Maintenance

Maintenance

Maintenance

Maintenance

Periodic Maintenance and Service Workshops

WARNING

Charging Power Unit Error

Short-circuiting the batteries can damage the machine.

  1. Disconnect the charging system from the mains with mains switch of the unit.

  2. Contact the manufacturer service workshop or manufacturer sales representative.

NOTE

Only qualified maintenance personnel can carry out periodic maintenance.

NOTE

Only an authorized electrician can carry out electrical work.

NOTE

Before opening or removing power modules, disconnect the charging device from the mains and wait for about 2 minutes before continuing.

Periodic maintenance interval depends on usage of the system. Activities includes both cleaning and testing.

See Reference Documentation

For service contact information, refer to the manufacturer website.

Preventive Maintenance Tasks and Interval

NOTE

Increase frequency in dusty, humid or salty conditions or when the temperature is outside the recommended range for the product.

The preventive maintenance plan gives indicative minimum intervals for maintenance tasks. By completing the maintenance tasks according to the schedule, you can extend the lifetime of the product and prevent the need for more extensive maintenance action.

NOTE

A failed power module does not stop the operation of the system. The dynamic system redirects the power of the other modules and channels as necessary

Recommended maintenance schedule based on site condition

Task

Normal condition

Dusty/Harsh condition

Clean the Air Filter Element of Power Unit

1 month

Once a week/ as necessary

Replace Air Filter Element of Power Unit

3 month

Once a month/ as necessary

Clean the Power Module

Every 3 month

Every 3 month

Replace the Power Module Cooling Fan

3 year / as necessary

3 year/ as necessary

Replace Charging Cable of Station Charger

2 year/ as needed

1 year/ as needed

Replace the Charging Cable of Charging Post Version 1

2 year/ as needed

1 year/ as needed

Replace the Liquid Charging Post Charging Cable

2 year/ as needed

1 year/ as needed

Clean the Control Module

Every 3 month

Every 3 month

Clean Dynamic Power Distribution Module

Every 3 month

Every 3 month

Inspect charging cable and vehicle charging inlet for damage/dust, refer to General Visual Inspection and Cleaning of Charging Post and Power Unit

1 month

Once a week/ as necessary

Clean the charging post, refer to General Visual Inspection and Cleaning of Charging Post and Power Unit

1 year

1 year

Clean the power unit, refer to General Visual Inspection and Cleaning of Charging Post and Power Unit

Every 3 month

Every 3 month

General Visual Inspection and Cleaning of Charging Post and Power Unit

  1. 1.
    Inspect the roof and the outer structure of the charging system from all sides.
  2. 2.
    Inspect the structure for any mechanical defects or dents.
  3. 3.
    Inspect the charging cable and vehicle connectors.
  4. 4.
    Clean the screens of the units.
  5. 5.
    Clean the outer portion of the cabinet and charge post with a lint-free cloth and a mild PH-neutral detergent.
  6. 6.
    If you notice any mechanical damages, repair or replace damaged parts as necessary.

Power Unit and Station Charger

Clean the Air Filter Element of Power Unit

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

Tools Required:

  • Clean and dry compressed air (max. 4 bar)

  • Fine brush (optional)

  1. 1.
    Unlock and open the door of the unit.

    NOTE

    The two filter elements are located in the filter housing on the inside the door of the unit.

  2. 2.
    Remove the two retaining screws located at the bottom corners of the filter housing with your hand.
  3. 3.
    Pull the filter elements down from the filter housing.
  4. 4.
    Clean the filter elements with a fine brush or clean and dry compressed air (max. 4 bar (58 psi)).

    NOTE

    Blow compressed air in the opposite direction of air intake to prevent contamination imbedding deeper in to the filter.

    1. If the filter elements cannot be cleaned adequately, replace them.
  5. 5.
    Push the filter elements back into the filter housing.
  6. 6.
    Install the two retaining screws back to the bottom corners of the filter housing with your hand.
  7. 7.
    Lock the door of the unit.

Replace Air Filter Element of Power Unit

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

Tools Required:

  • Clean and dry compressed air (max. 4 bar)

  • Fine brush (optional)

  • Replacement filter

  1. 1.
    Unlock and open the door of the unit.

    NOTE

    The two filter elements are located in the filter housing on the inside the door of the unit.

  2. 2.
    Remove the two retaining screws located at the bottom corners of the filter housing with your hand.
  3. 3.
    Pull the filter elements down from the filter housing.
  4. 4.
    Install a new air filter into the filter housing.
  5. 5.
    Install the two retaining screws back to the bottom corners of the filter housing with your hand.
  6. 6.
    Lock the door of the unit.

Replace the Power Module

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit.
  2. 2.
    Set the Miniature Circuit Break (MCB) for control voltage (B) to OFF position.
  3. 3.
    Set the main power switch (A) to OFF position.
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply (C) and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Set the power module circuit breakers in OFF position (down).
  6. 6.
    Remove the four T30 fixing screws on the edges of the module front panel.
  7. 7.
    Use the handles to carefully pull out the power module.

    NOTE

    The module moves on its rollers on the rack.

    NOTE

    Protect the components that are installed back into the unit from dirt.

  8. 8.
    Do not lift the power module from its guide pins.

    NOTE

    The power module has two guide pins at the rear.

  9. 9.
    Remove the four T30 fixing screws of the handles from the power module.
  10. 10.
    Install a new front panel to the new module with the handles and screws.
  11. 11.
    Make sure that the power module connectors and connector pins are in good operating condition. Be careful not to damage the connector pins when you push the power module into the unit.
  12. 12.
    If necessary, clean the connectors with a vacuum cleaner.
  13. 13.
    Spray the connectors with contact cleaner spray. If necessary, lightly apply electrical joint compound.
  14. 14.
    Push the power module into the unit. Make sure that you do not damage the module.

    NOTE

    Do not lift the power module from its guide pins.

  15. 15.
    Install the fixing screws to the edges of the module front panel.
  16. 16.
    Set the module circuit breakers in ON position (up).
  17. 17.
    Connect the AC power supply to the unit from the main supply point.
  18. 18.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  19. 19.
    Lock the door of the unit.

Clean the Power Module

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

Tools required:

  • Vacuum cleaner

  • Clean and dry compressed air (max. 4 bar)

  • Protective film or equivalent for the middle compartment

  • Antistatic plastic brush (optional)

  • Contact cleaner spray

  • Soft, nonlinting cloth

  1. 1.
    Unlock and open the door of the power unit.
  2. 2.
    Set the Miniature Circuit Break (MCB) for control voltage (B) to OFF position.
  3. 3.
    Set the main power switch (A) to OFF position.
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply (C) and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Set the power module circuit breakers in OFF position (down).
  6. 6.
    Remove the four T30 fixing screws on the edges of the module front panel.
  7. 7.
    Use the handles to carefully pull out the power module.

    NOTE

    The module moves on its rollers on the rack.

    NOTE

    Protect the components that are installed back into the unit from dirt.

  8. 8.
    Do not lift the power module from its guide pins.

    NOTE

    The power module has two guide pins at the rear.

  9. 9.
    Clean the power module circuit breakers if they are stuck. If necessary, replace the circuit breakers. Contact Epiroc maintenance personnel.
  10. 10.
    Do not connect if you see signs that the device is short circuited. Contact Epiroc maintenance personnel.
  11. 11.
    Clean the cover and both ends of the module with the vacuum cleaner, use a brush if needed.
  12. 12.
    Remove the 16 H3 fixing screws of the module cover and remove the cover.

    NOTE

    Do not remove the fixing screws of the module rollers.

  13. 13.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Make sure that the power supply is disconnected when energy isolation is necessary.
  14. 14.
    Measure to make sure that no voltage remains before you continue:
    1. Measure the voltage between terminals X5 and X6 of channel A (right side).
    2. Measure the voltage between terminal X1 of channel B (left side).
  15. 15.
    Examine all components, cables, and terminals.
    1. Make sure that all cables are connected.
    2. Make sure that cable connections are tight.
    3. Make sure that there is no unusual smell, visible damage, or discoloration.

    NOTE

    If the internal components are visibly damaged or discolored, or if there is an unusual smell, contact Epiroc.

  16. 16.
    Remove the four T25 fixing screws of the cooling fan grille and remove the grille.
  17. 17.
    Clean the fan blades with a soft cloth.
  18. 18.
    Make sure that the fans rotate freely and without unusual sounds.
  19. 19.
    Install the grille with its fixing screws.
  20. 20.
    Cover the middle compartment with protective film or equivalent to protect the sensitive components.
  21. 21.
    Carefully clean all components in channel A and B with a vacuum cleaner. If necessary, carefully remove impurities with a small, antistatic plastic brush.
  22. 22.
    Remove the protective film from the middle compartment.
  23. 23.
    Install the module cover with its fixing screws.

    NOTE

    Do not overtighten the fixing screws.

  24. 24.
    Make sure that the module's connectors and connector pins are in good operating condition. Careful not to damage the connector pins when you push the module into the unit.
  25. 25.
    Clean the connectors with a vacuum cleaner if necessary.
  26. 26.
    Spray the connectors with contact cleaner spray. If necessary, lightly apply electrical joint compound.
  27. 27.
    Push the power module into the unit. Make sure that you do not damage the module.

    NOTE

    Do not lift the power module from its guide pins.

  28. 28.
    Install the fixing screws to the edges of the module front panel.
  29. 29.
    Set the module circuit breakers in ON position (up).
  30. 30.
    Connect the AC power supply to the unit from the main supply point (C).
  31. 31.
    Set the MCB for control voltage (B) and main power switch (A) to ON position.
  32. 32.
    Lock the door of the unit.
  33. 33.
    Do an insulation resistance test and a protective earth continuity test.

Replace the Power Module Cooling Fan

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit.
  2. 2.
    Set the Miniature Circuit Break (MCB) for control voltage (B) to OFF position.
  3. 3.
    Set the main power switch (A) to OFF position.
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply (C) and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Set the power module circuit breakers in OFF position (down).
  6. 6.
    Remove the four T30 fixing screws on the edges of the module front panel.
  7. 7.
    Use the handles to carefully pull out the power module.

    NOTE

    The module moves on its rollers on the rack.

    NOTE

    Protect the components that are installed back into the unit from dirt.

  8. 8.
    Do not lift the power module from its guide pins.

    NOTE

    The power module has two guide pins at the rear.

  9. 9.
    Remove the 16 H3 fixing screws of the module cover and remove the cover.

    NOTE

    Do not remove the fixing screws of the module rollers.

  10. 10.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Make sure that the power supply is disconnected when energy isolation is necessary.
  11. 11.
    Measure to make sure that no voltage remains before you continue:
    1. Measure the voltage between terminals X5 and X6 of channel A (right side).
    2. Measure the voltage between terminal X1 of channel B (left side).
  12. 12.
    Examine all components, cables, and terminals.
    1. Make sure that all cables are connected.
    2. Make sure that cable connections are tight.
    3. Make sure that there is no unusual smell, visible damage, or discoloration.

    NOTE

    If the internal components are visibly damaged or discolored, or if there is an unusual smell, contact Epiroc.

  13. 13.
    Remove the four T25 fixing screws of the cooling fan grille and remove the grille.
  14. 14.
    Remove the grille and move the cooling fan assembly out of the way.
  15. 15.
    Find the protective sleeve of the fan power supply wire connector.

    NOTE

    It is located in the middle compartment of the power module.

  16. 16.
    Carefully remove the cable ties that hold the protective sleeve in place. Slide the sleeve out of the way.
  17. 17.
    Use long nose pliers to disconnect the connector.

    NOTE

    Be careful not to damage the circuit boards and other sensitive components near the connector.

  18. 18.
    Replace the cooling fan.
  19. 19.
    Assemble in reverse order.
  20. 20.
    Install the module cover with its fixing screws.

    NOTE

    Do not overtighten the fixing screws.

  21. 21.
    Make sure that the module's connectors and connector pins are in good operating condition. Careful not to damage the connector pins when you push the module into the unit.
  22. 22.
    Clean the connectors with a vacuum cleaner if necessary.
  23. 23.
    Spray the connectors with contact cleaner spray. If necessary, lightly apply electrical joint compound.
  24. 24.
    Push the power module into the unit. Make sure that you do not damage the module.

    NOTE

    Do not lift the power module from its guide pins.

  25. 25.
    Install the fixing screws to the edges of the module front panel.
  26. 26.
    Set the module circuit breakers in ON position (up).
  27. 27.
    Connect the AC power supply to the unit from the main supply point (3).
  28. 28.
    Set the MCB for control voltage (2) and main power switch (1) to ON position.
  29. 29.
    Lock the door of the unit.
  30. 30.
    Do an insulation resistance test and a protective earth continuity test.

Replace the Power Distribution Module

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit.
  2. 2.
    Set the Miniature Circuit Break (MCB) for control voltage (B) to OFF position.
  3. 3.
    Set the main power switch (A) to OFF position.
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply (C) and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the four T30 fixing screws on the edges of the module front panel.
  6. 6.
    Use the handles to carefully pull out the distribution module.

    NOTE

    The module moves on its rollers on the rack.

    NOTE

    Protect the components that are installed back into the unit from dirt.

  7. 7.
    Make sure that the distribution module connectors and connector pins are in good operating condition. Be careful not to damage the connector pins when you push the distribution module into the unit.
  8. 8.
    If necessary, clean the connectors with a vacuum cleaner.
  9. 9.
    Spray the connectors with contact cleaner spray. If necessary, lightly apply electrical joint compound.
  10. 10.
    Push the distribution module into the unit. Make sure that you do not damage the module.
  11. 11.
    Install the fixing screws to the edges of the module front panel.
  12. 12.
    Connect the AC power supply to the unit from the main supply point.
  13. 13.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  14. 14.
    Lock the door of the unit.

Clean Dynamic Power Distribution Module

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit.
  2. 2.
    Set the Miniature Circuit Break (MCB) for control voltage (B) to OFF position.
  3. 3.
    Set the main power switch (A) to OFF position.
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply (C) and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the four T30 fixing screws on the edges of the module front panel.
  6. 6.
    Use the handles to carefully pull out the distribution module.

    NOTE

    The module moves on its rollers on the rack.

    NOTE

    Protect the components that are installed back into the unit from dirt.

  7. 7.
    Remove the sixteen H3 fixing screws from the module cover and remove the cover.

    NOTE

    Do not remove the fixing screws of the module rollers.

  8. 8.
    Examine all components, cables, and terminals.
    1. Make sure that all cables are connected.
    2. Make sure that cable connections are tight.
    3. Make sure that there is no unusual smell, visible damage, or discoloration.

    NOTE

    If the internal components are visibly damaged or discolored, or if there is an unusual smell, contact Epiroc.

  9. 9.
    Carefully clean all components with instrument air or a gas duster.
  10. 10.
    Remove the four T25 fixing screws of the cooling fan grille and remove the grille.
  11. 11.
    Clean the fan blades with a soft cloth.
  12. 12.
    Make sure that the fans rotate freely and without unusual sounds.
  13. 13.
    Install the grille with its fixing screws.
  14. 14.
    Install the module cover with its fixing screws.

    NOTE

    Do not overtighten the fixing screws.

  15. 15.
    Make sure that the module connectors and connector pins are in good operating condition. Be careful not to damage the connector pins when you push the distribution module into the unit.
  16. 16.
    If necessary, clean the connectors with a vacuum cleaner.
  17. 17.
    Spray the connectors with contact cleaner spray. If necessary, lightly apply electrical joint compound.
  18. 18.
    Push the module into the unit. Make sure that you do not damage the module.
  19. 19.
    Install the fixing screws to the edges of the module front panel.
  20. 20.
    Connect the AC power supply to the unit from the main supply point.
  21. 21.
    Connect the AC power supply to the unit from the main supply point.
  22. 22.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  23. 23.
    Lock the door of the unit.

Replace the Control Module

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit.
  2. 2.
    Set the Miniature Circuit Break (MCB) for control voltage (B) to OFF position.
  3. 3.
    Set the main power switch (A) to OFF position.
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply (C) and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Disconnect all cables or wires connected the control module front panel.

    NOTE

    Before you detach wires, cables, or connectors, take a photograph of them.

  6. 6.
    Remove the four T30 fixing screws on the edges of the module front panel.
  7. 7.
    Use the handle to carefully pull out the module.

    NOTE

    The module moves on its rollers on the rack.

    NOTE

    Protect the components that are installed back into the unit from dirt.

  8. 8.
    Remove the sixteen H3 fixing screws of the module cover and remove the cover

    NOTE

    Do not remove the fixing screws of the module rollers.

  9. 9.
    Remove the serial number card from the control board of the old control module.
  10. 10.
    Attach the serial number card to the control board of the new control module.
  11. 11.
    Use the maintenance tool to make sure that the information is transferred correctly. If necessary, contact Epiroc.
  12. 12.
    Install the module's cover with its fixing screws.

    NOTE

    Do not overtighten the fixing screws

  13. 13.
    Make sure that the module connectors and connector pins are in good operating condition. Be careful not to damage the connector pins when you push the distribution module into the unit.
  14. 14.
    If necessary, clean the connectors with a vacuum cleaner.
  15. 15.
    Spray the connectors with contact cleaner spray. If necessary, lightly apply electrical joint compound.
  16. 16.
    Push the module into the unit. Make sure that you do not damage the module.
  17. 17.
    Install the fixing screws to the edges of the module front panel.
  18. 18.
    Connect the cables or wires.

    NOTE

    Make sure that all cables are correctly connected and locked.

  19. 19.
    Connect the AC power supply to the unit from the main supply point.
  20. 20.
    Connect the AC power supply to the unit from the main supply point.
  21. 21.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  22. 22.
    Lock the door of the unit.

Clean the Control Module

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit.
  2. 2.
    Set the Miniature Circuit Break (MCB) for control voltage (B) to OFF position.
  3. 3.
    Set the main power switch (A) to OFF position.
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply (C) and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Disconnect all cables or wires connected the control module front panel.

    NOTE

    Before you detach wires, cables, or connectors, take a photograph of them.

  6. 6.
    Remove the four T30 fixing screws on the edges of the module front panel.
  7. 7.
    Use the handles to carefully pull out the module.

    NOTE

    The module moves on its rollers on the rack.

    NOTE

    Protect the components that are installed back into the unit from dirt.

  8. 8.
    Clean the cover and both ends of the module with the vacuum cleaner use a brush if needed.
  9. 9.
    Clean the cable terminals and connectors with clean and dry compressed air of maximum 4 bar (58 psi), if necessary.
  10. 10.
    Spray the connectors with contact cleaner spray.
  11. 11.
    Apply a small amount of electrical contact lubricant to each connector when the connectors are dry.
  12. 12.
    Remove the sixteen H3 fixing screws from the module cover and remove the cover.

    NOTE

    Do not remove the fixing screws of the module rollers.

  13. 13.
    Examine all components, cables, and terminals.
    1. Make sure that all cables are connected.
    2. Make sure that cable connections are tight.
    3. Make sure that there is no unusual smell, visible damage, or discoloration.

    NOTE

    If the internal components are visibly damaged or discolored, or if there is an unusual smell, contact Epiroc.

  14. 14.
    Carefully clean all components with instrument air or a gas duster.
  15. 15.
    If necessary, carefully remove dirt with a small, antistatic plastic brush.
  16. 16.
    Install the module cover with its fixing screws.

    NOTE

    Do not overtighten the fixing screws.

  17. 17.
    Make sure that the module connectors and connector pins are in good operating condition. Be careful not to damage the connector pins when you push the distribution module into the unit.
  18. 18.
    If necessary, clean the connectors with a vacuum cleaner.
  19. 19.
    Spray the connectors with contact cleaner spray. If necessary, lightly apply electrical joint compound.
  20. 20.
    Push the module into the unit. Make sure that you do not damage the module.
  21. 21.
    Install the fixing screws to the edges of the module front panel.
  22. 22.
    Connect the cables and wires.

    NOTE

    Make sure that all cables are correctly connected and locked.

  23. 23.
    Connect the AC power supply to the unit from the main supply point.
  24. 24.
    Connect the AC power supply to the unit from the main supply point.
  25. 25.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  26. 26.
    Lock the door of the unit.

Replace the Control Board of the Control Module

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit.
  2. 2.
    Set the Miniature Circuit Break (MCB) for control voltage (B) to OFF position.
  3. 3.
    Set the main power switch (A) to OFF position.
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply (C) and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the four T30 fixing screws on the edges of the module front panel.
  6. 6.
    Use the handles to carefully pull out the module.

    NOTE

    The module moves on its rollers on the rack.

    NOTE

    Protect the components that are installed back into the unit from dirt.

  7. 7.
    Remove the sixteen H3 fixing screws from the module cover and remove the cover.

    NOTE

    Do not remove the fixing screws of the module rollers.

  8. 8.
    Examine all components, cables, and terminals.
    1. Make sure that all cables are connected.
    2. Make sure that cable connections are tight.
    3. Make sure that there is no unusual smell, visible damage, or discoloration.

    NOTE

    If the internal components are visibly damaged or discolored, or if there is an unusual smell, contact Epiroc.

  9. 9.
    Detach all connectors from the control board.

    NOTE

    Before you detach wires, cables, or connectors, take a photograph of them.

  10. 10.
    If a USB cable is connected to the control board, unlock the USB connector before you detach the USB cable.
  11. 11.
    Push the lock down to release the USB cable.
  12. 12.
    Remove the fixing nut of the serial number card with your hand. Remove the serial number card.
  13. 13.
    Remove the four fixing nuts of the control board with your hand. Remove the control board.
  14. 14.
    Install the new control board in the reverse order.
  15. 15.
    Carefully clean all components with instrument air or a gas duster.
  16. 16.
    Attach the serial number card again.
  17. 17.
    Connect all cables to the control board.

    NOTE

    Make sure that all cables are correctly connected and locked.

  18. 18.
    Install the module cover with its fixing screws.

    NOTE

    Do not overtighten the fixing screws.

  19. 19.
    Make sure that the module connectors and connector pins are in good operating condition. Be careful not to damage the connector pins when you push the module into the unit.
  20. 20.
    If necessary, clean the connectors with a vacuum cleaner.
  21. 21.
    Spray the connectors with contact cleaner spray. If necessary, lightly apply electrical joint compound.
  22. 22.
    Push the module into the unit. Make sure that you do not damage the module.
  23. 23.
    Install the fixing screws to the edges of the module front panel.
  24. 24.
    Connect the cables and wires.

    NOTE

    Make sure that all cables are correctly connected and locked.

  25. 25.
    Connect the AC power supply to the unit from the main supply point.
  26. 26.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  27. 27.
    Lock the door of the unit.

Examine the Tightening Torques of Terminal Blocks

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

NOTE

Tighten and torque the connections as per torque specification.

  1. 1.
    Unlock and open the door of the power unit.
  2. 2.
    Set the Miniature Circuit Break (MCB) for control voltage (B) to OFF position.
  3. 3.
    Set the main power switch (A) to OFF position.
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply (C) and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the four T30 fixing screws of the main module's front panel.
  6. 6.
    Remove the front panel.
  7. 7.
    Remove the four T30 fixing screws on the edges of the module front panel.
  8. 8.
    Use the handles to carefully pull out the module.

    NOTE

    The module moves on its rollers on the rack.

    NOTE

    Protect the components that are installed back into the unit from dirt.

  9. 9.
    If necessary, remove the power distribution module.
  10. 10.

    DANGER

    Electrical Shock

    High electrical voltage can cause serious injury or death.

    1. Measure the power terminals to make sure that no voltage remains before you continue.

    Use the torque wrench to inspect the tightening torques of the AC power terminal blocks, bus bars and the main switch. Tighten each screw terminal to the correct torque as necessary.

    NOTE

    The size of the cable fixing screws is H6. The tightening torque is also marked on the terminal block.

    Component

    Size

    Torque value

    Busbar (A)

    13.5 Nm (9.95 ft-lbs)

    16 mm2

    3.5 Nm (2.5 ft-lbs)

    AC terminal blocks (B)

    35–120 mm2

    26 Nm (19.1 ft-lbs)

    150–240 mm2

    40 Nm (29.5 ft-lbs)

    Main switch (C)

    50 Nm (36.8 ft-lbs)

  11. 11.
    Use the torque wrench to inspect the tightening torques of the DC power terminal blocks. Tighten each screw terminal to the correct torque as necessary.

    NOTE

    The size of the cable fixing screws is H6. The tightening torque is also marked on the terminal block.

    Size

    Torque

    6–25 mm2

    12 Nm (8.85 ft-lbs)

    35–95 mm2

    22 Nm (16.22 ft-lbs)

    25–60 mm2

    14 Nm (10.3 ft-lbs)

    70–150 mm2

    30 Nm (22.1 ft-lbs)

    16–50 mm2

    10 Nm (7.3 ft-lbs)

  12. 12.
    Inspect the tightness of the spring terminal blocks.
  13. 13.
    If the connections are loose, replace the terminal block.
  14. 14.
    Make sure that the module connectors and connector pins are in good operating condition. Be careful not to damage the connector pins when you push the module into the unit.
  15. 15.
    If necessary, clean the connectors with a vacuum cleaner.
  16. 16.
    Spray the connectors with contact cleaner spray. If necessary, lightly apply electrical joint compound.
  17. 17.
    If you removed the power distribution module, install it.
  18. 18.
    Push the module into the unit. Make sure that you do not damage the module.
  19. 19.
    Install the fixing screws to the edges of the module front panel.
  20. 20.
    Connect the cables and wires.

    NOTE

    Make sure that all cables are correctly connected and locked.

  21. 21.
    Install the main module's front panel with its fixing screws.
  22. 22.
    Connect the AC power supply to the unit from the main supply point.
  23. 23.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  24. 24.
    Lock the door of the unit.

Replace Terminal block

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit.
  2. 2.
    Set the Miniature Circuit Break (MCB) for control voltage (B) to OFF position.
  3. 3.
    Set the main power switch (A) to OFF position.
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply (C) and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the four T30 fixing screws on the edges of the module front panel.
  6. 6.
    Remove the front panel.

    NOTE

    Protect the components that are installed back into the unit from dirt.

  7. 7.
    Remove the four T30 fixing screws on the edges of the module front panel.
  8. 8.
    Use the handle to carefully pull out the module.

    NOTE

    The module moves on its rollers on the rack.

    NOTE

    Protect the components that are installed back into the unit from dirt.

  9. 9.
    Remove the sixteen H3 fixing screws of the module cover and remove the cover

    NOTE

    Do not remove the fixing screws of the module rollers.

  10. 10.

    DANGER

    Electrical Shock

    High electrical voltage can cause serious injury or death.

    1. Measure the power terminals to make sure that no voltage remains before you continue.

    Disconnect the AC supply power cables from the terminal block.

    NOTE

    The size of the cable fixing screws is H6.

  11. 11.
    Remove the T25 fixing screws of the terminal block.
  12. 12.
    Replace the terminal block.
  13. 13.
    Connect the cables.
  14. 14.
    Tighten each screw terminal to the correct torque.

    NOTE

    The tightening torque is marked on the terminal block.

  15. 15.
    Disconnect the DC output power cables from the terminal block.

    NOTE

    The size of the cable fixing screws is H6.

    NOTE

    Before you detach wires, cables, or connectors, take a photograph of them.

  16. 16.
    Replace the clip-type terminal block. Connect the cables.
  17. 17.
    Tighten each screw terminal to the correct torque.

    NOTE

    The tightening torque is marked on the terminal block.

  18. 18.
    Disconnect the control signal cable wires from the spring terminal block.

    NOTE

    Before you detach wires, cables, or connectors, take a photograph of them.

  19. 19.
    Make sure that the module connectors and connector pins are in good operating condition. Be careful not to damage the connector pins when you push the distribution module into the unit.
  20. 20.
    If necessary, clean the connectors with a vacuum cleaner.
  21. 21.
    Spray the connectors with contact cleaner spray. If necessary, lightly apply electrical joint compound.
  22. 22.
    Push the module into the unit. Make sure that you do not damage the module.
  23. 23.
    Install the fixing screws to the edges of the module front panel.
  24. 24.
    Connect the cables or wires.

    NOTE

    Make sure that all cables are correctly connected and locked.

  25. 25.
    Install the main module front panel with its fixing screws.
  26. 26.
    Connect the AC power supply to the unit from the main supply point.
  27. 27.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  28. 28.
    Lock the door of the unit.

Replace Charging Cable of Station Charger

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

NOTE

Do not remove the packaging of the machine connector before installation. It protects the machine connector from damages.

NOTE

For tasks related to the machine connector, read the machine connector manufacturer instructions.

  1. 1.
    Unlock and open the door of the power unit.
  2. 2.
    Set the Miniature Circuit Break (MCB) for control voltage (B) to OFF position.
  3. 3.
    Set the main power switch (A) to OFF position.
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply (C) and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Unlock the front panel with the triangle key.
  6. 6.
    Hold the handle and pull open the front panel.
  7. 7.

    WARNING

    Risk of Electric Shock

    High voltage electricity can cause severe damage or death.

    1. Make sure that the power supply is disconnected when energy isolation is necessary.

    2. Measure the terminals to make sure that no voltage remains before you continue.

    Disconnect the charging cable wires from the terminals.

    NOTE

    Before you disconnect wires, cables, or connectors, take a photograph of them.

  8. 8.
    Loosen the cable bushing below the spring holder.

    NOTE

    Depending on the charging cable, the size of the cable bushing is 55–68 mm.

  9. 9.
    Pull the charging cable out of the rubber grommet.
  10. 10.
    Remove the cable bushing and hose clamp and set them aside to be installed to the new charging cable.
  11. 11.
    Lift the support spring and charging cable out of the spring holder.
  12. 12.
    Remove the cable clamp from the end of the support spring with the ratchet and 15-mm socket.
  13. 13.
    Pull the charging cable out of the support spring.

    NOTE

    The size of the cable clamp's nuts is M10.

  14. 14.
    Install new charging cable:
    1. Tape the wire ends of the charging cable to avoid fraying.
    2. Tape the cable bundle together to make pulling the cable through the spring easier.
    3. Pull the charging cable through its support spring until approximately 400–600 mm (1) of the charging cable remains outside of the support spring.

      NOTE

      If necessary, use the draw tape and lubricant to pull the cable.

      NOTE

      To make the handling of the charging cable and support spring easier during installation, you can temporarily lock the charging cable inside its support spring. The size of the cable clamp's nuts is M10.

    4. Lift the support spring with the charging cable into the spring holder.
    5. First install the cable bushing and then the hose clamp on the charging cable.
    6. Route the charging cable inside the unit through the rubber grommet.
    7. Make sure that the part of the charging cable inside the unit has, approximately 50 mm of insulation and approximately 350–550 mm of stripped wire.
    8. Make sure that the wires reach the terminals.
    9. Tighten the cable bushing of the charging cable below the spring holder.

      NOTE

      Depending on the charging cable, the size of the cable bushing is 55–68 mm.

    10. Make sure that the rubber grommet's seal kits correctly on the charging cable.
    11. Push the charging cable slightly inside the unit so that the seal goes inside the unit.
    12. Tighten the seal in place with the hose clamp.
    13. Connect the wires to the terminals
    14. Tighten each screw terminal to the correct torque. The tightening torque is marked on the terminal block.
    15. Tighten the cable clamp to lock the charging cable in place inside its support spring with the ratchet and 15-mm socket,

      NOTE

      The size of the cable clamp's nuts is M10.

      NOTE

      Do not overtighten the cable clamp. Overtightening damages the charging cable.

    16. Examine the seal of the charging cable in the rubber grommet.
    17. If necessary, apply flexible polyurethane sealant to waterproof the opening.
    18. Lock the front panel with the triangle key.
  15. 15.
    Connect the AC power supply to the unit from the main supply point.
  16. 16.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  17. 17.
    Lock the door of the unit.

Replace the Connector Holder of Station Charger

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit.
  2. 2.
    Set the Miniature Circuit Break (MCB) for control voltage (B) to OFF position.
  3. 3.
    Set the main power switch (A) to OFF position.
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply (C) and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Unlock the front panel with the triangle key.
  6. 6.
    Hold the handle and pull open the front panel.
  7. 7.
    Remove the four T40 fixing screws and nuts of the vehicle connector holder frame.
  8. 8.
    Remove the vehicle connector holder frame.
  9. 9.
    Remove the four T20 screws of the vehicle connector holder.
  10. 10.
    Assemble in the reverse order.
  11. 11.
    Lock the front panel with the triangle key.
  12. 12.
    Connect the AC power supply to the unit from the main supply point.
  13. 13.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  14. 14.
    Lock the door of the unit.

Replace the Control Board of the Display Screen of Station Charger

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit.
  2. 2.
    Set the Miniature Circuit Break (MCB) for control voltage (B) to OFF position.
  3. 3.
    Set the main power switch (A) to OFF position.
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply (C) and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Unlock the front panel with the triangle key.
  6. 6.
    Hold the handle and pull open the front panel.
  7. 7.
    Disconnect all connectors from the control board.

    NOTE

    Before you detach wires, cables, or connectors, take a photograph of them.

  8. 8.
    If a USB cable is connected to the control board, unlock the USB connector before you disconnect the USB cable.
  9. 9.
    Push the lock down to release the USB cable.
  10. 10.
    Carefully unlock the locking lever of the flat cable connector before you disconnect the flat cable.

    NOTE

    The connector type is zero insertion force (ZIF).

  11. 11.
    Remove the fixing nut of the serial number card with your hand. Remove the serial number card.
  12. 12.
    Remove the four fixing nuts of the control board with your hand. Remove the control board.
  13. 13.
    Install the new control board in the reverse order. Attach the serial number card again.
  14. 14.
    Remove the four T40 fixing screws and nuts of the vehicle connector holder frame.
  15. 15.
    Connect all cables to the control board.
  16. 16.
    Make sure that all cables are correctly connected and locked.
  17. 17.
    Make sure that the flat cables are correctly connected. Lock the connectors.
  18. 18.
    Lock the front panel with the triangle key.
  19. 19.
    Connect the AC power supply to the unit from the main supply point.
  20. 20.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  21. 21.
    Lock the door of the unit.

Replace the Display Screen of Station Charger

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit.
  2. 2.
    Set the Miniature Circuit Break (MCB) for control voltage (B) to OFF position.
  3. 3.
    Set the main power switch (A) to OFF position.
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply (C) and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Unlock the front panel with the triangle key.
  6. 6.
    Hold the handle and pull open the front panel.
  7. 7.
    Disconnect all connectors from the control board.

    NOTE

    Before you detach wires, cables, or connectors, take a photograph of them.

  8. 8.
    Carefully unlock the locking lever of the flat cable connector before you disconnect the flat cable.

    NOTE

    The connector type is zero insertion force (ZIF).

  9. 9.
    If a USB cable is connected to the control board, unlock the USB connector before you disconnect the USB cable.
  10. 10.
    Push the lock down to release the USB cable.
  11. 11.
    Remove the four T30 fixing screws and nuts of the control board assembly.
  12. 12.
    Remove the control board assembly.
  13. 13.
    Remove the old display screen from its holders.
  14. 14.
    Replace the display screen.
  15. 15.
    Make sure to remove the protective film. Be careful not to scratch the display screen.
  16. 16.
    Make sure that there is no dirt or moisture between the display screen and the protective cover.
  17. 17.
    Clean both surfaces with a soft, non linting cloth.
  18. 18.
    Assemble in the reverse order.
  19. 19.
    Make sure that all cables are correctly connected and locked.
  20. 20.
    Connect the AC power supply to the unit from the main supply point.
  21. 21.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  22. 22.
    Lock the door of the unit.

Replace the Charging Status Indicator LED Panel of Station Charger

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit.
  2. 2.
    Set the Miniature Circuit Break (MCB) for control voltage (B) to OFF position.
  3. 3.
    Set the main power switch (A) to OFF position.
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply (C) and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove as many power modules as necessary to make space for removing the LED panel.
  6. 6.
    Replace one LED panel at a time.

    NOTE

    The LED panel consists of LEDs (LED) soldered to a printed circuit board (PCB).

    NOTE

    The LED panel is attached to the unit frame and the LED cover.

    NOTE

    Note the orientation of the LED panel. The parts are not symmetrical.

  7. 7.
    Set the power module circuit breakers in OFF position (down).
  8. 8.
    Remove the four T30 fixing screws on the edges of the module front panel.
  9. 9.
    Remove the four T30 fixing screws on the edges of the module front panel.
  10. 10.
    Use the handle to carefully pull out the module.

    NOTE

    The module moves on its rollers on the rack.

    NOTE

    Protect the components that are installed back into the unit from dirt.

  11. 11.
    Do not lift the power module from its guide pins.

    NOTE

    The power module has two guide pins at the back end.

  12. 12.
    Remove the two T20 fixing screws of the LED panel.

    NOTE

    Do not remove the LED cover. It is glued to the unit frame.

    NOTE

    Before you disconnect wires, cables, or connectors, take a photograph of them.

  13. 13.
    Carefully turn the LED panel to remove it.
  14. 14.
    Disconnect the wires from the LED panel.
  15. 15.
    Examine the condition of the LED cover gluing. If necessary, apply weatherproof glue to the seam.
  16. 16.
    Assemble in the reverse order.
  17. 17.
    Make sure that all wires are correctly connected.
  18. 18.
    Push the power module into the unit. Make sure that you do not damage the module.

    NOTE

    Do not lift the power module from its guide pins.

  19. 19.
    Install the fixing screws to the edges of the module's front panel.
  20. 20.
    Set the module's circuit breakers in ON position (up).
  21. 21.
    Connect the AC power supply to the unit from the main supply point.
  22. 22.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  23. 23.
    Lock the door of the unit.

Replace Main Switch and MCB of the Charging Power Unit

DANGER

High Voltage

High voltage installation can cause severe injury or death.

  1. Make sure that the units are correctly isolated when necessary during installation, service, or maintenance work.

  2. Know and obey general and local safety regulations and procedures.

  3. Know and obey general and local safety regulations and procedures.

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit.
  2. 2.
    Set the Miniature Circuit Break (MCB) for control voltage (B) to OFF position.
  3. 3.
    Set the main power switch (A) to OFF position.
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply (C) and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the four T30 fixing screws on the edges of the module front panel.
  6. 6.
    Use the handle to carefully pull out the module.

    NOTE

    The module moves on its rollers on the rack.

    NOTE

    Protect the components that are installed back into the unit from dirt.

  7. 7.
    Remove the four T30 fixing screws on the edges of the power distribution module's front panel.
  8. 8.
    Do not lift the power module from its guide pins.

    NOTE

    The power module has two guide pins at the back end.

  9. 9.
    Use the handle to carefully pull out the module.

    NOTE

    The module moves on its rollers on the rack.

    NOTE

    Protect the components that are installed back into the unit from dirt.

  10. 10.
    Remove the four T30 fixing screws of the main module's front panel.
  11. 11.
    Remove the front panel.

    NOTE

    Protect the components that are installed back into the unit from dirt.

  12. 12.

    DANGER

    Electrical Shock

    High electrical voltage can cause serious injury or death.

    1. Measure the power terminals to make sure that no voltage remains before you continue.

    Replace the main switch:
    1. Remove the six M12 connection screws of the busbars on the main switch.
    2. Disconnect the three busbars from above and the three busbars from below the main switch.

      NOTE

      Make sure that you know how to connect each busbar to the correct terminal.

    3. Remove the four M5 fixing screws of the main switch. Remove the main switch.
    4. Install the new main switch with its fixing screws. Tightening torque 3 Nm (2.2 lb-ft).
    5. Attach the busbars to the terminals.
    6. Tighten the M12 connection screws of the busbars. Tightening torque 50 Nm (36.8 lb-ft).

      NOTE

      Make sure that you connect the busbars to the correct terminals.

  13. 13.
    Replace the MCB:

    NOTE

    The clip-type miniature circuit breaker (MCB) is located next to the main switch.

    1. Loosen the screws and disconnect the wires from the MCB.
    2. Remove the MCB.

      NOTE

      Before you disconnect wires, cables, or connectors, take a photograph of them.

    3. Install the new MCB.
    4. Attach the wires to the terminals.
    5. Tighten the screws. Tightening torque 2.5 Nm (1.8 lb-ft).

      NOTE

      Make sure that all wires are correctly connected.

  14. 14.
    Install the main module's front panel with its fixing screws.
  15. 15.
    Make sure that the module connectors and connector pins are in good operating condition. Be careful not to damage the connector pins when you push the distribution module into the unit.
  16. 16.
    If necessary, clean the connectors with a vacuum cleaner.
  17. 17.
    Spray the connectors with contact cleaner spray. If necessary, lightly apply electrical joint compound.
  18. 18.
    Push the power distribution module into the unit. Make sure that you do not damage the module.
  19. 19.
    Install the fixing screws to the edges of the module's front panel.
  20. 20.
    Carefully push the control module into the unit.
  21. 21.
    Install the fixing screws to the edges of the module's front panel.
  22. 22.
    Attach the cables or wires.

    NOTE

    Make sure that all cables are correctly connected and locked.

    NOTE

    When you have replaced the main switch, configure its settings.

  23. 23.
    Connect the AC power supply to the unit from the main supply point.
  24. 24.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  25. 25.
    Lock the door of the unit.

Configure the Main Switch of Charging Power Unit

DANGER

High Voltage

High voltage installation can cause severe injury or death.

  1. Make sure that the units are correctly isolated when necessary during installation, service, or maintenance work.

  2. Know and obey general and local safety regulations and procedures.

  3. Know and obey general and local safety regulations and procedures.

NOTE

Make sure that selectivity requirements are fulfilled in accordance with local laws and regulations.

  1. 1.
    Set the unit's main switch and the miniature circuit breaker (MCB) to OFF position (down).
  2. 2.
    If the front panel of the mains module is in place, remove it.
  3. 3.
    Identify the manufacturer of the main switch and follow the respective instructions.
  4. 4.
    Push the circuit breaker's test button and make sure that the unit trips after you finish configuring the main switch.
  5. 5.
    Make sure that the rating of the supply side circuit breaker is higher than that of the cabinet's main switch.

Configure ABB Circuit Breaker

  1. 1.
    Adjust the switches according to the number of power modules in the cabinet.
  2. 2.
    Use the appropriate factor to include the short circuit value in the selected settings.
  3. 3.
    Adjust the DIP switches carefully to avoid damaging them.
  4. 4.
    Select the correct values on the DIP switch panel marked L at the bottom of the circuit breaker.

    NOTE

    ON = up, OFF = down

    Number of power modules

    Value

    DIP switch setting (L)

    0.04

    0.08

    0.16

    0.32

    4

    368 A

    ON

    OFF

    ON

    ON

    3

    272 A

    ON

    ON

    ON

    OFF

    2

    192 A

    ON

    ON

    OFF

    OFF

    1

    160 A

    ON

    OFF

    OFF

    OFF

Configure Chint Circuit Breaker

  1. 1.
    Adjust the switches according to the number of power modules in the cabinet.
  2. 2.
    Use the appropriate factor to include the short circuit value in the selected settings.
  3. 3.
    Adjust the DIP switches carefully to avoid damaging them.
  4. 4.
    Select the correct values on the DIP switch panel marked lr at the bottom of the circuit breaker.

    NOTE

    ON = up, OFF = down

    Number of power modules

    Value

    DIP switch setting (lr)

    ON

    Middle

    Right

    4

    360 A

    ON

    OFF

    ON

    3

    280 A

    OFF

    ON

    ON

    2

    200 A

    OFF

    OFF

    ON

    1

    160 A

    OFF

    OFF

    OFF

Configure Schneider Circuit Breaker

  1. 1.
    Adjust the switches according to the number of power modules in the cabinet.
  2. 2.
    Use the appropriate factor to include the short circuit value in the selected settings.
  3. 3.
    Turn the rotary switch carefully with a flat screwdriver. Do not rotate the switch 360 degrees.
  4. 4.
    Select the correct values on the left-hand side rotary switch at the bottom of the circuit breaker.

    NOTE

    You should feel when the switch engages on the setting.

    Number of power modules

    Rotary switch setting (left-hand side)

    4

    400 A

    3

    300 A

    2

    200 A

    1

    125 A

Charging Post Version 1

Examine the Tightening Torque of Charging Post 1 Terminal Blocks

WARNING

Loose Cable

Loose cable terminal connections can cause fire, severe injury, or death.

  1. Make sure are all the cable terminal connections are tightened properly.

If the spring terminals are loose, replace them. Only screw terminals can be tightened.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws.
  6. 6.
    Open the front panel of the unit.
  7. 7.

    DANGER

    Electrical Shock

    High electrical voltage can cause serious injury or death.

    1. Measure the power terminals to make sure that no voltage remains before you continue.

    Use the torque wrench to inspect the tightening torques of the DC power terminal blocks.

    NOTE

    The size of the cable fixing screws is H6.

  8. 8.
    Tighten each screw terminal to the correct torque.

    NOTE

    The tightening torque is marked on the terminal block.

  9. 9.
    Inspect the tightness of the spring terminal blocks. If the connections are loose, replace the terminal block.
  10. 10.
    Close the front panel of the unit.
  11. 11.
    Install the three security T30 screws.

    NOTE

    In older models, the size of the front panel's screws is H3.

  12. 12.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  13. 13.
    Make sure that no cables push against the LED panel on the front panel of the unit.
  14. 14.
    Connect the AC power supply to the unit from the main supply point.
  15. 15.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  16. 16.
    Lock the door of the unit.

Replace the Charging Post Version 1 Terminal Block

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws.
  6. 6.
    Open the front panel of the unit.
  7. 7.

    DANGER

    Electrical Shock

    High electrical voltage can cause serious injury or death.

    1. Measure the power terminals to make sure that no voltage remains before you continue.

    Disconnect the DC power cables from the terminal block.

    NOTE

    The size of the cable fixing screws is H6.

    NOTE

    Before you disconnect wires, cables, or connectors, take a photograph of them.

  8. 8.
    Replace the clip-type terminal block.
  9. 9.
    Connect the cables again.
  10. 10.
    Tighten each screw terminal to the correct torque.

    NOTE

    The tightening torque is marked on the terminal block.

  11. 11.
    Disconnect the control signal cable wires from the spring terminal block.

    NOTE

    Before you disconnect wires, cables, or connectors, take a photograph of them.

  12. 12.
    Replace the clip-type terminal block.
  13. 13.
    Connect the control signal cable wires again.
  14. 14.
    Close the front panel of the unit. Install the three security T30 screws.

    NOTE

    In older models, the size of the front panel screws is H3.

  15. 15.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  16. 16.
    Make sure that no cables push against the LED panel on the front panel of the unit.
  17. 17.
    Connect the AC power supply to the unit from the main supply point.
  18. 18.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  19. 19.
    Lock the door of the unit.

Replace the Charging Cable of Charging Post Version 1

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

NOTE

In dusty conditions replace the charging cable every second year.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws.
  6. 6.
    Open the front panel of the unit.
  7. 7.

    WARNING

    Risk of Electric Shock

    High voltage electricity can cause severe damage or death.

    1. Make sure that the power supply is disconnected when energy isolation is necessary.

    2. Measure the terminals to make sure that no voltage remains before you continue.

    Disconnect the charging cable wires from the terminals.

    NOTE

    Before you disconnect wires, cables, or connectors, take a photograph of them.

  8. 8.
    Loosen the cable bushing below the spring holder.

    NOTE

    Depending on the charging cable, the size of the cable bushing is 55–68 mm.

  9. 9.
    Pull the charging cable out of the rubber grommet.
  10. 10.
    Remove the cable bushing and hose clamp and set them aside to be installed to the new charging cable.
  11. 11.
    Lift the support spring and charging cable out of the spring holder.
  12. 12.
    Remove the cable clamp from the end of the support spring with the ratchet and 15-mm socket.
  13. 13.
    Pull the charging cable out of the support spring.

    NOTE

    The size of the cable clamp's nuts is M10.

  14. 14.
    Install new charging cable:
    1. Tape the wire ends of the charging cable to avoid fraying.
    2. Tape the cable bundle together to make pulling the cable through the spring easier.
    3. Pull the charging cable through its support spring until approximately 400–600 mm (1) of the charging cable remains outside of the support spring.

      NOTE

      If necessary, use the draw tape and lubricant to pull the cable.

      NOTE

      To make the handling of the charging cable and support spring easier during installation, you can temporarily lock the charging cable inside its support spring. The size of the cable clamp's nuts is M10.

    4. Lift the support spring with the charging cable into the spring holder.
    5. First install the cable bushing and then the hose clamp on the charging cable.
    6. Route the charging cable inside the unit through the rubber grommet.
    7. Make sure that the part of the charging cable inside the unit has, approximately 50 mm of insulation and approximately 350–550 mm of stripped wire.
    8. Make sure that the wires reach the terminals.
    9. Tighten the cable bushing of the charging cable below the spring holder.

      NOTE

      Depending on the charging cable, the size of the cable bushing is 55–68 mm.

    10. Make sure that the rubber grommet's seal kits correctly on the charging cable.
    11. Push the charging cable slightly inside the unit so that the seal goes inside the unit.
    12. Tighten the seal in place with the hose clamp.
    13. Connect the wires to the terminals
    14. Tighten each screw terminal to the correct torque. The tightening torque is marked on the terminal block.
    15. Tighten the cable clamp to lock the charging cable in place inside its support spring with the ratchet and 15-mm socket,

      NOTE

      The size of the cable clamp's nuts is M10.

      NOTE

      Do not overtighten the cable clamp. Overtightening damages the charging cable.

    16. Examine the seal of the charging cable in the rubber grommet.
    17. If necessary, apply flexible polyurethane sealant to waterproof the opening.
    18. Lock the front panel with the triangle key.
  15. 15.
    Close the front panel of the unit. Install the three security T30 screws.

    NOTE

    In older models, the size of the front panel screws is H3.

  16. 16.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  17. 17.
    Make sure that no cables push against the LED panel on the front panel of the unit.
  18. 18.
    Connect the AC power supply to the unit from the main supply point.
  19. 19.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  20. 20.
    Lock the door of the unit.

Lock the Charging Cable in Support Spring

Use method A or method B to lock the charging cable in place inside its support spring.

  1. 1.
    Method A:
    1. Make sure that the cable bushing below the spring holder is correctly tightened.
    2. Push the charging cable into its support spring so that it touches the top side of the support spring.
  2. 2.
    Method B:
    1. Make sure that the cable bushing below the spring holder is correctly tightened.
    2. Have another person hold the support spring in an extended position. Pull the charging cable from the support spring.
    3. Tighten the cable clamp to lock the charging cable in place inside its support spring.

      NOTE

      The size of the cable clamp's nuts is M10.

      NOTE

      Have the cable clamp's locking part face toward the inside bend of the charging cable to avoid it hitting the vehicle during charging.

      NOTE

      Have the cable clamp's locking part face toward the inside bend of the charging cable to avoid it hitting the vehicle during charging.

    4. Make sure that the charging cable is in contact with the top part of its support spring when it is not in use.

      NOTE

      This protects the charging cable from chafing against its support spring or the cable gland when it is extended.

Replace the Control Board of Charging Post Version 1 Display Screen

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws.
  6. 6.
    If a USB cable is connected to the control board, unlock the USB connector before you disconnect the USB cable.
  7. 7.
    Push the lock down to release the USB cable.
  8. 8.
    Carefully unlock the locking lever of the flat cable connector before you disconnect the flat cable.

    NOTE

    The connector type is zero insertion force (ZIF).

  9. 9.
    Remove the four fixing nuts of the control board with your hand. Remove the control board.

    NOTE

    The serial number card is attached to the cables with a zip tie. If you replace cables, make sure to attach the serial number card again.

  10. 10.
    Install the new control board.
  11. 11.
    Attach the serial number card again.
  12. 12.
    Connect all cables to the control board.
  13. 13.
    Make sure that all cables are correctly connected and locked.
  14. 14.
    Make sure that the flat cables are correctly connected. Lock the connectors
  15. 15.
    Make sure that the flat cables are correctly connected. Lock the connectors

    NOTE

    In older models, the size of the front panel's screws is H3.

  16. 16.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  17. 17.
    Make sure that no cables push against the LED panel on the front panel of the unit.
  18. 18.
    Connect the AC power supply to the unit from the main supply point.
  19. 19.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  20. 20.
    Lock the door of the unit.

Replace the Charging Post Version 1 Display Screen

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws.
  6. 6.
    If a USB cable is connected to the control board, unlock the USB connector before you disconnect the USB cable.
  7. 7.
    Push the lock down to release the USB cable.
  8. 8.
    Carefully unlock the locking lever of the flat cable connector before you disconnect the flat cable.

    NOTE

    The connector type is zero insertion force (ZIF).

  9. 9.
    Remove the four fixing nuts of the control board with your hand. Remove the control board.

    NOTE

    The serial number card is attached to the cables with a zip tie. If you replace cables, make sure to attach the serial number card again.

  10. 10.
    Remove the two T20 fixing screws of each display holder.
  11. 11.
    Remove the four display holders.
  12. 12.
    Replace the display screen.
  13. 13.
    Make sure to remove the protective film.

    NOTE

    Be careful not to scratch the display screen.

  14. 14.
    Make sure that there is no dirt or moisture between the display screen and the protective cover.
  15. 15.
    Clean both surfaces with a soft, nonlinting cloth.
  16. 16.
    Make sure that the flat cables are correctly connected. Lock the connectors.
  17. 17.
    Assemble in the reverse order.
  18. 18.
    Make sure that all cables are correctly connected and locked.
  19. 19.
    Connect the AC power supply to the unit from the main supply point.
  20. 20.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  21. 21.
    Lock the door of the unit.

Replace the Charging Post Version 1 Status Indicator LED Panel

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws.
  6. 6.
    Do not remove the LED cover. It is glued to the unit frame.
  7. 7.
    Remove the four T20 fixing screws of the LED panel. Carefully remove the LED panel.

    NOTE

    Before you detach wires, cables, or connectors, take a photograph of them.

  8. 8.
    Detach the wires from the LED panel.
  9. 9.
    Examine the condition of the LED cover's gluing. If necessary, apply weatherproof glue to the seam.
  10. 10.
    Assemble in the reverse order.
  11. 11.
    Make sure that all wires are correctly connected.
  12. 12.
    Close the front panel of the unit. Install the three security T30 screws.

    NOTE

    In older models, the size of the front panel's screws is H3.

  13. 13.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  14. 14.
    Make sure that no cables push against the LED panel on the front panel of the unit.
  15. 15.
    Connect the AC power supply to the unit from the main supply point.
  16. 16.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  17. 17.
    Lock the door of the unit.

Charging Post Version 2

Replace the Charging Post 2 Terminal Block

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws.
  6. 6.
    Open the front panel of the unit.
  7. 7.

    DANGER

    Electrical Shock

    High electrical voltage can cause serious injury or death.

    1. Measure the power terminals to make sure that no voltage remains before you continue.

    Disconnect the DC power cables from the terminal block.

    NOTE

    The size of the cable fixing screws is H6.

    NOTE

    Before you disconnect wires, cables, or connectors, take a photograph of them.

  8. 8.
    Replace the clip-type terminal block.
  9. 9.
    Connect the cables again.
  10. 10.
    Tighten each screw terminal to the correct torque.

    NOTE

    The tightening torque is marked on the terminal block.

  11. 11.
    Disconnect the control signal cable wires from the spring terminal block.

    NOTE

    Before you disconnect wires, cables, or connectors, take a photograph of them.

  12. 12.
    Replace the clip-type terminal block.
  13. 13.
    Connect the control signal cable wires again.
  14. 14.
    Close the front panel of the unit. Install the three security T30 screws.

    NOTE

    In older models, the size of the front panel screws is H3.

  15. 15.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  16. 16.
    Make sure that no cables push against the LED panel on the front panel of the unit.
  17. 17.
    Connect the AC power supply to the unit from the main supply point.
  18. 18.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  19. 19.
    Lock the door of the unit.

Liquid Cooled Charging Post

Examine the Tightening Torque of Liquid Cooled Charging Post Terminal Blocks

WARNING

Loose Cable

Loose cable terminal connections can cause fire, severe injury, or death.

  1. Make sure are all the cable terminal connections are tightened properly.

If the spring terminals are loose, replace them. Only screw terminals can be tightened.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws from each frame.
  6. 6.
    Open the front panel of both frames.
  7. 7.

    DANGER

    Electrical Shock

    High electrical voltage can cause serious injury or death.

    1. Measure the power terminals to make sure that no voltage remains before you continue.

    Use the torque wrench to inspect the tightening torques of the DC power terminal blocks.

    NOTE

    The size of the cable fixing screws is H6.

  8. 8.
    Inspect the tightness of the spring terminal blocks. If the connections are loose, replace the terminal block.
  9. 9.
    Tighten each screw terminal to the correct torque.

    NOTE

    The tightening torque is marked on the terminal block.

  10. 10.
    Inspect the tightness of the cable lugs.
  11. 11.
    Tighten each screw terminal to the correct torque to 28 Nm (20.65 lb-ft)

    NOTE

    The tightening torque is also marked on the terminal block.

  12. 12.
    Inspect the tightness of the charging voltage measurement fuse block. Tighten each screw terminal to the correct torque as necessary. 1 x 0.75-25 mm2 to 2.0-2.5 Nm and 2 x 0.75-10 mm2: 2.0-2.5 Nm

    NOTE

    The tightening torque is also marked on the terminal block.

  13. 13.
    Close the front panel of the unit.
  14. 14.
    Install the three security T30 screws to each frame.

    NOTE

    In older models, the size of the front panel's screws is H3.

  15. 15.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  16. 16.
    Make sure that no cables push against the LED panel on the front panel of the unit.
  17. 17.
    Connect the AC power supply to the unit from the main supply point.
  18. 18.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  19. 19.
    Lock the door of the unit.

Replace the Liquid Cooled Charging Post Terminal Block

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws from each frame.
  6. 6.
    Open the front panel of the unit.
  7. 7.

    DANGER

    Electrical Shock

    High electrical voltage can cause serious injury or death.

    1. Measure the power terminals to make sure that no voltage remains before you continue.

    Disconnect the DC power cables from the terminal block.

    NOTE

    The size of the cable fixing screws is H6.

    NOTE

    Before you disconnect wires, cables, or connectors, take a photograph of them.

  8. 8.
    Replace the clip-type terminal block.
  9. 9.
    Connect the cables again.
  10. 10.
    Tighten each screw terminal to the correct torque.

    NOTE

    The tightening torque is marked on the terminal block.

  11. 11.
    Disconnect the control signal cable wires from the spring terminal block.

    NOTE

    Before you disconnect wires, cables, or connectors, take a photograph of them.

  12. 12.
    Replace the clip-type terminal block.
  13. 13.
    Connect the control signal cable wires again.
  14. 14.
    Close the front panel of the unit. Install the three security T30 screws.

    NOTE

    In older models, the size of the front panel screws is H3.

  15. 15.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  16. 16.
    Make sure that no cables push against the LED panel on the front panel of the unit.
  17. 17.
    Connect the AC power supply to the unit from the main supply point.
  18. 18.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  19. 19.
    Lock the door of the unit.

Replace the Liquid Charging Post Charging Cable

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

NOTICE

Danger to Environment

The coolant is harmful to the environment.

  1. Do not spill the coolant.

  2. Dispose of the coolant according to local laws and regulations.

NOTE

Do not remove the packaging of the machine connector before installation. It protects the machine connector from damages.

NOTE

For tasks related to the machine connector, read the machine connector manufacturer instructions.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws from each frame.
  6. 6.
    Open the front panel of both frames.
  7. 7.

    WARNING

    Hot Surface

    If used recently, the coolant can be hot and cause burns or serious injury.

    1. Do a temperature test by touching the side of the expansion tank before releasing the pressure.

    2. If necessary, use a thermometer to measure the temperature of the coolant after opening the cap.

    Carefully open the expansion tank cap to release the pressure. Listen for the click sound from the cap.
  8. 8.
    Fully open the cap after releasing the pressure.
  9. 9.
    Position a drain pan large enough to collect the coolant (total volume: 2.5 L) under the drain bolt on the radiator side.
  10. 10.
    Open the drain bolt to empty the coolant.
  11. 11.
    Position the drain pan under the coolant hose connectors.
  12. 12.
    Open the connectors to empty the coolant.

    NOTE

    You can also use clean and dry compressed air from the radiator side to empty the charging cable side.

    NOTE

    If necessary, disconnect the cooling blocks from the terminals for access to the connectors.

  13. 13.
    Remove the cable ties from the charging cable temperature sensors.
  14. 14.
    Mark the sensors with red and black electrical tape make it easier to identify them later.
  15. 15.

    WARNING

    Risk of Electric Shock

    High voltage electricity can cause severe damage or death.

    1. Make sure that the power supply is disconnected when energy isolation is necessary.

    2. Measure the terminals to make sure that no voltage remains before you continue.

    Disconnect the charging cable wires from the cooling blocks.

    NOTE

    Before you disconnect wires, cables, or connectors, take a photograph of them.

  16. 16.
    Disconnect the charging cable control wires from the green control connector.
  17. 17.
    Loosen the cable bushing below the spring holder.

    NOTE

    The size of the cable bushing is 68 mm.

  18. 18.
    Pull the charging cable out of the rubber grommet.
  19. 19.
    Remove the cable bushing and hose clamp and set them aside to be installed to the new charging cable.
  20. 20.
    Lift the support spring and charging cable out of the spring holder.
  21. 21.
    Remove the cable clamp from the end of the support spring with the ratchet and 15-mm socket.
  22. 22.
    Pull the charging cable out of the support spring.

    NOTE

    The size of the cable clamp's nuts is M10.

  23. 23.
    Install new charging cable:
    1. Tape the wire ends of the charging cable to avoid fraying.
    2. Tape the cable bundle together to make pulling the cable through the spring easier.
    3. Pull the charging cable through its support spring until approximately 400–600 mm (1) of the charging cable remains outside of the support spring.

      NOTE

      If necessary, use the draw tape and lubricant to pull the cable.

      NOTE

      To make the handling of the charging cable and support spring easier during installation, you can temporarily lock the charging cable inside its support spring. The size of the cable clamp's nuts is M10.

    4. Lift the support spring with the charging cable into the spring holder.
    5. First install the cable bushing and then the hose clamp on the charging cable.
    6. Route the charging cable inside the unit through the rubber grommet.
    7. Make sure that the part of the charging cable inside the unit has, approximately 50 mm of insulation and approximately 350–550 mm of stripped wire.
    8. Make sure that the wires reach the terminals.
    9. Tighten the cable bushing of the charging cable below the spring holder.

      NOTE

      Depending on the charging cable, the size of the cable bushing is 68 mm.

    10. Connect the coolant pipes.
    11. Connect the wires to the terminals. Tighten the cooling block terminals to 26 Nm.
    12. Use cable ties to connect the temperature sensors to the charging cables.
    13. Make sure that the sensors are positioned 25–40 mm from the cooling blocks.

      NOTE

      Use the electrical tape marking you made earlier as references for connecting the sensors.

    14. Lock the charging cable into place.
  24. 24.
    Close the front panel of the unit. Install the three security T30 screws.

    NOTE

    In older models, the size of the front panel screws is H3.

  25. 25.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  26. 26.
    Connect the AC power supply to the unit from the main supply point.
  27. 27.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  28. 28.
    Lock the door of the unit.

Replace Charging Cable Temperature Sensor

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws from each frame.
  6. 6.
    Open the front panel of both frames.
  7. 7.
    Remove the cable ties from the charging cable temperature sensors.
  8. 8.
    Disconnect the temperature sensors from the terminal block.

    NOTE

    T1 is for the positive and T2 is for the negative side of the charging cable.

  9. 9.
    Route the replacement temperature sensors along the back panel of the frame with the user interface.

    NOTE

    Make sure to mark the sensors if installing both sensors simultaneously.

  10. 10.
    Connect the sensor wires to the terminal block. White for negative wire and brown for positive wire.

    NOTE

    T1 is for the positive and T2 is for the negative side of the charging cable.

  11. 11.
    Secure the sensors to the charging cables using cable ties. Position the sensors 25–40 mm from the cooling blocks.
  12. 12.
    Close the front panel of the unit. Install the three security T30 screws.

    NOTE

    In older models, the size of the front panel screws is H3.

  13. 13.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  14. 14.
    Connect the AC power supply to the unit from the main supply point.
  15. 15.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  16. 16.
    Lock the door of the unit.

Inspect the Condition of the Coolant

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

NOTICE

Danger to Environment

The coolant is harmful to the environment.

  1. Do not spill the coolant.

  2. Dispose of the coolant according to local laws and regulations.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws from each frame.
  6. 6.
    Open the front panel of both frames.
  7. 7.

    WARNING

    Hot Surface

    If used recently, the coolant can be hot and cause burns or serious injury.

    1. Do a temperature test by touching the side of the expansion tank before releasing the pressure.

    2. If necessary, use a thermometer to measure the temperature of the coolant after opening the cap.

    Carefully open the expansion tank cap to release the pressure. Listen for the click sound from the cap.
  8. 8.
    Fully open the cap after releasing the pressure.
  9. 9.
    Use an coolant tester to examine the condition of the coolant. Make sure that the freezing point is a minimum of -36 °C.
  10. 10.
    Do a visual inspection of the coolant.
  11. 11.
    Make sure that there are no visible particles such as rust in the coolant and that there is no discoloration of the coolant. If necessary, replace the coolant.
  12. 12.
    Close the expansion tank cap.
  13. 13.
    Close the front panel of the unit. Install the three security T30 screws.
  14. 14.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  15. 15.
    Connect the AC power supply to the unit from the main supply point.
  16. 16.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  17. 17.
    Lock the door of the unit.

Replace the Coolant

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

NOTICE

Danger to Environment

The coolant is harmful to the environment.

  1. Do not spill the coolant.

  2. Dispose of the coolant according to local laws and regulations.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws from each frame.
  6. 6.
    Open the front panel of both frames.
  7. 7.

    WARNING

    Hot Surface

    If used recently, the coolant can be hot and cause burns or serious injury.

    1. Do a temperature test by touching the side of the expansion tank before releasing the pressure.

    2. If necessary, use a thermometer to measure the temperature of the coolant after opening the cap.

    Carefully open the expansion tank cap to release the pressure. Listen for the click sound from the cap.
  8. 8.
    Fully open the cap after releasing the pressure.
  9. 9.
    Position a drain pan large enough to collect the coolant (total volume: 2.5 L) under the drain bolt on the radiator side.
  10. 10.
    Open the drain bolt to empty the coolant.
  11. 11.
    Position the drain pan under the coolant hose connectors.
  12. 12.
    Open the connectors to empty the coolant.

    NOTE

    You can also use clean and dry compressed air from the radiator side to empty the charging cable side.

    NOTE

    If necessary, disconnect the cooling blocks from the terminals for access to the connectors.

  13. 13.
    Connect all the hose connectors and tighten the drain bolt.

    NOTE

    If you disconnected the cooling blocks from the terminals, connect them again. Tighten to the correct torque.

  14. 14.
    Use a funnel to fill the expansion tank to 1/2 full with the replacement coolant.

    NOTE

    For non-transparent expansion tanks, use a dip stick to measure the level of the coolant.

  15. 15.
    Operate the pump to bleed the air out of the system.
  16. 16.
    Make sure that there are no leaks in the system.
  17. 17.
    Use a funnel to fill the expansion tank to 1/3 full.

    NOTE

    For non-transparent expansion tanks, use a dip stick to measure the level of the coolant.

  18. 18.
    Do a visual inspection. Make sure that there are no coolant leaks and every connector has been installed again and tightened correctly
  19. 19.
    Close the front panel of the unit. Install the three security T30 screws.
  20. 20.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  21. 21.
    Connect the AC power supply to the unit from the main supply point.
  22. 22.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  23. 23.
    Lock the door of the unit.

Replace the Coolant Pump

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

NOTICE

Danger to Environment

The coolant is harmful to the environment.

  1. Do not spill the coolant.

  2. Dispose of the coolant according to local laws and regulations.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws from each frame.
  6. 6.
    Open the front panel of both frames.
  7. 7.

    WARNING

    Hot Surface

    If used recently, the coolant can be hot and cause burns or serious injury.

    1. Do a temperature test by touching the side of the expansion tank before releasing the pressure.

    2. If necessary, use a thermometer to measure the temperature of the coolant after opening the cap.

    Carefully open the expansion tank cap to release the pressure. Listen for the click sound from the cap.
  8. 8.
    Fully open the cap after releasing the pressure.
  9. 9.
    Position a drain pan large enough to collect the coolant (total volume: 2.5 L) under the drain bolt on the radiator side.
  10. 10.
    Open the drain bolt to empty the coolant.
  11. 11.
    Position a drain pan under the disconnected pipes to catch any catch any left over coolant.
  12. 12.
    Disconnect the coolant hoses from the pump assembly.
  13. 13.
    Disconnect the electrical connectors from the pressure switch.
  14. 14.
    Remove the four T25 screws to remove the pump.
  15. 15.
    Install the replacement pump. Tighten the four T25 screws.
  16. 16.
    Connect the pressure switch connectors again.
  17. 17.
    Connect the coolant hoses again.
  18. 18.
    Use a funnel to fill the expansion tank to 1/2 full with the replacement coolant.

    NOTE

    For non-transparent expansion tanks, use a dip stick to measure the level of the coolant.

  19. 19.
    Operate the pump to bleed the air out of the system.
  20. 20.
    Make sure that there are no leaks in the system.
  21. 21.
    Use a funnel to fill the expansion tank to 1/3 full.

    NOTE

    For non-transparent expansion tanks, use a dip stick to measure the level of the coolant.

  22. 22.
    Close the front panel of the unit. Install the three security T30 screws.
  23. 23.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  24. 24.
    Connect the AC power supply to the unit from the main supply point.
  25. 25.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  26. 26.
    Lock the door of the unit.

Replace the Expansion Tank

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

NOTICE

Danger to Environment

The coolant is harmful to the environment.

  1. Do not spill the coolant.

  2. Dispose of the coolant according to local laws and regulations.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws from each frame.
  6. 6.
    Open the front panel of both frames.
  7. 7.
    Position a drain pan large enough to collect the coolant (total volume: 2.5 L) under the drain bolt on the radiator side.
  8. 8.
    Open the drain bolt to empty the coolant.
  9. 9.
    Remove the float switch. Use a 27 mm open-ended wrench.
  10. 10.
    Disconnect the coolant pipe from the bottom of the tank. Use a 22 mm open ended wrench.
  11. 11.
    Disconnect the overflow pipe. Use needle nose pliers.
  12. 12.
    Hold the expansion tank in place as you loosen the four screws holding it in place.
  13. 13.
    Slide the tank up along the rails to remove it.
  14. 14.
    Remove the four screws and the brackets from the expansion tank.
  15. 15.
    Install the brackets and the four screws to the replacement expansion tank.
  16. 16.
    Slide the replacement expansion tank into place. Use the radiator pipe for reference
  17. 17.
    Tighten the four screws to hold it in place.
  18. 18.
    Connect the coolant pipe to the bottom of the tank again.
  19. 19.
    Connect the overflow pipe again.
  20. 20.
    Install the float switch. Use a 27 mm open-ended wrench.
  21. 21.
    Use a funnel to fill the expansion tank to 1/2 full with the replacement coolant.

    NOTE

    For non-transparent expansion tanks, use a dip stick to measure the level of the coolant.

  22. 22.
    Operate the pump to bleed the air out of the system.
  23. 23.
    Make sure that there are no leaks in the system.
  24. 24.
    Use a funnel to fill the expansion tank to 1/3 full.

    NOTE

    For non-transparent expansion tanks, use a dip stick to measure the level of the coolant.

  25. 25.
    Close the front panel of the unit. Install the three security T30 screws.
  26. 26.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  27. 27.
    Connect the AC power supply to the unit from the main supply point.
  28. 28.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  29. 29.
    Lock the door of the unit.

Replace the Float Switch

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

NOTICE

Danger to Environment

The coolant is harmful to the environment.

  1. Do not spill the coolant.

  2. Dispose of the coolant according to local laws and regulations.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws from each frame.
  6. 6.
    Open the front panel of both frames.
  7. 7.

    WARNING

    Hot Surface

    If used recently, the coolant can be hot and cause burns or serious injury.

    1. Do a temperature test by touching the side of the expansion tank before releasing the pressure.

    2. If necessary, use a thermometer to measure the temperature of the coolant after opening the cap.

    Carefully open the expansion tank cap to release the pressure. Listen for the click sound from the cap.
  8. 8.
    Fully open the cap after releasing the pressure.
  9. 9.
    Disconnect the float switch from the terminal block. White wire: SEN-B, Brown wire: XCON.

    NOTE

    Before you detach wires, cables, or connectors, take a photograph of them.

  10. 10.
    Remove the float switch. Use a 27 mm open-ended wrench.
  11. 11.
    Install the replacement float switch. Use a 27 mm open-end wrench to tighten it into place.
  12. 12.
    Connect the float switch to the terminal block. White wire: SEN-B, Brown wire: XCON.
  13. 13.
    Close the front panel of the unit. Install the three security T30 screws.
  14. 14.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  15. 15.
    Connect the AC power supply to the unit from the main supply point.
  16. 16.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  17. 17.
    Lock the door of the unit.

Replace the Air Filter Elements

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

NOTE

Contact Epiroc for air filter replacement.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws from each frame.
  6. 6.
    Open the front panel of both frames.
  7. 7.
    Remove the two T20 screws from the filter holder. Slide the filter holder along the rails the remove it.
  8. 8.
    Repeat for all four filter holders.
  9. 9.
    Remove the filter elements from the filter holder.
  10. 10.
    Push the replacement filter elements into the filter holder.
  11. 11.
    Fully open the cap after releasing the pressure.
  12. 12.
    Install the filter holder again. Tighten the two T20 screws for each filter holder.
  13. 13.
    Close the front panel of the unit. Install the three security T30 screws.
  14. 14.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  15. 15.
    Connect the AC power supply to the unit from the main supply point.
  16. 16.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  17. 17.
    Lock the door of the unit.

Replace the Rubber Duct

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

NOTICE

Danger to Environment

The coolant is harmful to the environment.

  1. Do not spill the coolant.

  2. Dispose of the coolant according to local laws and regulations.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws from each frame.
  6. 6.
    Open the front panel of both frames.
  7. 7.

    WARNING

    Hot Surface

    If used recently, the coolant can be hot and cause burns or serious injury.

    1. Do a temperature test by touching the side of the expansion tank before releasing the pressure.

    2. If necessary, use a thermometer to measure the temperature of the coolant after opening the cap.

    Carefully open the expansion tank cap to release the pressure. Listen for the click sound from the cap.
  8. 8.
    Fully open the cap after releasing the pressure.
  9. 9.
    Position a drain pan large enough to collect the coolant (total volume: 2.5 L) under the drain bolt on the radiator side.
  10. 10.
    Open the drain bolt to empty the coolant.
  11. 11.
    Position the drain pan under the coolant hose connectors.
  12. 12.
    Open the connectors to empty the coolant.

    NOTE

    You can also use clean and dry compressed air from the radiator side to empty the charging cable side.

    NOTE

    If necessary, disconnect the cooling blocks from the terminals for access to the connectors.

  13. 13.
    Disconnect the coolant pipes that go through the duct on the cooling unit side.

    NOTE

    Before you detach wires, cables, or connectors, take a photograph of them

  14. 14.
    Disconnect the four wires. Green: FAN-B, Yellow: PUM-B, Grey: SEN-B, Black: XCON.

    NOTE

    Before you detach wires, cables, or connectors, take a photograph of them.

  15. 15.
    Pull the pipes and the wires through the passage.
  16. 16.
    Remove the eight T30 screws to remove the rubber duct.
  17. 17.
    Install the replacement rubber duct. Use the eight T30 screws to secure it.
  18. 18.
    Route the two hoses and four wires to the radiator's side of the unit.
  19. 19.
    Connect the electrical wires. Green: FAN-B, Yellow: PUM-B, Grey: SEN-B, Black: XCON.
  20. 20.
    Connect the coolant pipes.
  21. 21.
    Use a funnel to fill the expansion tank to 1/2 full with the replacement coolant.

    NOTE

    For non-transparent expansion tanks, use a dip stick to measure the level of the coolant.

  22. 22.
    Operate the pump to bleed the air out of the system.
  23. 23.
    Make sure that there are no leaks in the system.
  24. 24.
    Use a funnel to fill the expansion tank to 1/3 full.

    NOTE

    For non-transparent expansion tanks, use a dip stick to measure the level of the coolant.

  25. 25.
    Close the front panel of the unit. Install the three security T30 screws.
  26. 26.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  27. 27.
    Connect the AC power supply to the unit from the main supply point.
  28. 28.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  29. 29.
    Lock the door of the unit.

Replace the Radiator Fan

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws from each frame.
  6. 6.
    Open the front panel of both frames.
  7. 7.
    Remove the four H3 fixing screws and the electrical connector of the radiator fan. Remove the fan.
  8. 8.
    Install the replacement radiator fan.
  9. 9.
    Make sure that the orientation is correct, with the arrow pointing towards the radiator.
  10. 10.
    Make sure that the electrical connector is connected.
  11. 11.
    Make sure that the four fixing screws are tightened.
  12. 12.
    Close the front panel of the unit. Install the three security T30 screws.
  13. 13.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  14. 14.
    Connect the AC power supply to the unit from the main supply point.
  15. 15.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  16. 16.
    Lock the door of the unit.

Replace the Radiator

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

NOTICE

Danger to Environment

The coolant is harmful to the environment.

  1. Do not spill the coolant.

  2. Dispose of the coolant according to local laws and regulations.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Remove the three security T30 screws from each frame.
  6. 6.
    Open the front panel of both frames.
  7. 7.

    WARNING

    Hot Surface

    If used recently, the coolant can be hot and cause burns or serious injury.

    1. Do a temperature test by touching the side of the expansion tank before releasing the pressure.

    2. If necessary, use a thermometer to measure the temperature of the coolant after opening the cap.

    Carefully open the expansion tank cap to release the pressure. Listen for the click sound from the cap.
  8. 8.
    Fully open the cap after releasing the pressure.
  9. 9.
    Position a drain pan large enough to collect the coolant (total volume: 2.5 L) under the drain bolt on the radiator side.
  10. 10.
    Open the drain bolt to empty the coolant.
  11. 11.
    Position the drain pan under the coolant hose connectors.
  12. 12.
    Open the connectors to empty the coolant.

    NOTE

    You can also use clean and dry compressed air from the radiator side to empty the charging cable side

  13. 13.
    Disconnect the coolant hoses from the radiator.
  14. 14.
    Open the hose connectors on top of the drain pan as the hoses might still contain a small amount of coolant.
  15. 15.
    Cut the cable ties that hold the overflow pipe to the fans.
  16. 16.
    Remove the four H3 fixing screws and one electrical connector for each of the three fans. Remove all of the radiator fans.
  17. 17.
    Hold the radiator in place as you loosen the four screws holding it in place. Do not completely remove the screws.
  18. 18.
    Slide the radiator down to the end of the inside rail and tilt the top brackets out of the rails.
  19. 19.
    Slide the radiator down to the end of the inside rail and tilt the top brackets out of the rails.
  20. 20.
    Remove the four screws and brackets from the old radiator.
  21. 21.
    Install the brackets using the four screws to the replacement radiator.
  22. 22.
    Slide the radiator brackets into the rails from the widening and tighten the screws. Position the radiator so that the tank's coolant pipe reaches the radiator.
  23. 23.
    Install the radiator fans.
  24. 24.
    Make sure that the orientation is correct, with the arrow pointing towards the radiator.
  25. 25.
    Make sure that the electrical connector is connected.
  26. 26.
    Make sure that the four fixing screws are tightened.
  27. 27.
    Connect the coolant hoses. Use cable ties to fix the overflow pipe to the fan bolts.
  28. 28.
    Use a funnel to fill the expansion tank to 1/2 full with the replacement coolant.

    NOTE

    For non-transparent expansion tanks, use a dip stick to measure the level of the coolant.

  29. 29.
    Operate the pump to bleed the air out of the system.
  30. 30.
    Make sure that there are no leaks in the system.
  31. 31.
    Use a funnel to fill the expansion tank to 1/3 full.

    NOTE

    For non-transparent expansion tanks, use a dip stick to measure the level of the coolant.

  32. 32.
    Close the front panel of the unit. Install the three security T30 screws.
  33. 33.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  34. 34.
    Connect the AC power supply to the unit from the main supply point.
  35. 35.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  36. 36.
    Lock the door of the unit.

Wall Charger Post with CCS Cable

Inspect the Tightening Torques of Terminal Blocks

WARNING

Loose Cable

Loose cable terminal connections can cause fire, severe injury, or death.

  1. Make sure are all the cable terminal connections are tightened properly.

If the spring terminals are loose, replace them. Only screw terminals can be tightened.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Unlock and open the front panel.
  6. 6.

    DANGER

    Electrical Shock

    High electrical voltage can cause serious injury or death.

    1. Measure the power terminals to make sure that no voltage remains before you continue.

    Use the torque wrench to inspect the tightening torques of the DC power terminal blocks.

    NOTE

    The size of the cable fixing screws is H6.

  7. 7.
    Tighten each screw terminal to the correct torque. 95 mm2: 22 Nm, 150 mm2: 30 Nm.

    NOTE

    The tightening torque is marked on the terminal block.

  8. 8.
    Inspect the tightness of the spring terminal blocks. If the connections are loose, replace the terminal block.
  9. 9.
    Close and lock the front panel of the unit.
  10. 10.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  11. 11.
    Make sure that no cables push against the LED panel on the front panel of the unit.
  12. 12.
    Connect the AC power supply to the unit from the main supply point.
  13. 13.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  14. 14.
    Lock the door of the unit.

Replace the Terminal Block

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Unlock and open the front panel.
  6. 6.

    DANGER

    Electrical Shock

    High electrical voltage can cause serious injury or death.

    1. Measure the power terminals to make sure that no voltage remains before you continue.

    Disconnect the DC power cables from the terminal block.

    NOTE

    The size of the cable fixing screws is H6.

    NOTE

    Before you disconnect wires, cables, or connectors, take a photograph of them.

  7. 7.
    Replace the clip-type terminal block.
  8. 8.
    Connect the cables again.
  9. 9.
    Tighten each screw terminal to the correct torque.

    NOTE

    The tightening torque is marked on the terminal block.

  10. 10.
    Disconnect the control signal cable wires from the spring terminal block.

    NOTE

    Before you disconnect wires, cables, or connectors, take a photograph of them.

  11. 11.
    Replace the clip-type terminal block.
  12. 12.
    Connect the control signal cable wires again.
  13. 13.
    Close and lock the front panel of the unit.
  14. 14.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  15. 15.
    Make sure that no cables push against the LED panel on the front panel of the unit.
  16. 16.
    Connect the AC power supply to the unit from the main supply point.
  17. 17.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  18. 18.
    Lock the door of the unit.

Replace the Charging Cable of Wall Charger Post

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Unlock and open the front panel.
  6. 6.

    WARNING

    Risk of Electric Shock

    High voltage electricity can cause severe damage or death.

    1. Make sure that the power supply is disconnected when energy isolation is necessary.

    2. Measure the terminals to make sure that no voltage remains before you continue.

    Disconnect the charging cable wires from the terminals.

    NOTE

    Before you disconnect wires, cables, or connectors, take a photograph of them.

  7. 7.
    Pull the charging cable out of the rubber grommet.
  8. 8.
    Route the new charging cable into the unit. Make sure that the wires reach the terminals.
  9. 9.
    Tighten the cable bushing.
  10. 10.
    Connect the wires to the terminals.
  11. 11.
    Tighten each screw terminal to the correct torque. 25-50 mm2: 14 Nm, 70-150 mm2: 30 Nm.
  12. 12.
    Close and lock the front panel.
  13. 13.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  14. 14.
    Make sure that no cables push against the LED panel on the front panel of the unit.
  15. 15.
    Connect the AC power supply to the unit from the main supply point.
  16. 16.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  17. 17.
    Lock the door of the unit.

Replace the DC Voltage Measurement Fuses

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Unlock and open the front panel.
  6. 6.

    WARNING

    Risk of Electric Shock

    High voltage electricity can cause severe damage or death.

    1. Make sure that the power supply is disconnected when energy isolation is necessary.

    2. Measure the terminals to make sure that no voltage remains before you continue.

    Disconnect the wires connected to the DC voltage measurement fuses.

    NOTE

    Before you disconnect wires, cables, or connectors, take a photograph of them.

  7. 7.
    Pull the lever to remove the fuse.
  8. 8.
    Install the replacement fuse.
  9. 9.
    Connect the wires to the replacement fuse.
  10. 10.
    Close and lock the front panel.
  11. 11.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  12. 12.
    Make sure that no cables push against the LED panel on the front panel of the unit.
  13. 13.
    Connect the AC power supply to the unit from the main supply point.
  14. 14.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  15. 15.
    Lock the door of the unit.

Replace the Control Board

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Unlock and open the front panel.
  6. 6.

    WARNING

    Risk of Electric Shock

    High voltage electricity can cause severe damage or death.

    1. Make sure that the power supply is disconnected when energy isolation is necessary.

    2. Measure the terminals to make sure that no voltage remains before you continue.

    Disconnect the wires connected to the DC voltage measurement fuses.

    NOTE

    Before you disconnect wires, cables, or connectors, take a photograph of them.

  7. 7.
    Remove the four fixing nuts of the control board with your hand. Remove the control board.

    NOTE

    The serial number card is attached to the cables with a zip tie. If you replace cables, make sure to attach the serial number card again.

  8. 8.
    Install the new control board. Attach the serial number card again.

    NOTE

    Make sure that all cables are correctly connected and locked.

  9. 9.
    Close and lock the front panel.
  10. 10.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  11. 11.
    Make sure that no cables push against the LED panel on the front panel of the unit.
  12. 12.
    Connect the AC power supply to the unit from the main supply point.
  13. 13.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  14. 14.
    Lock the door of the unit.

Adjust the Door Switch

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Unlock and open the front panel.
  6. 6.
    Loosen the two fixing screws.
  7. 7.
    Move the switch out as far as possible.
  8. 8.
    Tighten the two fixing screws.
  9. 9.
    Close and lock the front panel of the unit.
  10. 10.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  11. 11.
    Make sure that no cables push against the LED panel on the front panel of the unit.
  12. 12.
    Connect the AC power supply to the unit from the main supply point.
  13. 13.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  14. 14.
    Lock the door of the unit.

Replace the Door Switch

WARNING

Hot Surface

The internal surfaces can be hot during operation and can cause burns.

  1. Allow the charging power unit to cool before you remove the modules.

NOTICE

Damage to Battery Charger

Wet condition can cause damage to the battery charger.

  1. Weatherproof the working area before you open any doors, panels, or covers of the battery charger.

  1. 1.
    Unlock and open the door of the power unit (C).
  2. 2.
    Set the Miniature Circuit Break (MCB) (B) for control voltage to OFF position.
  3. 3.
    Set the main power switch to OFF position (A).
  4. 4.

    DANGER

    Risk of Electrocution

    Residual voltage from the capacitors can cause electrocution and series injury or death.

    1. After disconnecting the main power supply, wait at least 2 minutes for the capacitors of the power modules to discharge.

    Disconnect the AC power supply to the unit from the main power supply and complete the Lockout-Tagout (LOTO) procedure.
  5. 5.
    Unlock and open the front panel.
  6. 6.
    Remove the two fixing screws to remove the switch.
  7. 7.
    Install the replacement switch using the two fixing screws. Make sure to move the switch out as far as possible.
  8. 8.
    Install the two fixing screws.
  9. 9.
    Close and lock the front panel of the unit.
  10. 10.
    Make sure that no cables are caught between the front panel and the frame of the unit.
  11. 11.
    Make sure that no cables push against the LED panel on the front panel of the unit.
  12. 12.
    Connect the AC power supply to the unit from the main supply point.
  13. 13.
    Set the (MCB) for control voltage (B) and main power switch (A) to ON position
  14. 14.
    Lock the door of the unit.

Actions After Every Maintenance or Repair Task

Report the completed tasks to ChargEye.

When you replace parts under warranty, keep the faulty part until you have made sure that Epiroc does not need to inspect it.

  1. 1.
    Complete the Epiroc field visit report. Submit the completed document to Kempower ChargEye.
  2. 2.
    Do a visual inspection before you connect the main power supply and set the main switch of the charging power unit to ON position
    1. Mae sure that all cables are intact and cable connections are tight.
    2. Make sure that all parts, panels, and cables are correctly in place.
    3. Make sure that no cables are caught between the unit frame and the panels.
  3. 3.
    Connect the main power supply and set the main switch of the charging power unit to ON position. Make sure that the system operates correctly.
  4. 4.
    Make sure that the internet connection operates correctly.
  5. 5.
    Do all required electrical safety tests according to local laws, regulations and requirements

Do a Sensory Inspection

The electrical contractor does the sensory inspection. Its purpose is to verify that the installation obeys the local laws, regulations, and requirements. Make sure that:

  1. 1.
    Make sure that:
    1. Fire safety is inspected and approved.
    2. The voltage-carrying conductors are correctly touch-protected.
    3. The bending of cables does not exceed the minimum bending radius specified by the cable manufacturer.
    4. All components and cables are in place, correctly installed, and protected.
    5. All units are in operating condition and have no visible damages.
    6. All charging cables, vehicle connectors, and possible charging sockets are in operating condition and have no visible damages.
    7. All units are firmly secured to their installation surface.
    8. All labels on the units are clear and obey the electrical design documentation.
    9. If the configuration has an equipment stop button (option), it is in place and operates correctly.
    10. If the configuration requires an emergency stop circuit, it is in place and operates correctly.

Do an Electrical Installation and Safety Inspection

Make sure that the electrical safety tests have been done according to local laws and regulations.

you remove touch protection for the inspection, install it back again.

Note the name, number and revision of the electrical design documentation.

The electrical contractor does the electrical installation and safety inspection. Its purpose is to verify that the installation obeys the local laws, regulations, and requirements.

  1. 1.
    Inspect the following:

    Item to inspect

    Power unit

    Station charger

    Satellite

    Liquid cooled satellite

    Phase order of AC supply power cable connections correct

    Yes

    Yes

    Tightening torques of AC supply power cable connections correct

    Yes

    Yes

    DC output power cables correctly labeled at both ends

    Yes

    Yes

    Yes

    Tightening torques of DC output power cable connections correct

    Yes

    Yes

    Yes

    Yes

    Control cables correctly labeled at both ends

    Yes

    Yes

    Yes

    Yes

    Charging cable wires connected to correct terminals

    Yes

    Yes

    Cable bushings of charging cables correctly tightened

    Yes

    Yes

    Yes

    Ethernet cables tested with LAN tester

    Yes

    Yes

    Yes

    Yes

Example of Connecting Cables to the Satellites

Charging Post Version 1 with one CCS vehicle connector

NOTE

Ground the Ethernet shield at one end only, near the Ethernet switch of the charging power unit.

A

Configuration tag (right vehicle connector)

B

CT line signal wires

C

Charging cable

D

Vehicle connector signal wires

E

Voltage measurement wires

F

Communication cable

G

DC output power cables + PE

H

Control cable (CT line)

Charging Post Version 1 with Two CCS Vehicle Connector

NOTE

Ground the Ethernet shield at one end only, near the Ethernet switch of the charging power unit.

A

Configuration tag (left vehicle connector)

B

Configuration tag (right vehicle connector)

C

CT line signal wires

D

Vehicle connector signal wires (right)

E

Voltage measurement wires

F

Vehicle connector signal wires (left)

G

Charging cable (right)

H

Charging cable (left)

J

Communication cable

K

DC output power cables + PE (left)

L

DC output power cables + PE (right)

M

Control cable (CT line)

Charging Post Version 2 with One CCS Vehicle Connector

NOTE

Ground the Ethernet shield at one end only, near the Ethernet switch of the charging power unit.

A

Configuration tag (right vehicle connector)

B

CT A line signal wires (CT B not connected)

C

Vehicle connector signal wires

D

Charging cable

E

PE wire connected to installation flange with wire clamp

F

Communication cable

G

DC output power cables + PE

H

Control cable (CT line)

Charging Post 2 with Two CCS Vehicle Connectors

NOTE

Ground the Ethernet shield at one end only, near the Ethernet switch of the charging power unit.

A

Configuration tag (left vehicle connector)

B

Configuration tag (right vehicle connector)

C

Charging cable (left)

D

CT line signal wires

E

Charging cable (right)

F

Vehicle connector signal wire (left)

G

Vehicle connector signal wire (right)

H

Communication cable

J

DC output power cables (left)

K

DC output power cables + PE (right)

L

Control cable (CT line)

Control Unit 300 A with One CCS Vehicle Connector

NOTE

Ground the Ethernet shield at one end only, near the Ethernet switch of the charging power unit.

A

Cover opening limit switch

B

Vehicle connector signal wires

C

Voltage and insulation monitor (A019)

D

DC power charging cable (vehicle connector)

E

DC Voltage measurement fuses (1000 VDC)

F

DC- terminal (X2-)

G

DC+ terminal (X2+)

H

Charging cable Phoenix Connector

J

Communication cable

K

Equipment stop button cable

L

Control cable

M

DC power cable from cabinet

Control Signal Wires of the Charging Cable

The units have pre-installed wiring harnesses with mating connectors for the control signal wires of the charging cable.

CCS Charging Cable

Before you connect the signal wires to the mating connector, terminate the signal wires with ferrules to protect the wires from corrosion.

Connect the five control signal wires of the CCS charging cable to the mating connector:

  • X2 for the charging cable on the right hand side.

  • X3 for the charging cable on the left hand side.

Unit Wiring
Amphenol Charging Cable
Amphenol Charging Wires (Numbered Wires)
Brugg/Phoenix Charging Cable
Brugg/Phoenix Charging Cable (Numbered Wires)
REMA Charging Cable