 01.2025 – Release hose clips -arrows- on the thermal management unit connections -1- using hose clamp pliers. – Disconnect the coolant hoses -2- and water drain hose -3- at the thermal management unit connections -1-. – Disconnect the electrical connector -1-. –...
Page 61: Removing And Installing Ventilation Grilles
⇒ “ Assembly overview – housing cover” on page 43 ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 ◆ ⇒ “ Assembly overview – main fuse carrier” on page 199 Removing and installing ventilation grilles Removal and installation is described for the rear ventilation grille.
Page 62: Working With The Air Conditioner Service Station
– Unscrew the bolts -2- on the ventilation grille -1-. – Unlock the ventilation grille -1- -arrow A- and remove -arrow B-. Installing Install in reverse order of removal, observing the following: ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆...
Page 63 If repairs need to be made to the refrigerant circuit of the air conditioning system of a Flexpole that has had chemical substances (leak-stop additives) added to its refrigerant circuit to seal leaky components (or if there...
Page 64: Connecting The Air Conditioner Service Station To The Refrigerant Circuit
Workshop Manual 01.2025 that have built up in the components of the refrigerant circuit may become detached at a later date, possi- bly causing the air conditioning system to fail again. ◆ Contaminated refrigerant may render the entire load of your air conditioner service station unusable. ◆...
Page 65 Workshop Manual 01.2025 ◆ ⇒ “ Safety precautions when working on air conditioning systems” on page 5 ◆ ⇒ “ Safety precautions when using air conditioner service stations” on page 5 ⇒ “ Removing and installing the covers for maintenance access” on page –...
Page 66: Performing A Refrigerant Gas Analysis
Workshop Manual 01.2025 – Perform gas analysis using the air conditioner service station (only necessary if refrigerant is to be extrac- ⇒ “ Working with the air conditioner serv- ted or if the pressures in the refrigerant circuit are to be checked) ice station”...
Page 67 Workshop Manual 01.2025 – Connect the gas analyser or the air conditioner service sta- tion-1- to the refrigerant circuit in accordance with the rele- vant operating manual and switch it on. ⇒ Air conditioner ⇒ “ Connecting the air con- service station operating manual, ditioner service station to the refrigerant circuit”...
Page 68 If contaminated refrigerant is detected during the gas analysis, talk to the customer before continuing the work and make them aware of the following: The Flexpole’s refrigerant circuit contains contaminated refrigerant or refrigerant of unknown composition that does not comply with the manufacturer's specifications. This refrigerant: ◆...
Page 69: Discharging The Refrigerant Circuit
– Drain the refrigerant circuit using the air conditioner service station in accordance with the appropriate operating manual. If work on the Flexpole is to be carried out after draining, for which the air conditioner service station is not required.
Page 70: Evacuating The Refrigerant Circuit
– Open the refrigerant circuit at a connection. Condition ● Never operate the Flexpole when the refrigerant circuit is empty. There is a danger that the air conditioner compressor will be damaged. – Perform the work required on the refrigerant circuit.
Page 71 Workshop Manual 01.2025 ● The workflow is to be followed as described in the operating manual for your air conditioner service station -1- ⇒ Air con- ditioner service station operating manual. ● The quantity of refrigerant oil in the air conditioner service station -1- has been checked and rectified where necessary ⇒ ...
Page 72 Workshop Manual 01.2025 If there is a suspected leak in the refrigerant circuit, switch off the air conditioner service station if necessary and allow it to stand for as long as possible (e.g. at least 1 hour to check the air-tightness of the refrigerant circuit) ⇒ ...
Page 73 Workshop Manual 01.2025 ◆ If the pressure in the refrigerant circuit rises only slowly after evacuation, e.g. due to refrigerant (or mois- ture) evaporating from the refrigerant oil, evacuate the refrigerant circuit again and observe the vacuum indicator for a longer period of time. ◆...
Page 74: Charging The Refrigerant Circuit
62 If work is to be carried out on the Flexpole after evacuation for which the air conditioner service station is not required. ◆ Disconnect the air conditioner service station from the refrigerant circuit and switch off ⇒ ...
Page 75 Workshop Manual 01.2025 – Connect the air conditioner service station -1- to the refriger- ⇒ “ Connecting the air conditioner service station ant circuit to the refrigerant circuit” on page – Evacuate the refrigerant circuit using the air conditioner ⇒ ...
Page 76: Switching Off Air Conditioner Service Station And Separating From Refrigerant Circuit
If one of these two valves (the valve on the service connection of the Flexpole or the valve in the service coupling to the filler hose) does not close properly, all the refrigerant may escape from the refrigerant cir- cuit of the Flexpole or from the filler hose.
Page 77 Workshop Manual 01.2025 of the service connections of the refrigerant circuit might not be leak-tight and refrigerant is escaping from the refrigerant circuit (extract the refrigerant and renew the defective valve). Before conveying the refrigerant from the filler hoses back into the air conditioner service station, unscrew the handwheels of both service couplings as far as they will go.
Page 78: Communication
Workshop Manual 01.2025 91 - Communication Infotainment system/components/control units Assembly overview of components/control units in the front area of the Flexpole 1 - Additional display and operating unit, ⇒ “ Removing and installing the addi- tional display and operating unit, HMI”...
Page 79: Assembly Overview Of Components/Control Units In The Middle Area Of The Flexpole
SJ 17 - Payment terminal, POS q Different versions available ⇒ “ Removing and installing the payment terminal” on page 79 Assembly overview of components/control units in the middle area of the Flexpole 1 - Bolt q 4 pcs. q 2 Nm 2 - Support q 2 pcs.
Page 80 Workshop Manual 01.2025 8 - Control unit for the charging unit, CCU2 ⇒ “ Removing and installing the control unit for the charging unit, CCU1/2,” on page 179 9 - Bolt q 4 pcs. q 2 Nm 10 - Support 11 - Holder q for the control unit for the charging unit ⇒ ...
Page 81: Assembly Overview Of Components/Control Units In The Rear Area Of The Flexpole
24 - Control unit for battery management system, BMS1 ⇒ “ Removing and installing the battery management system control unit, BMS1/2” on page 177 Assembly overview of components/control units in the rear area of the Flexpole 1 - Holder q for telecommunica- tions control unit ⇒ ...
Page 82: Removing And Installing Components/Control Units
Observe the safety information. ◆ ⇒ “ Safety precautions when working in the vicinity of high-voltage components” on page 4 The images shown here may differ depending on the retrofit/conversion status of the Flexpole! Removing ⇒ “ Opening the door” on page –...
Page 83 – 137. Tightening torques ◆ ⇒ “ Assembly overview of components/control units in the front area of the Flexpole” on page 70 ◆ ⇒ “ Assembly overview – covers and trim” on page 44 2 Removing and installing components/control units...
Page 84: Removing And Installing The Additional Display And Operating Unit, Hmi
137. Tightening torques ◆ ⇒ “ Assembly overview of components/control units in the front area of the Flexpole” on page 70 ◆ ⇒ “ Assembly overview – covers and trim” on page 44 Removing and installing the telecommunications control unit, TBOX1/2 Observe the safety information.
Page 85: Removing And Installing The Telecommunications Control Unit, Tbox2 (Lnbox710)
⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 Removing and installing the telecommunications control unit, TBOX2 (lnBox710) Observe the safety information. ◆...
Page 86: Removing And Installing The Control Unit For High-Voltage Charge Monitoring And Release, Secc1/2
Tightening torques ◆ Aerial cable tightening torque 0.4 Nm ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 Removing and installing the control unit for high-voltage charge moni- toring and release, SECC1/2 Observe the safety information.
Page 87: Removing And Installing The Payment Terminal
Check the current software version, see ⇒ Diagnostic manual. Tightening torques ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 Removing and installing the payment terminal 2.6.1 Removing and installing the payment terminal, OPM-C60 Observe the safety information.
Page 88: Removing And Installing The Payment Terminal, Im30
137. Tightening torques ◆ ⇒ “ Assembly overview of components/control units in the front area of the Flexpole” on page 70 ◆ ⇒ “ Assembly overview – covers and trim” on page 44 2.6.2 Removing and installing the payment terminal, IM30 Observe the safety information.
Page 89: Removing And Installing The Payment Terminal Control Unit, Opm-C60
137. Tightening torques ◆ ⇒ “ Assembly overview of components/control units in the front area of the Flexpole” on page 70 ◆ ⇒ “ Assembly overview – covers and trim” on page 44 Removing and installing the payment terminal control unit, OPM-C60 Observe the safety information.
Page 90 ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆ ⇒ “ Assembly overview of components/control units in the front area of the Flexpole” on page 70 ◆ ⇒ “ Assembly overview – covers and trim” on page 44 Repair Group 91 - Communication...
Page 91: Removing And Installing The Tray With The Control Units For Telecommunication, Tbox1/2
● Return all cable positions and their fasteners to the delivery condition in order to avoid damage! ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 2 Removing and installing components/control units...
Page 92: Removing And Installing The Tray With Control Unit 2 For High-Voltage Charge Monitoring And Release, Secc2
M8 socket bit M8 screw bit ESD glove M4 socket bit Extension Removing ⇒ “ Switching off the Flexpole” on – Switch off the Flexpole page 133. Condition ● The LED status indicators -1- are off. – Disconnect the electrical connectors -arrows-.
Page 93: Removing And Installing The Tray With Control Unit 1 For High-Voltage Charge Monitoring And Release, Secc1
◆ Potential equalisation line bolt: 8 Nm ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 2.10 Removing and installing the tray with control unit 1 for high-voltage charge monitoring and release, SECC1 2.10.1 Removing and installing the tray with the control unit 1 for high-voltage...
Page 94 Workshop Manual 01.2025 Tools M8 screw bit ESD glove M4 socket bit Extension Removing ⇒ “ Switching off the Flexpole” on – Switch off the Flexpole page 133. Condition ● The LED status indicators -1- are off. – Open the front door.
Page 95 Workshop Manual 01.2025 – Disconnect or remove the electrical connections -1- and -2-. – Loosen the cable ties -arrows- and move the electrical wires aside. – Disconnect the electrical connector from the control unit, SECC1. – Unscrew screws for potential equalisation line. –...
Page 96: Removing And Installing The Tray With The Control Unit 1 For High-Voltage Charge Monitor- Ing And Release, Secc1, With Remote Emergency Stop Function
◆ Potential equalisation line bolt: 8 Nm ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 2.10.2 Removing and installing the tray with the control unit 1 for high-voltage charge monitoring and release, SECC1, with Remote Emergency Stop func- tion Observe the safety information.
Page 97 Workshop Manual 01.2025 Removing ⇒ “ Switching off the Flexpole” on – Switch off the Flexpole page 133. Condition ● The LED status indicators -1- are off. – Open the front door. – Disconnect the electrical connector on the high-voltage wires -1- from the high-voltage battery charging unit.
Page 98 Workshop Manual 01.2025 – Disconnect the electrical connectors -1- and -2- from the control unit, SECC1. – Loosen the cable ties -arrows- and move the electrical wires aside. – Unscrew screw for potential equalisation line. – Disconnect or remove the electrical connections -1- and -2-. –...
Page 99 ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆ Potential equalisation line bolt: 8 Nm ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 2 Removing and installing components/control units...
Page 100: Overhaul Of The Network Distributor For Internet Access, Esp
2.5 Allen key (installed on the first Flexpoles) Torx T20 Ratchet (1/4 inch) + extension Slotted screwdriver/slotted bit for ratchet Cable ties Diagonal cutter Light Removing ⇒ “ Switching off the Flexpole” on page 133 – Repair Group 91 - Communication...
Page 101 Workshop Manual 01.2025 – Open the front door. – Disconnect the electrical connectors for the high-voltage wires -1- from the charging unit for high-voltage battery charging. In order to do so, press the connector lock -1-. Condition ● Fit caps on cables and connections! Dirt on cables and connections can cause contact problems.
Page 102 Workshop Manual 01.2025 – Press the network distributor -1- in the -direction of arrow A- from the front. – Pull the network distributor -1- upwards in the direction of ar- row -B- at the rear and remove it. Installing Condition ●...
Page 103 Workshop Manual 01.2025 Port on the network LAN cable labelling Associated ECU IP address of the asso- distributor ciated ECU – Glue the rubber block -2- to the network distributor -1-. – Place the network distributor -1- on the guide rail -arrow A- and fasten it to the guide rail -arrow B-.
Page 104 Workshop Manual 01.2025 Install the connection for the 24-V power supply. – Remove the old power supply connector. – Assemble the new connector -1- as shown in the figure -magnified-. ◆ “Red cable/ESP (D24V+)” to PWR1“V1+” ◆ “Black cable/ESP (D24V-)” to PWR1“V1-” –...
Page 105 – Route the SECC1 LAN cable -1- to the connector of the high-voltage unit -2- and fix in position -arrows-. – Route the SECC1 LAN cable -1- between the high-voltage battery and the outer wall towards the rear of the Flexpole. 2 Removing and installing components/control units...
Page 106 – Route the SECC2 LAN cable -1- to the connection terminal of the high-voltage unit -2- and fix in position -arrow-. – Route the SECC2 LAN cable -1- between the high-voltage battery and the outer wall towards the rear of the Flexpole. Repair Group 91 - Communication...
Page 107: Overhauling The Network Distributor For Internet Access, High-Voltage Unit Removed
Condition ● Check all components by means of 2 test charging processes (left and right side). ⇒ “ Switching on the Flexpole” on page 137 – 2.11.2 Overhauling the network distributor for internet access, high-voltage unit re- moved Observe the safety information.
Page 108 Workshop Manual 01.2025 Tools Slotted screwdriver/slotted bit for ratchet Cable ties Diagonal cutter Light Removing ⇒ “ Removing and installing the – Remove the high-voltage unit high-voltage unit” on page 174. – Disconnect the power cable -1-. – Disconnect all Ethernet cables -2-. Depending on the version, 6 Ethernet cables can be connected to the network distributor.
Page 109 Workshop Manual 01.2025 – Press the network distributor -1- in the -direction of arrow A- from the front. – Pull the network distributor -1- upwards in the direction of ar- row -B- at the rear and remove it. Installing –...
Page 110 Workshop Manual 01.2025 – Position the locking clamps -1- on the network distributor. – Tighten the screws of the locking clamps -1- to 0.6 Nm. Install the connection for the 24-V power supply. – Remove the old power supply connector. –...
Page 111 Workshop Manual 01.2025 Condition ● The assignment of the ports with the associated Ethernet ca- bles must be observed in all cases! – Connect all Ethernet cables (including the new additional LAN cables for SECC1+2) to the ports. The rotated top view has been chosen for better illustration. The -arrow- in the illustration indicates the installation direction! Depending on the software version, communication with the re- spective control unit is only possible if the connections are cor-...
Page 112: Removing And Installing The Water Sensor, Sj
Condition ● Check all components by means of 2 test charging processes (left and right side). ⇒ “ Switching on the Flexpole” on page 137 – 2.12 Removing and installing the water sensor, SJ Removing ⇒ ...
Page 113 Install in reverse order of removal, observing the following: Condition ● Perform a functional test of the water sensor, SJ⇒ Maintenance instructions Specified torques ◆ ⇒ “ Assembly overview of components/control units in the front area of the Flexpole” on page 70 2 Removing and installing components/control units...
Page 114: Electric Drive
Workshop Manual 01.2025 93 - Electric drive High-voltage battery Assembly overview – high-voltage battery 1 - High-voltage battery ⇒ “ Notes on replac- ing high-voltage bat- teries” on page 109 ⇒ “ Removing and installing the high- voltage battery, 1 – 4”...
Page 115: Assembly Overview - Battery Modules
Workshop Manual 01.2025 q 20 Nm 12 - Bolt q for potential equalisation line q M8 x 12 q 8 Nm Assembly overview – battery modules 1 - Bolt q 42 pcs. q Renew after remov- q M5 x 16 q 5 ± 0.5 Nm 2 - Upper part of battery housing ⇒ ...
Page 116 Workshop Manual 01.2025 1 - Battery modules ⇒ “ Removing bat- tery modules” on page 121 q 12 pcs. 2 - Battery regulation control unit q 3-in-1 control unit 3 - Nut q 4 pcs. q Renew after remov- q 5 ± 0.7 Nm 4 - Nut q 2 pcs.
Page 117: Notes On Replacing High-Voltage Batteries
Workshop Manual 01.2025 q Renew after removal q 10 ± 1.5 Nm 14 - Fuse for high-voltage system 15 - HV connector q 2 pcs. 16 - Contactor 17 - Nut q 2 pcs. q Renew after removal q 2 Nm 18 - Nut q Renew after removal q 7 ± 1 Nm 19 - Bolt q 2 pcs.
Page 118: Removing And Installing The High-Voltage Battery
A high-voltage battery with the APEU index 1 or 3 must always be installed Compartment 4 A high-voltage battery with the APEU index 2 or 4 must always be installed Combination options With regard to the APEU index, the following combinations are possible on a Flexpole! ◆ 1/2/3/4 ◆ 1/2/1/2 ◆ 3/4/1/2 ◆...
Page 119 ● Wear the protective clothing required in accordance with DGUV Regulation 3 when working on the Flex- pole. ● Only trained specialists in accordance with IEC 60050 may perform work inside the Flexpole while the door is open. Observe the safety information and safety rules.
Page 120 Removal and installation are described for the high-voltage battery, 3 as an example. Removing ⇒ “ Switching off the Flexpole” on page – De-energise the high-voltage system 133. ⇒ “ Visual inspection of the high-voltage battery” on –...
Page 121 Close off electrical connectors using suitable aids and thereby protect them from dirt and the entry of coolant. The images shown here may differ depending on the retrofit/ conversion status of the Flexpole! – Release the tray -arrows- for the communication line for the high-voltage battery -1-.
Page 122 Workshop Manual 01.2025 – Unscrew the screws -arrows- and remove the retainer plate -1-. – Unscrew the nuts -3- and remove the stop plate -2-. Rear side of the high-voltage battery – Unscrew the nuts -2- and remove the stop plate -1-. NOTICE Risk of damage to components caused by forklift truck or moving scissor-type assembly plat- form.
Page 123 Workshop Manual 01.2025 – Unlock and open the rear stop -2- of the battery insertion aid -3-. – Pull out the high-voltage battery -1- onto the battery insertion aid -3-. – Close and lock the rear stop -2- of the battery insertion aid -3-.
Page 124: Forklift Truck
Workshop Manual 01.2025 – Use the shackle -1- to join the two retaining straps -2- above the high-voltage battery. – Hook the shackle -1- into the load mount of the forklift truck or workshop crane -3-. – Lift the high-voltage battery out of the battery insertion aid and temporarily store it on a pallet.
Page 125 – Ensure sufficient clearance from lines and connectors. – Position the forklift truck with the battery insertion aid -3- in front of the empty battery compartment of the Flexpole. – Unlock and open the rear stop -2- of the battery insertion aid -3-.
Page 126 Workshop Manual 01.2025 Front side of the high-voltage battery – Secure the stop plate -1- with nuts -2-. Condition ● First the upper ones, then the lower ones. – Secure the retainer plate -1- with screws -arrows-. Rear side of the high-voltage battery –...
Page 127: Visual Inspection Of The High-Voltage Battery
● Wear the protective clothing required in accordance with DGUV Regulation 3 when working on the Flex- pole. ● Only trained specialists in accordance with IEC 60050 may perform work inside the Flexpole while the door is open. Observe the safety information and rules of safety: ◆...
Page 128: Remove And Install Stop Plate
Workshop Manual 01.2025 CAUTION Poisonous dust and fluids pose a health hazard. – Never work on high-voltage batteries which have short-circuited. CAUTION Danger of burns from hot high-voltage battery. Risk of burns to the hands. – Wear protective gloves. If complaints about the high-voltage battery arise during the visual inspection, inform the high-voltage expert.
Page 129: Removing Battery Modules
Workshop Manual 01.2025 – Unscrew the screws -arrows- on the base frame -1-. – Remove stop plate -2- from the base frame -1-. Installing Install in reverse order of removal, observing the following: Specified torques ◆ ⇒ “ Assembly overview – high-voltage battery” on page 106 Removing battery modules Important: There is currently no approval for these disassembly instructions! DANGER...
Page 130 Workshop Manual 01.2025 DANGER Danger to life from high voltage. Death or severe bodily injury due to electric shock. – Wear arc-tested clothing. – Wear an insulated helmet with face shield. – Wear protective gloves. – Wear protective footwear. –...
Page 131 Workshop Manual 01.2025 Condition ● Mark the installation position of the electrical connectors. – Disconnect the connectors of the electrical wires -1-. – Undo the cable ties -2- on the electrical wires. – Move the wiring harness clear. – Remove the protective cover -1- from the battery module. –...
Page 132 Workshop Manual 01.2025 – Unscrew the screw -arrows- and remove the HV connector -1-. – Remove the protective covers -1- from the connections of the battery modules. – Unscrew the nuts -1- of the HV connectors. – Remove the HV connectors -2- from the battery modules. –...
Page 133 Workshop Manual 01.2025 – Use the module spreader to lift the battery modules -1- out of the housing -2- in sequence. Install in reverse order of removal, observing the following: Installing Tightening torques ◆ ⇒ “ Assembly overview – battery modules” on page 107 2 High-voltage cables...
Page 134: High-Voltage Cables
Workshop Manual 01.2025 High-voltage cables Overview of fitting locations – high-voltage cables 1 - High-voltage connec- tor 5 2 - High-voltage connec- tor 4 3 - High-voltage connec- tor 2 4 - High-voltage connec- tor 1 5 - High-voltage unit ⇒ “ Assembly over- view – high-voltage unit” on page 173 6 - High-voltage connec- tion q for high-voltage unit...
Page 135: Removing And Installing The High-Voltage Wire, Dc Output For Voltage Converter
● Position the ferrite ring, secure with insulating tape and cable ties. ● Return all cable positions and their fasteners to the delivery condition in order to avoid damage! ⇒ “ Switching on the Flexpole” on page – 137.
Page 136: Removing And Installing The High-Voltage Wire, Dc Output For Voltage Converter
Workshop Manual 01.2025 ◆ ⇒ “ Assembly overview – charging unit for high-voltage battery charging” on page 139 ◆ ⇒ “ Assembly overview – main fuse carrier” on page 199 Removing and installing the high-voltage wire, DC output for voltage converter G5/G6 Observe the safety information.
Page 137: Removing And Installing The High-Voltage Wire, Dc Input For Voltage Converter
⇒ “ Assembly overview – main fuse carrier” on page 199 ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 Removing and installing the high-voltage wire, DC input for voltage con- verter G3–G6...
Page 138: Removing And Installing The High-Voltage Cable, High-Voltage Connector For Voltage Con- Verter
● Position the ferrite rings, secure with insulating tape and cable ties. ● Return all cable positions and their fasteners to the delivery condition in order to avoid damage! ⇒ “ Switching on the Flexpole” on page – 137.
Page 139 ⇒ “ Assembly overview – voltage converter, G1 – G6” on page 188 ◆ ⇒ “ Assembly overview – main fuse carrier” on page 199 ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 2 High-voltage cables...
Page 140: Removing The Mains Connecting Cable Of The Cee Connector, Flexpole With Mains Connection Block
Workshop Manual 01.2025 Removing the mains connecting cable of the CEE connector, Flexpole with mains connection block Observe the safety information. ◆ ⇒ “ Safety measures when working on charging stations that use high-voltage systems” on page 3 Removing ⇒ ...
Page 141: Energising The High-Voltage System
– Persons without the corresponding qualification must not actively work on the Flexpole. – Observe country-specific requirements and laws, e.g. first aid training. When working on the Flexpole, it must always be switched off! When working on the system, observe the safety instructions! Condition ●...
Page 142 Workshop Manual 01.2025 – Disconnect the CEE socket -1- on the mains connecting ca- ble from the CEE connector -2- on the Flexpole. – The CEE connector -1- must be protected against accidental contact by the fuse -2-. Condition ●...
Page 143 Workshop Manual 01.2025 Continuation – Open the rear door using the door handle -1-. CAUTION Risk of injury from unsecured doors – Open the doors of the system carefully in windy conditions. – Secure doors to prevent unintentional closing. –...
Page 144 Workshop Manual 01.2025 – Switch off the circuit breaker CB2 of the 12-V back-up bat- tery, BAT -1-. Models with battery protection device – Switch off the circuit breaker CB3 -1-. Switching off the circuit breaker CB3 -1- also switches off the single-phase socket XS1! Continuation Switch off the circuit breakers...
Page 145: Re-Energising High-Voltage System
Re-energising high-voltage system Switching on the Flexpole After high-voltage batteries are replaced or the Flexpole has spent an extended period in storage, an incor- rect SoC “State of Charge” may be calculated. For this reason, the internal batteries must be charged for approx.
Page 146 The doors are part of the safety system. A safety shutdown oc- curs when the door is open. The system self-test starts and the Flexpole system will start up. This may take a few minutes. It may be necessary to reset the internal DTCs in the web con- figuration interface so that the Flexpole can start.
Page 147: Charging Unit For High-Voltage Battery
Workshop Manual 01.2025 Charging unit for high-voltage battery Assembly overview – charging unit for high-voltage battery charging 1 - High-voltage cable q for the DC output voltage converter, G5/G6 ⇒ “ Removing and installing the high- voltage wire, DC output for voltage converter G5/G6”...
Page 148 Workshop Manual 01.2025 q 1 Nm 10 - LAN cable q for the electricity meters for delivered energy, WH1/2 11 - Sensor units, SU1/2 ⇒ “ Removing and installing the sensor unit SU1/2 for the electricity meters for delivered energy” on page 184 12 - Charging unit for high-voltage battery ⇒ ...
Page 149: Assembly Overview - Charging Cable For High-Voltage Battery Charging
Workshop Manual 01.2025 Assembly overview – charging cable for high-voltage battery charging 1 - Charging cable q with CCS2 charging ⇒ “ As- connector sembly overview – CCS2 charging con- nector for high-volt- age battery charg- ing” on page 144 q Length: 3 m and ⇒ ...
Page 150 Workshop Manual 01.2025 11 - Bolt q for waterproof gland q 2 pcs. q 2 Nm 12 - Bolt q on PE bus bar q 4 Nm Assembly overview – waterproof bushing, new build status 1 - Nut - 40 Nm 2 - Sealing washer 3 - Waterproof gland 4 - Kink protection Change of colours of control lines for charging cables The cable colours of the control lines have been changed from a colour coding to a numerical coding...
Page 151 Workshop Manual 01.2025 The cable colours of the control lines have been changed from a colour coding to a numerical coding Old build sta- New version Assignment Assignment tus item I item II High-voltage High-voltage (The white battery battery control lines charging charging...
Page 152: Assembly Overview - Ccs2 Charging Connector For High-Voltage Battery Charging
Workshop Manual 01.2025 Assembly overview – CCS2 charging connector for high-voltage battery charging 1 - Base housing, charg- ing connector 2 - DC cable connection q 2 pcs. 3 - PE cable connection 4 - Sealing ring q for connector plate 5 - Connector plate 6 - Retaining clip q for PE cable con- nection and CP/PP contact pins 7 - Sealing ring...
Page 153: Removing And Installing The Charging Unit For The High-Voltage Battery
Workshop Manual 01.2025 17 - DC contact pin ⇒ “ Replacing the PE/DC contact pins on the CCS2 charging connector” on page 156 q 2 pcs. q 3 Nm 18 - PE contact pin ⇒ “ Replacing the PE/DC contact pins on the CCS2 charging connector” on page 156 q 3 Nm 19 - Retaining clip q for DC cable connections...
Page 154 Workshop Manual 01.2025 Removing ⇒ “ Switching off the Flexpole” on – Switch off the Flexpole page 133. Condition ● The LED status indicators -1- are off. – Open the front door. – Disconnect the electrical connectors of the high-voltage wires -1-.
Page 155 Workshop Manual 01.2025 Flexpole with measuring equipment compliant with calibra- tion law – Remove adhesive seal from sensor units, SU1/2 and charg- ing cable connections. The adhesive seals cannot be removed without destruction! – Remove the covers -1- of the sensor units, SU1/2 -2-.
Page 156 Workshop Manual 01.2025 – If present: open the cover for the charging cable connection. – Remove the screws -arrows- of the right-hand charging ca- ble (charging socket A) -2-. – Disconnect the electrical connectors -1- of the charging ca- ble -2-.
Page 157 Workshop Manual 01.2025 – The high-voltage unit is removed to the rear. Condition ● Two fitters are required for this work. – Disconnect the electrical connectors -arrows-. – Unscrew the bolts -2- of the charging unit -1-. – Together with a second fitter, lift the charging unit -1- -arrows A- and remove.
Page 158: Removing And Installing Charging Cable For High-Voltage Battery Charging
Workshop Manual 01.2025 – Restore calibration conformity, see ⇒ Maintenance instruc- tions/Checking devices in operation. ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆ ⇒ “ Assembly overview – charging unit for high-voltage battery charging” on page 139 ◆...
Page 159 Workshop Manual 01.2025 Removing ⇒ “ Switching off the Flexpole” on – Switch off the Flexpole page 133. Condition ● The LED status indicators -1- are off. Charging cable for charging point A: ⇒ “ Removing and installing the tray with control unit 1 for high-voltage charge monitoring and release, –...
Page 160 Workshop Manual 01.2025 – Remove the cover -1- of the sensor unit, SU1 -2-. – Release the screws -2- of the sensor unit, SU1 -1-. – Disconnect the electrical wires -3- and move clear. – If present: remove the ferrite ring on the negative terminal wire (VN LEM) of the sensor unit, SU1.
Page 161 Workshop Manual 01.2025 – Unscrew the screws -1- on the PE bus bar -2-. – Release the clip -arrows- and move the PE lines of the charging cable -3- aside. – Release the ferrite ring -1- on the charging cable -2- and re- move.
Page 162 Workshop Manual 01.2025 Current models Condition ● Preparation tool Open-end spanner Area to be removed Width across flats 55 mm 94 mm – Using appropriate means, adjust the width of the tool -1- and remove the hatched area -2-. It may be necessary to correct the tool thickness.
Page 163 Workshop Manual 01.2025 – Unscrew the nut inside with the tool shown, torque wrench -1- with attachment (AF55) -2-. On older models, the nut was glued in place with locking fluid. Non-destructive removal of the nut is not possible in this case! –...
Page 164: Repairing The Ccs2 Charging Connector For High-Voltage Battery Charging
⇒ “ Assembly overview – charging cable for high-voltage battery charging” on page 141 ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 Repairing the CCS2 charging connector for high-voltage battery charg- 5.6.1 Replacing the PE/DC contact pins on the CCS2 charging connector...
Page 165 Cordless screwdriver 1.5–2.8 Nm Torx bit TX 15 with safety hole Removing ⇒ “ Switching off the Flexpole” on page – 133. – Unscrew the screws -2- from the front housing -1- using the “Torx bit TX 15 with locking hole”.
Page 166: Replacing The Cp/Pp Contact Pins And Front Housing On The Ccs2 Charging Connector
– Place new screws -2- with new sealing rings. – Insert the screws -2- into the front housing -1- using the “Torx bit TX 15 with locking hole”. ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆...
Page 167 Harting crimping tool RM 09 99 000 0021 Special wrench for screwing the cable nut Removing ⇒ “ Switching off the Flexpole” on page – 133. – Unscrew the screws -2- from the front housing -1- using the “Torx bit TX 15 with locking hole”.
Page 168 Workshop Manual 01.2025 – Unscrew the screws -1- from the connector plate -2- using the “Torx bit TX 20”. – Unscrew the screws -1- from the end cap -2- using the “Torx bit TX 20”. – Push the end cap -2- back. –...
Page 169 Workshop Manual 01.2025 – Unscrew the nut -1- using the “special wrench” -2-. – Push the cable -1- inwards -arrow A- until the connector plate comes out of the base housing -2--arrow B-. Push it out far enough to ensure that assembly is possible (ap- prox.
Page 170 Workshop Manual 01.2025 – Cover the brown cable -1- with heat-shrink tubing with a length of 30 mm. – Pull the heat-shrink tubing with a length of 30 mm over the grey and black cables -2- together. – Strip 7 mm of insulation from the cables -1- and -2- using the “stripping tool”...
Page 171 Workshop Manual 01.2025 – Place the contact pins -arrows- in the connector plate -1-. Condition ● Ensure correct placement. CP-> brown; PP-> grey with re- sistor. – Secure the contact pins -arrows- with the securing clip -2-. – Push the base housing -1- back in the direction of the arrow until the plug plate -2- is positioned inside the base housing -1-.
Page 172 Workshop Manual 01.2025 – Place a new sealing ring in the new front housing -1- -arrow-. – Lightly grease the holes of the CP/PP contact pins -2- with silicone. – Renew all the sealing rings on the contact pins -3- and grease with silicone.
Page 173: Removing And Installing Holder For Ccs2 Charging Connector
– Slide the end housing -2- onto the base housing. – Screw in the screws -1- using the “Torx bit TX 20”. Condition ● Perform a continuity check on newly crimped contact pins. ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆...
Page 174: Removing And Installing The Switching Contactor For The Charging Function
– Remove the holder for CCS2 charging connector -1- from the door in the direction of the arrow. Installing – Install in reverse order of removal, observing the following: Check seal and replace if necessary! ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆...
Page 175 Extension Material 400 grit sandpaper Dust-free cloth Bottle of ethanol Removing ⇒ “ Switching off the Flexpole” on – Switch off the Flexpole page 133. Condition ● The LED status indicators -1- are off. ⇒ “ Removing and installing the charging unit for the high-voltage battery” on –...
Page 176 Workshop Manual 01.2025 – Unscrew the nuts -1-. – Unscrew the bolts -arrows-. – Remove the bus bars -2-. – Unscrew the nuts -arrows-. – Unscrew the bolts -1-. – Remove the bus bars -2- with the connected electrical wires. Condition ●...
Page 177 Workshop Manual 01.2025 Prepare the switching contactor, K3/K4 for the charging function for installation – Sand the copper contact surfaces of the switching contactor for the charging function, K3/K4 with 400-grit sandpaper. – After sanding, clean the copper contact surfaces using a dust-free cloth and alcohol (ethanol).
Page 178 Workshop Manual 01.2025 – Place the switching contactors for the charging function, K3/K4 -1-, on the charging unit -3-. – Screw on the nuts -arrows-. – Connect the electrical connectors -2- of the high-voltage connectors, K3/K4 -1-. – Install the bus bars -2- with the connected electrical wires. –...
Page 179 Workshop Manual 01.2025 – Connect the power supply for the switching contactor for the charging function (13 V) -1- with the wiring harness -2-. – Connect the wiring harness -2- to the power supply for the switching contactor for the charging function -magnified-. –...
Page 180 Workshop Manual 01.2025 Tightening torques ◆ ⇒ “ Assembly overview – charging unit for high-voltage battery charging” on page 139. Repair Group 93 - Electric drive...
Page 181: High-Voltage Components
Workshop Manual 01.2025 High-voltage components Assembly overview – high-voltage unit 1 - Cover 2 - Bolt q 6 pcs. q M6 x 12 q 4 Nm 3 - High-voltage cable q for DC input voltage converter,G5/G6 ⇒ “ Removing and installing the high- voltage wire, DC in- put for voltage con- verter G3–G6”...
Page 182: Removing And Installing The High-Voltage Unit
◆ ⇒ “ Safety precautions when working in the vicinity of high-voltage components” on page 4 Removing ⇒ “ Switching off the Flexpole” on page – Switch off the Flexpole 133. ⇒ “ Removing and installing the holder with the –...
Page 183 Workshop Manual 01.2025 – Disconnect the electrical connectors of the high-voltage ca- bles -2- on the high-voltage unit -1-. – Push the connector lock -3- to do so. Move the high-voltage cables -2- aside. Condition ● If the electrical connector is damaged, the high-voltage cable must be replaced.
Page 184 ● The connector lock on the electrical connectors -2- must en- gage when the high-voltage wires are installed. – Check that the catches on the high-voltage wires have en- gaged by pulling the wires. ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques...
Page 185: Removing And Installing The Battery Management System Control Unit, Bms1/2
⇒ “ Assembly overview – main fuse carrier” on page 199 ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 ◆ ⇒ “ Assembly overview of components/control units in the middle area of the Flexpole” on page 71...
Page 186: Removing And Installing The Energy Management System Control Unit, Ems
– 137. Tightening torques ◆ ⇒ “ Assembly overview of components/control units in the middle area of the Flexpole” on page 71 Removing and installing the energy management system control unit, Observe the safety information. ◆ ⇒ “ Safety precautions when working in the vicinity of high-voltage components” on page 4 Removing ⇒ ...
Page 187: Removing And Installing The Holder With The Management System Control Units
◆ Bolts for potential equalisation line: 8 Nm ◆ ⇒ “ Assembly overview of components/control units in the middle area of the Flexpole” on page 71 Removing and installing the control unit for the charging unit, CCU1/2, Observe the safety information.
Page 188: Removing And Installing The Holder With The Control Unit For Telecommunications, Ccu1/2
– 137. Tightening torques ◆ ⇒ “ Assembly overview of components/control units in the middle area of the Flexpole” on page 71 Removing and installing the holder with the control unit for telecommu- nications, CCU1/2 Observe the safety information. ◆...
Page 189 ● Return all cable positions and their fasteners to the delivery condition in order to avoid damage! Flexpole with measuring equipment compliant with calibra- tion law – Establish calibration conformity, see ⇒ Maintenance instruc- tions/Checking devices in operation. ⇒ “ Switching on the Flexpole” on page – 137. 6 High-voltage components...
Page 190: Removing And Installing The Electricity Meters For Delivered Energy, Wh1/2
Tightening torques ◆ Bolts for potential equalisation line: 8 Nm ◆ ⇒ “ Assembly overview of components/control units in the middle area of the Flexpole” on page 71 Removing and installing the electricity meters for delivered energy, WH1/2 The electricity meters for delivered energy, WH1/2 can only be replaced as a pair.
Page 191: Removing And Installing The Tray With The Electricity Meters For Delivered Energy, Wh1/2
– 137. Tightening torques ◆ ⇒ “ Assembly overview of components/control units in the middle area of the Flexpole” on page 71 Removing and installing the tray with the electricity meters for delivered energy, WH1/2 Observe the safety information. ◆...
Page 192: Removing And Installing The Sensor Unit Su1/2 For The Electricity Meters For Delivered Energy
137. Tightening torques ◆ ⇒ “ Assembly overview of components/control units in the middle area of the Flexpole” on page 71 6.10 Removing and installing the sensor unit SU1/2 for the electricity meters for delivered energy Observe the safety information.
Page 193 ● Note the information about adhesive seals for Flexpoles with measuring equipment compliant with cali- bration law! ● Compliance with calibration law must be restored after repairs have been carried out! Removing ⇒ “ Switching off the Flexpole” on page – Switch off the Flexpole 133. Sensor unit, SU1 ⇒ ...
Page 194 Workshop Manual 01.2025 – If present: open the cover for the charging cable connection. – Pull cover -1- upwards and unscrew the nuts -arrows-. – Unscrew the bolt -2-. – Release the bus bars -3- with the connected electrical wires. –...
Page 195 ⇒ “ Assembly overview – charging unit for high-voltage battery charging” on page 139 ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 ◆ ⇒ “ Assembly overview – main fuse carrier” on page 199...
Page 196: Voltage Converter
Workshop Manual 01.2025 Voltage converter Assembly overview – voltage converter, G1 – G6 1 - Bolt q for potential equali- sation line q 12 pcs. q M6 x 12 q 8 Nm 2 - Potential equalisation line q 6 pcs. 3 - High-voltage connec- q 2 pcs. 4 - Bolt q 16 pcs.
Page 197: Notes On Replacing And Addressing Voltage Converters
Workshop Manual 01.2025 ⇒ “ Removing and installing the communication line for voltage converters” on page 194 12 - Bolt q for communication line to PE q M6 x 12 q 8 Nm 13 - Voltage converter G3/G4 q for DC/DC ⇒ “ Notes on replacing and addressing voltage converters” on page 189 ⇒ ...
Page 198: Removing And Installing The Voltage Converters, G1/2 For Ac/Dc
◆ 3. You can also enter the addresses “correctly” in the Config- file and then upload the “adapted Configfile”. Observe the following assignment as shown in the figure. Component Flexpole configuration Charging point AC power supply quantity 2 Voltage converter, G1...
Page 199 Workshop Manual 01.2025 ⇒ “ Removing and installing the tray with control unit 2 for high- – Remove the tray with control unit, SECC2 voltage charge monitoring and release, SECC2” on page ⇒ “ Removing and installing the tray with –...
Page 200: Removing And Installing The Voltage Converters, G3 - G6 For Dc/Dc
⇒ “ Assembly overview – main fuse carrier” on page 199 ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 Removing and installing the voltage converters, G3 – G6 for DC/DC Observe the safety information.
Page 201 Removal and installation is described for the voltage converters, G5/G6. The removal and installation of the voltage converters G3/G4 is carried out in the same way. Removing ⇒ “ Switching off the Flexpole” on page – Switch off the Flexpole 133.
Page 202: Removing And Installing The Communication Line For Voltage Converters
⇒ “ Assembly overview – main fuse carrier” on page 199 ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 Removing and installing the communication line for voltage converters Observe the safety information.
Page 203 -2-. – Move the communication line for the voltage converter -1- clear and remove it. Installing Install in reverse order of removal, observing the following: ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆...
Page 204: Lights, Bulbs, Switches - Interior
Electricity meter 3 for delivered energy B, WH2 ⇒ “ Assembly overview of components/control units in the middle area of the Flexpole” on page 71 6 - Additional display and operating unit, HMI ⇒ “ Assembly overview of components/control units in the front area of the Flexpole” on page 70 7 - Stop button, SB1...
Page 205: Removing And Installing The Stop Button, Sb1
⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆ ⇒ “ Assembly overview of components/control units in the front area of the Flexpole” on page 70 ◆ ⇒ “ Assembly overview – covers and trim” on page 44 1 Controls...
Page 206: Setting The Door Contact Switch
Open the door slightly. The Flexpole must switch off after approx. 5 cm +/- 1 cm. ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆ ⇒ “ Assembly overview of components/control units in the rear area of the Flexpole” on page 73 Repair Group 96 - Lights, bulbs, switches – interior...
Page 207: Lines
Assembly overview – main fuse carrier 1 - Mains connections q for CEE connector ⇒ “ Removing the mains connecting cable of the CEE connector, Flexpole with mains connec- tion block” on page 132 2 - Circuit breaker q 1x 4-pole circuit breaker, QF1 with...
Page 208: Removing And Installing The Main Fuse Carrier
- 2 Nm 2 - Mains connecting cable via the CEE connector - ⇒ “ Removing the mains connecting cable of the CEE con- nector, Flexpole with mains connection block” on page 132 3 - Mains connecting cable via a direct connection - See: ⇒ Initial setup 4 - Bolt...
Page 209 Condition ● The LED status indicators -1- are off. The images shown here may differ depending on the retrofit/conversion status of the Flexpole! – Unscrew the bolts -arrows- and remove the cover -1-. Specification variant with 4-pole load transfer switch, QS –...
Page 210 Installing Install in reverse order of removal, observing the following: Condition ● Return all cable positions and their fasteners to the delivery condition in order to avoid damage! ⇒ “ Switching on the Flexpole” on page – 137. Tightening torques ◆...
Page 211: Removing And Installing The Auxiliary Contact For Circuit Breakers
⇒ “ Switching off the Flexpole” on page – Switch off the Flexpole 133. The images shown here may differ depending on the retrofit/conversion status of the Flexpole! – Unscrew the bolts -arrows- and remove the cover -1-. Condition ● Mark the wiring to make sure that the cables are connected again correctly later.
Page 212 Workshop Manual 01.2025 – Release the catch -2- on the circuit breaker CB2 -1-. – Remove circuit breaker CB2 with auxiliary contact -1- in the direction of the arrow. – Release the clip -arrow A- of the auxiliary contact on the cir- cuit breaker CB2 -2-.
Page 213: Removing And Installing The Esd Safety Relay, Ks
The ESD safety relay KS is installed in Flexpoles with index EB/DB (HW1.0) and index ED/DD (HW2.0). Condition ● Removal may only be carried out when the Flexpole is switched off! Observe the safety information. ◆ ⇒ “ Safety measures when working on charging stations that use high-voltage systems” on page 3 ◆...
Page 214: Installing And Removing Or Retrofitting The Battery Protection Device
Installing and removing or retrofitting the battery protection device 1.5.1 Installing and removing the battery protection device, index E/DA Condition ● Installation may only be carried out when the Flexpole is switched off! Observe the safety information. ◆ ⇒ “ Safety measures when working on charging stations that use high-voltage systems” on page 3 ◆...
Page 215 ◆ light up green continuously ◆ flash blue ◆ flash red (forced full recharge mode) Determine the index of the Flexpole from the type plate. In this case, it is the “index E”-1-. Check components -1...8- (according to index) for complete- ness.
Page 216 Workshop Manual 01.2025 Step 1 Remove cover for main fuse carrier -1- (Torx T20). Step 2 Remove the locking elements -1-. Move the 3-phase overvoltage protection device FVC1 and re- sidual current device RCD -2-, approx. 16 mm to the right. Step 3 Mount charger P5, control relay KA8 and monitoring relay KV1 -1- on the DIN rail.
Page 217 Workshop Manual 01.2025 Establish connection to residual current circuit breaker with cir- cuit breaker CB3 -1- with “2 Nm”. Establish connection to the 12 V charger P5 -2- with “0.8 Nm”. Condition ● Observe assignment of cables -L- and -N-! Step 5 Remove the 12 V power supply cable -1- from the circuit break- er CB2 -2-.
Page 218 Workshop Manual 01.2025 Step 7 Install connecting cable on KA8 (520300003319A0). Connection to contact “15” of the monitoring relay Connection to contact “8” of the control relay KA8 Connection to contact “6” of the control relay KA8 Connection to contact “18” of the monitoring relay Connect the red cable (KA8-6) to connection “6”...
Page 219 Workshop Manual 01.2025 Connect cable (CB2-11) to circuit breaker CB2 -1- with “2 Nm”. Connect cable (P5_V+) to connection “3” of the 12 V charger P5 -2- “0.8 Nm”. Connect the cable (KV1_12V) to the connection “V” of the moni- toring relay KV1 -1- “1.3 Nm”.
Page 220 Workshop Manual 01.2025 Connect the cable (P5_V-) to connection “2” of the 12 V charger P5 -1- “0.8 Nm”. Connect the cable (KV1_GND) to the “GND” connection of the monitoring relay KV1 -2- “1.3 Nm”. Connect the cable (KA8-7) to terminal “7” of the control relay, KA8 -3- “1.3 Nm”.
Page 221 In addition, a multimeter can also be connected between termi- nals “1 and 3” on the 12 V charger P5 -1-. Condition ● The Flexpole should switch off from a voltage of approx. 12.3 V. 1 Relay carriers, fuse carriers, electronics boxes...
Page 222: Installing And Removing The Battery Protection Device, Index Eb/Db/Ea/Dc
Delete existing faults via the local web interface! 1.5.2 Installing and removing the battery protection device, index EB/DB/EA/DC Condition ● Installation may only be carried out when the Flexpole is switched off! Observe the safety information. ◆ ⇒ “ Safety measures when working on charging stations that use high-voltage systems” on page 3 ◆...
Page 223 ◆ light up green continuously ◆ flash blue ◆ flash red (forced full recharge mode) Determine the index of the Flexpole from the type plate. In this case, it is the “index E”-1-. 1 Relay carriers, fuse carriers, electronics boxes...
Page 224 AC/DC to KA8 cable = 520300003321A0 AC/DC power cable (input) = 520300002898A2 Check cover for main fuse carrier -1- (according to index). Cover = 510502001725A7 Neutral conductor = 520300002329R0 ⇒ “ Switching off the Flexpole” on Switch off the Flexpole page 133. Step 1 Remove cover for main fuse carrier -1- (Torx T20).
Page 225 Workshop Manual 01.2025 Step 2 Remove the locking elements -1-. Move the 3-phase overvoltage protection device FVC1 and re- sidual current device RCD -2-, approx. 16 mm to the right. Step 3 Mount charger P5, control relay KA8 and monitoring relay KV1 -1- on the DIN rail.
Page 226 Workshop Manual 01.2025 Step 5 Install AC/DC power cable “input” (520300002898A2). Connections to the 12 V charger P5 Connections to residual current device with circuit breaker CB3 Establish connection to residual current circuit breaker with cir- cuit breaker CB3 -1- with “2 Nm”. Establish connection to the 12 V charger P5 -2- with “0.8 Nm”.
Page 227 Workshop Manual 01.2025 Connect the AC/DC power cable to the charging connector -1-. Connect the black cable to connection “1” (V-) of the 12 V charger P5 -2- “0.8 Nm”. Connect the red cable to connection “4” of the control relay KA8 -3- “1.3 Nm”.
Page 228 Workshop Manual 01.2025 Step 9 Install CB2 input cable (520300003320A0). Connection to circuit breaker CB2 Connection to contact “3” of the 12 V charger P5 Connection to contact “V” of the monitoring relay Connection to contact “T” of the monitoring relay Connection to contact “6”...
Page 229 Workshop Manual 01.2025 Step 10 Install AC/DC to KA8 cable (520300003321A0). Connection to contact “7” of the control relay KA8 Connection to contact “2” of the 12 V charger P5 Connection to contact “GND” of monitoring relay Connect cable (P5_V-) to connection “2” of the 12 V charger P5 -1- “0.8 Nm”.
Page 230 Switch off residual current device with circuit breaker CB3 -1-. Condition ● The circuit breaker CB2 -2- remains switched on! Adjust the monitoring relay KV1 -3- as shown in the figure. Condition ● The Flexpole should now switch off after 5–10 min. Repair Group 97 - Lines...
Page 231 In addition, a multimeter can also be connected between termi- nals “1 and 3” on the 12 V charger P5 -1-. Condition ● The Flexpole should switch off from a voltage of approx. 12.3 V. Step 13 Adjusting the monitoring relay Adjust the monitoring relay KV1 -1- as shown in the figure.
Page 232: Installing And Removing The Battery Protection Device, Index Ed/Dd
Workshop Manual 01.2025 1.5.3 Installing and removing the battery protection device, index ED/DD The battery protection device with “index ED/DD” is installed in the same way as the battery protec- tion device with “index EB/DB/EA/DC”. The 12 V charger = 520600002759A0 is already installed in the Flexpoles with “index ED/DD”! Condition ●...

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