EXICOM POWER SOLUTIONS Harmony Series User manual

Preface
This document is valid for the Harmony series EV Charger only.
The images used in this document are for illustration and instruction purposes only. The images and
descriptions in this document refer to a representative device design. The devices used by the user may
differ in their appearance and design.
We recommend that the charging station is always kept updated with the latest version of the software (as
per the latest release by the manufacturer), as this will ensure functional enhancements and product
improvements from time to time.
Purpose of this Guide
The document describes the troubleshooting of Harmony series EV Charger.
*Note: This document includes the latest information available at the time of printing. Exicom Tele-
Systems Ltd. reserves the right to make changes to this manual or product without further notice.
Changes, modifications, or repairs to this product by parties other than an authorized service provider
could void the product warranty.
Introduction to charger
Harmony – Fast charger solution is Exicom’s most innovative design till date and a true representation of
interoperability. The system has three connectors - CCS, CHAdeMO & AC TYPE 2: 142kW (DC: 120kW + AC:
22kW).
All guns can be used in Parallel for charging. The charger is equipped with multiple components as shown
below:
INTRODUCTION
Troubleshooting Guide - Harmony series EV Charger

[1] Housing The Cover [2] Key Operated Lock
[3] LEDs [4] LCD Display
[5] RFID Reader [6] Emergency Switch
[7] Cable Gland [8] Charging Cable
[9] Charging Gun Plug [10] SMR’s Cover
[11] Ventilation [12] Charging Gun Dummy Socket

Harmony series EV Charger complies with IEC 61851
components. IEC 61851-
1 Safety Standard is an International safety standard and Exicom Tele
the first Indian company
to comply with the same.
For the safety of the user, all charging stations are equipped with a ground fault detector to reduce the risk
of electric shock. The user is never exposed to dangerous voltages or currents because the connector pins
are not energi
zed until the connector is inserted properly in the EV charging socket and communication
has been established between the vehicle and the charging station. Besides, the connector is sealed to
protect the live components from the weather.
Representation of
Safety Instructions
Meanings of the symbols used in this document:
Danger
Direct or indirect contact through moist objects with these components can result in
fatal injury.
Attention
Damage to property can occur if the corresponding safety measures are
ESD
Electrostatically Sensitive Components
Ground Protection
Ensure that the equipment is grounded before use
SAFETY MEASURES AND INSTRUCTIONS
Harmony series EV Charger complies with IEC 61851
-
1 Safety Standard and uses only certified
1 Safety Standard is an International safety standard and Exicom Tele
to comply with the same.
For the safety of the user, all charging stations are equipped with a ground fault detector to reduce the risk
of electric shock. The user is never exposed to dangerous voltages or currents because the connector pins
zed until the connector is inserted properly in the EV charging socket and communication
has been established between the vehicle and the charging station. Besides, the connector is sealed to
protect the live components from the weather.
Safety Instructions
Meanings of the symbols used in this document:
Direct or indirect contact through moist objects with these components can result in
Damage to property can occur if the corresponding safety measures are
Electrostatically Sensitive Components
– Do Not Touch
Ground Protection
Ensure that the equipment is grounded before use
.
SAFETY MEASURES AND INSTRUCTIONS
1 Safety Standard and uses only certified
1 Safety Standard is an International safety standard and Exicom Tele
-Systems is
For the safety of the user, all charging stations are equipped with a ground fault detector to reduce the risk
of electric shock. The user is never exposed to dangerous voltages or currents because the connector pins
zed until the connector is inserted properly in the EV charging socket and communication
has been established between the vehicle and the charging station. Besides, the connector is sealed to
Direct or indirect contact through moist objects with these components can result in
Damage to property can occur if the corresponding safety measures are
not followed.

Prohibited Areas
Any unauthorized personnel should not open the cover. It can lead to risk of bodily harm and will result in
losing warranty qualification.
Safety Precautions
 Make sure that the equipment is well-grounded to avoid electric shock before opening
the equipment.
 Do not add to, modify or alter any part of this product without consulting the back-end
team.
 Please make sure the input voltage, frequency and other conditions conform to
equipment requirements before the power on.
 To ensure a proper service life of the equipment and its stable operation, do not use the
equipment in an environment that contains volatile gas or is flammable.
Dos & Don’ts for charger troubleshooting
 Do not touch any live part in the system while troubleshooting when the system is ON.
 Do not make any changes in the system without consulting the backend team.
 Do not make any false commitment/give false explanations to the customer for any issue.
 Understand the problem scenario before troubleshooting the issue.
 Carry all required tools to site & spares for troubleshooting.
Required Tools
 Multimeter, Clamp meter.
 SD Card, U-Drive.
 USB-RS232 serial tool, USB-UART serial tool
 LAN Cable, IXXAT CAN Converter, LAPTOP.

The basic steps to approach the correct issue and resolve it are given below:
STEP 1 – Identify the issue
TROUBLESHOOTING APPROACH

STEP 2 – Check the issue
STEP 3 – Locate the issue

STEP 4 – Resolve the issue
Software:
 Update Software
 Use the latest Software
Faulty Parts:
 Replace the faulty item
 Use the correct MPN part
Other Faults:
 Correct wiring,if loose
 Take action as per the fault detail.

During charging, the vehicle requests for voltage & current and the charger delivers the same by
limiting the current as per requested current. However, charging may be stopped/interrupted by
various reasons. Charging can be stopped by the charger, the vehicle or by any other means. Charger
generates stop reason based on the nature of the cause of why the charging stops. The commonly
occurring stop reasons along with their explanations and resolutions are given below:
Charging Stopped/Interrupted by Charger
Parameter configuration failed
Error Code 201
Error Name Param config failed
Error Cause Related to charger PLC parameters configuration
Error Solution 1. Retry Charging.
2. If generated frequently take PLC serial and CAN log of the
respective gun and share for analysis.
Charging Enable timeout
Error Code 202
Error Name Charging enable timeout
Error Cause Start charging command is not received from the vehicle.
Error Solution 1. Retry Charging.
2. If generated frequently, please inform the vehicle
manufacturer regarding this.
3. If the issue persists, take PLC serial and CAN log of the
respective gun and share for analysis.
CHARGING STOP REASON TROUBLESHOOTING

Abnormal volt of outside bus
Error Code 203
Error Name Abnormal volt outside bus
Error Cause The pilot controller voltage measurement has deviation.
Error Solution 1. Check wires of 10-J30 connectors for the respective gun.
2. Check if rectifiers are building the voltage.
3. Please check if the backup battery voltage is within
range(330V-438V DC)
4. Check if DC contactors of the respective guns are working OK.
5. Re-calibrate the settings.
6. Take PLC serial and CAN log of the respective gun and share
for analysis.
Unable lock charging gun
Error Code 204
Error Name Unable lock gun
Error Cause Unable to lock the GUN.
Error Solution 1. Check the 12VDC output of Aux. the power supply.
2. Check if the pilot controller is sending a 12VDC signal to GUN.
3. Check if lock feedback sense wiring is OK.

Insulation inspection abnormally
Error Code 205
Error Name Insulation inspect abnormally
Error Cause Insulation test failed during charging initialization
Error Solution 1. Check if rectifiers are building the voltage.
2. Please check if the backup battery voltage is within
range(330V-438V DC)
3. Measure voltage at output.
4. Check voltage on the insulation board.
5. Change the vehicle and test again.
6. Take PLC serial and CAN log of the respective gun and
share for analysis.
Insulation inspection timeout
Error Code 206
Error Name Insulation inspect timeout
Error Cause Insulation test function timed out during charging initialization
Error Solution 1. Check if rectifiers are building the voltage.
2. Please check if the backup battery voltage is within
range(330V-438V DC)
3. Change the vehicle and test again.
4. Take PLC serial and CAN log of the respective gun and
share for analysis.