Troubleshooting Checklist for Communication Charging Station Mainboard: CP/CC/PE/RCD/Temperature Rise/Measurement

The general principle for troubleshooting the motherboard of the communication charging station is to first cut off the power and gun, and then test each item one by one. Safety priority, signal priority, power and metering last. First observe the phenomenon for each item, then measure the key points, and finally replace the parts for verification.

1、 CP control guidance

• Phenomenon: Unable to start, reported vehicle not connected, suddenly stopped charging.

• Troubleshooting: Check if the CP voltage at the pile end jumps normally between 12V/9V/6V; Measure whether the PWM duty cycle corresponds to the rated current; Check if the CP line is short circuited to ground or power supply; Check if the vehicle is responding.

• Solution: Repair the wiring harness, replace the CP sampling circuit, and confirm that the duty cycle matches the rated power of the pile.

2、 CC connection confirmation

• Phenomenon: Unable to recognize gun, limited power, intermittent charging and interruption.

• Troubleshooting: Pull out the gun to measure the resistance of CC to PE, insert the gun and then measure again to see if the resistance changes according to the cable capacity; Check if the CC line is broken, has poor contact, or is damp.

• Solution: Replace the gun wire, repair the CC detection circuit, and ensure stable resistance after inserting the gun.

3、 PE protective grounding

• Phenomenon: RCD frequently trips, insulation alarm, and cannot be closed.

• Troubleshooting: Check whether the PE connection is continuous and whether the grounding resistance is qualified; Check if PE and N are mixed together; Check if the equipotential connection is in place.

• Solution: Reconnect to ensure that the PE is connected first and then disconnected, and prohibit PE from connecting switches or fuses in series.

4、 RCD residual current protection

• Phenomenon: Jumps upon closing, randomly jumps during charging, and must jump on rainy days.

• Troubleshooting: Distinguish between leakage inside the pile and leakage at the vehicle end; Test whether the leakage current is AC or DC; check the insulation of the cable, whether the charging port has water ingress, and the insulation of the vehicle.

• Solution: Disconnect and troubleshoot in sections, replace RCD, install DC 6mA protection if necessary, and repair insulation.

5、 Abnormal temperature rise

• Phenomenon: Power reduction, shutdown, terminal burning, smell of burning.

• Troubleshooting: Measure the temperature of relay/contactor contacts, measure the torque of terminal screws, check if the wire diameter is sufficient, check the fan and heat dissipation channel, and record the ambient temperature.

• Solution: Tighten the terminals, replace the ablated parts, improve heat dissipation, and if necessary, reduce the rated operation.

6、 Measurement abnormality

• Phenomenon: inaccurate billing, power fluctuations, and no data in the backend.

• Troubleshooting: Compare the meter reading with the pile display, check the CT/shunt wiring, check the voltage sampling, and check the communication of the metering chip.

• Solution: Calibrate the measurement, replace faulty meters or sampling devices, and repair communication.

Summary:

CP/CC looks at signals, PE/RCD looks at safety, temperature rise looks at power circuits, and measurement looks at sampling and communication. By following this sequence of troubleshooting, it is possible to quickly locate whether the problem is at the pile end, vehicle end, or grid side.

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