Volkswagen Flexible fast charging station Operating and maintenance instructions

Flexible fast charging station
Maintenance instructions
Edition 06.2023
Service 3
Service Department. Technical Information

Maintenance instructions
Edition 06.2023
The following information regarding repairs and the use of the documentation must be observed:
Model-related information does not necessarily reflect current charging status data. Repair work
may only be carried out on the charging station by specialist personnel who have been trained in
advance. The safety and repair workshop manuals must be observed for every repair. The work-
shop manuals are interdependent; completeness is only guaranteed in the overall context. Links to
other workshop manuals must be followed. The listed and approved special tools must be used for
every repair.
3Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2023 Volkswagen AG, Wolfsburg Printed in Germany

Contents
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Safety instructions, regulations and installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.2 Qualification of maintenance staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Protective clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.4 Handling critical high-voltage batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.5 Safety measures when working on charging stations that use high-voltage systems . . . . . . 6
3.6 Safety precautions when working in the vicinity of high-voltage components . . . . . . . . . . . . . . . 7
3.7 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.8 Safety precautions when working on air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.9 Safety precautions when using air conditioner service stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.10 Safety precautions when working with chemical substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.11 The five safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Legal texts and regulations, air conditioning systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Provisions and directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Charging refrigerant circuit with different refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Occupational health and safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Storage of the mobile charging station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 General safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Storing the mobile charging station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.3 Checking, storing and charging the mobile charging station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Maintenance concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1 Maintenance concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7 Maintenance tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.2 Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.3 Periodic servicing work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.3.1 Recurring checks to be carried out once a year, based on DIN VDE 0105-100 (2015:10) . 17
7.3.2 Measurement tests, carried out once a year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.4 Environment-specific servicing work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.5 Event-related servicing work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.5.1 Initial commissioning, based on DIN VDE 0100-600 (2017:06) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
00 -
Maintenance instructions 06.2023 3
Contents

7.5.2 Change of location without fixed connection, in accordance with DIN VDE 0100-600
(2017:06) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.5.3 Change of location with fixed connection, in accordance with DIN VDE 0100-600
(2017:06) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.6 Maintenance table for measuring equipment compliant with calibration law . . . . . . . . . . . . . . . . 27
7.7 Review of electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.1 Entries in the maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.2 Harsh operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.3 Hot countries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.4 Dusty countries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9 Work descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.1 Opening the doors for servicing work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.2 Switching on the mobile charging station after maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.3 Cleaning and maintaining the flexible charging station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.3.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.3.2 Cleaning the air intakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.4 Checking the water sensor, SJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.4.1 Assembly overview for the water sensor, SJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.4.2 Checking the mounting of the water sensor, SJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.5 Checking the 12-V backup battery, BAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.6 High-voltage components and high-voltage cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.7 Visual inspection for corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.8 Checking the coolant level and renewing coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.8.1 Checking the coolant level and topping it up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.8.2 Renewing the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9.9 Checking the filling quantities for refrigerant R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9.10 Renewing the advertising screen fan filter, AD-HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.11 Checking threaded connections for foundation/charging station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.12 Visual inspection for leaks and damage on the interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.13 Visual inspection for damage and contamination on the exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.14 Checking warning stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9.15 Query of the energy level of AC measuring equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.15.1 Query of energy quantity of the AC measuring device, models without remote emergen-
cy stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.15.2 Query of energy quantity of the AC measuring device, models with remote emergency
stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.16 Calling up the log for all systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
9.17 Status query for backend connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
9.18 Checking devices in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3
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9.18.1 Checking devices in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
9.18.2 Special testing equipment or testing software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.18.3 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.18.4 Visual inspection of adhesive seal, calibration-law-compliant measuring device . . . . . . . . . . . 83
9.19 Querying plug cycle counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
10 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10.1 Technical data of the mobile charging station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10.2 Displays and controls, electricity meters for delivered energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
10.3 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.4 Filling quantities for refrigerant R1234yf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
11 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
11.1 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
12 Legal information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
12.1 Legal information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
13 The CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
13.1 The CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Maintenance instructions 06.2023 3
Contents

3
Maintenance instructions 06.2023
Contents

00 - Technical data
1 Revision history
V1.3_20230718_EN_GB
1.1 Revision history
Issue/date Changes/amendments
First edition October 2021 added ⇒ “Query of energy quantity of the AC meas-
uring device, models without remote emergency
stop function” on page 77
May 2022 added ⇒ “Checking devices in operation” on
page 80
May 2022 added ⇒ “Special testing equipment or testing soft-
ware” on page 82
May 2022 added ⇒ “Identification” on page 83
May 2022 added ⇒ “Visual inspection of adhesive seal, cali-
bration-law-compliant measuring device” on
page 83
July 2022 added ⇒ “Query of energy quantity of the AC meas-
uring device, models with remote emergency stop
function” on page 78
October 2022 revised ⇒ “Storing the mobile charging station” on
page 14
February 2023 revised ⇒ “Checking, storing and charging the mo-
bile charging station” on page 15
February 2023 Adaptation of master list terms/template structure
February 2023 revised ⇒ “Opening the doors for servicing work” on
page 53
February 2023 added ⇒ “Switching on the mobile charging station
after maintenance work” on page 56
April 2023 Maintenance table, recurring checks of electrical de-
vices in accordance with DIN VDE 0702 removed
April 2023 revised ⇒ “Cleaning” on page 57
April 2023 revised ⇒ “Filling quantities for refrigerant R1234yf”
on page 89
April 2023 revised ⇒ “Checking the 12-V backup battery, BAT”
on page 59
April 2023 revised ⇒ “Renewing the coolant” on page 64
April 2023 added ⇒ “Checking the filling quantities for refriger-
ant R1234yf” on page 70
April 2023 added ⇒ “Renewing the advertising screen fan filter,
AD-HMI” on page 71
April 2023 added ⇒ “Querying plug cycle counter” on page 85
Maintenance instructions 06.2023 3
1 Revision history 1

2 Preface
2.1 Preface
This document is intended for trained technicians and con-
tains information on maintaining the mobile charging sta-
tion.
This documentation about the mobile charging station is based
around the product’s life cycle.
The individual life cycles are described in a range of additional
documents. The Workshop Manual comprises the individual
documents listed:
◆Initial setup
◆Diagnostic Manual
◆Owner’s Manual
◆Workshop Manual
◆Maintenance instructions
Only genuine replacement parts are to be used. Operation
with incorrect, faulty or non-approved parts is expressly
prohibited. Such usage renders the CE declaration and ap-
proval of the mobile charging station null and void.
Using incorrectly installed or non-approved parts poses a
risk to life and health.
Condition
● You must observe the information and safety instructions
provided.
The distributor is responsible for providing further information
on any peripheral equipment for the mobile charging station that
is not included in the supplied equipment.
3 Safety instructions, regulations
and installation guidelines
3.1 Target group
The document is aimed at trained, instructed personnel who are
responsible for maintenance and operation of the flexible charg-
ing station ⇒ “Qualification of maintenance staff” on page 3.
All technical specifications remain valid at all times, and are not
affected by these additional instructions.
Issues that do not relate directly to maintenance can be found
in the other documentation for the respective application case.
Operation of electrical systems requires comprehensive
preparation and compliance with legal requirements and
regulations. Safe operation is only possible and permitted
if these requirements and rules have also been complied
with. Compliance with the technical requirements must be
3
Maintenance instructions 06.2023
2Repair Group 00 - Technical data

checked. The operator or the instructed personnel are re-
sponsible for secure operation of the flexible charging sta-
tion.
When work is carried out on the flexible quick charging sta-
tion within the network operator’s area of authority, the re-
quirements of DIN VDE 0105-100 (EN 50110-1) “Operation
of electrical installations” shall apply.
The country-specific regulations, safety instructions and
installation specifications apply.
3.2 Qualification of maintenance staff
Condition
● Only trained specialists in accordance with IEC 60050 may
perform work inside the charging station while the door is
open.
● Repair and servicing work on the quick-charging station re-
frigerant circuit may only be carried out by persons who can
verify their relevant expertise in accordance with Regulation
(EC) No. 307/2008 (applies to countries in which this regula-
tion applies, different regulations or laws may apply in other
countries).
● The safety instructions, regulations and installation specifica-
tions must be observed.
Maintenance of the mobile charging station must be per-
formed by personnel who have previously been trained and
instructed in the tasks of servicing work. Faulty or improp-
er maintenance may result in danger to the life and limb of
third parties and is therefore strictly prohibited!
3.3 Protective clothing
The protective clothing required in accordance with DGUV 3
specifications must be worn at all times when working on the
flexible charging station.
The appropriate protective equipment such as helmet, gloves
and safety shoes as set out in EN ISO 20345 S3 must always
be worn for transport work and when working under suspended
loads.
When working with the doors open, the appropriate protective
clothing for electrical work must be worn, consisting of a helmet,
safety goggles, gloves and safety footwear.
During servicing work, additional protection may be required
when handling coolant and refrigerant.
The safety data sheets for handling chemical substances must
be observed.
3.4 Handling critical high-voltage batteries
By agreement with the relevant professional associations,
this description applies to work carried out on vehicles in a
Maintenance instructions 06.2023 3
3 Safety instructions, regulations and installation guidelines 3

dealership. This description may differ for the flexible fast
charging station. However, the basic safety and security
regulations remain the same.
Special tools and workshop equipment required
◆
-VAS 6649;Warnschild "Warnung vor gefährlicher elektrischer Spannung"-
◆
-VAS 6786;Warnschild "Warnung vor Gefahren durch Batterien-
◆-VAS 6881;Verbotsschild "Betreten Verboten-
◆-VAS 6882;Verbotsschild "Kein Feuer"-
◆-VAS 6886;Temperaturmessgerät-
DANGER
If the high-voltage battery is badly damaged, or if you are
otherwise in doubt, do not perform diagnostics without
consulting an electrically skilled person in accordance
with IEC 60050.
Always observe and follow these points:
◆A high-voltage technician or an electrically skilled person in
accordance with IEC 60050 must be notified upon delivery of
a mobile charging station that is defective or has been in-
volved in an accident.
◆If possible, the mobile charging station with high-voltage lithi-
um iron phosphate batteries must be unloaded directly onto
a suitable surface.
◆The Volkswagen dealership must contact the nearest high-
voltage service centre or importer as a matter of urgency.
◆The mobile charging station must be marked with the warn-
ing sign 'Danger: High voltage'. Additional labels must be af-
fixed if quarantine is required.
◆Ensure that no unauthorised persons can access the flexible
fast charging station.
◆It is imperative that badly damaged charging stations and
high-voltage lithium iron phosphate batteries that have been
removed are protected from rain and moisture.
◆The use of a sealed base plate is recommended.
Condition
● Observe the safety instructions and warnings ⇒ “Handling
critical high-voltage batteries” on page 3.
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Concept for setting up a quarantine area
1 -
-VAS 6786;Warnschild "Warnung vor Gefahren durch Batterien-
2 -
-VAS 6649;Warnschild "Warnung vor gefährlicher elektrischer Spannung"-
3 - -VAS 6882;Verbotsschild "Kein Feuer"-
4 - -VAS 6881;Verbotsschild "Betreten Verboten-
5 - Parking area incl. hazard marking
6 - Outer safety zone
7 - Suitable open area (e.g. car park)
Next steps
Condition
● Immediately report the issue to the technical support team of
the relevant mobile charging station importer.
– Inspect the damaged mobile charging station carefully and
assess the following assessment criteria.
Assessment criteria Meaning
Is there any indication of a fire? If a question is answered with “YES”, then exercise
caution: Danger! ►Follow measure (a). If all ques-
tions were answered with No, then continue with (b)
In particular, can you detect sparks, smoke or va-
pours?
Can you hear unusual noises from inside the high-
voltage battery (such as cracking or hissing)?
Is there an acrid smell?
Are fluids leaking from the high-voltage battery
and/or do you suspect fluids have entered the bat-
tery system (e.g. electrolyte, leaked coolant)?
Is there serious mechanical damage involving ex-
posed electrical conductors or contacts on the high-
voltage battery?
Is the high-voltage battery accessible to take a tem-
perature measurement (e.g. the battery is accessi-
ble due to missing or damaged housing compo-
nents) and is the surface temperature of the high-
voltage battery greater than 80°C?
Tip
Use the -VAS 6886;Temperaturmessgerät- to measure the tem-
perature.
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3 Safety instructions, regulations and installation guidelines 5

a) For “Caution: Danger!”, take the following action:
Keep a safe distance and observe the mobile charging station/high-voltage batteries.
Be prepared to extinguish fires, and call the fire service immediately if there is any indication that a fire
may occur. Evacuate the building if necessary.
Do not inhale smoke fumes.
If there is mechanical damage to the high-voltage battery involving exposed, accessible contacts and con-
ductors, do not touch the mobile charging station or the high-voltage batteries.
Quarantine the battery if possible.
Cordon off a wide area around the battery and notify the responsible electrically skilled person (EFK) or
the importer.
b) If the damaged charging station can be classified as non-hazardous on the basis of the assess-
ment criteria, perform the following actions:
Carry out the “Guided Functions” test program on the “diagnostic tester” to classify and assess the condi-
tion of the high-voltage lithium iron phosphate battery. There may be a different test program for the quick-
charging station.
Follow the instructions in the test program.
Refer to the pertinent repair manual or handling instructions for details of how to proceed.
3.5 Safety measures when working on
charging stations that use high-voltage
systems
Danger to life due to high voltage
The high-voltage system conducts high voltages. Death or se-
vere bodily injuries due to electric shock or electric arcs are
possible.
◆The high-voltage system must be de-energised when work-
ing on the high-voltage system.
◆The high-voltage system must also be de-energised in a
number of cases when performing work that does not in-
volve the high-voltage system directly.
◆Have the high-voltage system de-energised by a high-volt-
age technician (HVT) or a high-voltage expert (HVE).
Danger to life due to electrical and magnetic fields
Electrical and magnetic fields can arise at the high-voltage sys-
tem. Death or severe bodily injury due to malfunction of active
implants (e.g. pacemakers, insulin pumps) is possible.
◆Persons with active implants may not perform any work on
the high-voltage system.
Risk of damage to high-voltage cables
Improper handling of high-voltage cables or high-voltage con-
nectors may result in damage to their insulation.
3
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6Repair Group 00 - Technical data

◆Never support body weight on high-voltage cables or high-
voltage connectors.
◆Never rest any tools on high-voltage cables or high-voltage
connectors.
◆Never kink or severely bend high-voltage cables.
◆Always observe the coding when connecting high-voltage
connectors.
3.6 Safety precautions when working in the
vicinity of high-voltage components
Danger to life due to high voltage
The high-voltage system conducts high voltages. Death or se-
vere bodily injury due to electric shock or electric arc in the
event of damage to high-voltage components and high-voltage
cables is possible.
◆Perform visual check of high-voltage components and high-
voltage cables.
◆Never use cutting, deforming or sharp-edged tools near
high-voltage components and high-voltage cables.
◆Never weld, solder, perform thermal bonding or use hot air
near the area of high-voltage components and high-voltage
cables.
3.7 Safety precautions when working on
the cooling system
Danger of scalding by hot coolant
In a warm operating state, the cooling system is under high
pressure. Hot steam/hot coolant can escape – risk of scalding.
◆Before opening the cooling system:
◆Wear protective gloves.
◆Wear safety goggles.
◆To relieve pressure, cover the cap of the coolant expansion
tank with a cleaning cloth, and open it carefully.
3.8 Safety precautions when working on air
conditioning systems
Risk of fatal injury and explosions due to ignition sources
Risk of fatal injury and explosions due to ignition sources near
air conditioning systems and refrigerant tanks. Escaping refrig-
erant can ignite and cause explosions. Risk of severe or fatal
injury from explosions.
◆Never bring ignition sources into the vicinity of air condition-
ing systems and refrigerant tanks.
◆Avoid electrostatic discharge, sparks from striking tools, and
hot surfaces.
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3 Safety instructions, regulations and installation guidelines 7

Risk of asphyxiation and poisoning due to refrigerant
Refrigerant fumes can cause dry coughing and nausea or even
asphyxiation and poisoning.
◆Never breathe in refrigerant fumes.
◆Only work on the refrigerant circuit and store refrigerant
tanks in well ventilated rooms.
◆Never work in or near basement entrances or other below-
ground areas.
Risk of freezing due to refrigerant
When working on the air conditioning system, refrigerant can
escape under pressure. This can cause freezing of the skin and
other body parts.
◆Wear protective gloves.
◆Wear safety goggles.
◆Extract or drain the refrigerant and immediately open the re-
frigerant circuit.
◆If extraction or draining was performed more than 10 mi-
nutes ago and the refrigerant circuit has not been opened,
extract or drain refrigerant again. Post-evaporation has pro-
duced pressure in the refrigerant circuit.
3.9 Safety precautions when using air con-
ditioner service stations
Condition
● Before connecting the filling system to the air conditioning
system, ensure that all shut-off valves present are closed.
● Before the air conditioner service station is disconnected
from the air conditioning system, make sure that the process
is completed so that as little refrigerant as is technically fea-
sible enters the atmosphere.
● Once an external pressurised gas tank has been filled with
cleaned refrigerant from the air conditioner service station /
exhaust extraction, the hand shut-off valves on the bottle
and on the filling system should be closed.
● Do not expose the air conditioner service station, extraction
and filling system to any moisture and do not use in a wet
environment.
● Before performing servicing work on the air conditioner serv-
ice station, extraction and filling system, interrupt the current
supply.
● To reduce the risk of fire, the use of extension cables should
be avoided. If this is unavoidable, use an extension cable
with cross section of at least 2.5 mm2.
● In the event of fire, remove the external bottle.
● If oil from the air conditioning system is drained from the
suction accumulator of the air conditioner service station into
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8Repair Group 00 - Technical data

the measuring beaker supplied, ensure that it is filled back
into a sealable tank as the oil contains a small amount of re-
frigerant. Do not allow refrigerant to escape into the environ-
ment.
● When the air conditioner service station is parked, it must be
secured to prevent it rolling away.
Only park and use the air conditioner service station with refrig-
erant R1234yf in cool, well ventilated locations.
Condition
● Protect it against heat and direct sunlight, do not park and
use it in areas with temperatures above 50°C.
● Do not park or use it in or near basements or other below-
ground
● Only park and use it in areas with adequate ventilation (com-
plete air exchange at least once per hour in the workshop
area and three times per hour in below-ground areas, e.g. in
inspection pits).
3.10 Safety precautions when working with
chemical substances
Danger of damage to health and/or the environment
Chemical substances can be absorbed through the skin (der-
mal), the respiratory tract (inhalative) or by swallowing (oral).
This can result in acute and chronic damage to health. Physi-
cal-chemical effects such as fire and explosion risks, heat or
cold and environmental hazards must also be observed.
◆Observe the safety data sheet and additional information
provided by the manufacturer.
◆Do not eat, smoke or drink when handling chemical substan-
ces.
◆Use personal protective equipment when necessary, e.g.
respiratory mask, chemical-resistant gloves, goggles, protec-
tive clothing.
3.11 The five safety rules
Observe the five safety rules:
1. De-energise In systems up to 1,000 V, de-energisation usually
takes place by switching off wiring protection
switches, residual current protective devices, fuse
switch disconnectors or circuit breakers.
2. Secure against reactivation The second safety rule always involves placing a
warning sign prohibiting switching operations. If the
system is not in a sealed room, an additional me-
chanical safeguard must be attached to prevent re-
activation. Close off maintenance flaps and doors. It
must not be possible to detach the mechanical safe-
guard without tools or a key.
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3 Safety instructions, regulations and installation guidelines 9

Observe the five safety rules:
3. Verify that the installation is de-energised at all
poles
Use a suitable measuring device to verify de-energi-
sation at all poles. To do this, you must use a two-
pole voltage measuring device (e.g. Duspol, Fluke).
4. Earth and short-circuit Earthing and short-circuiting provides a last safety
resort if the system is re-energised despite all the
other measures. This step also prevents residual
voltages from being discharged via your body if you
touch the installation. In installations with a voltage
of less than 1,000 V, this safety rule may be omitted.
5. Cover or block-off adjacent live components The fifth rule must be applied if you work within a
predefined proximity range to live components. The
components are covered or blocked off by means of
mechanically fixed safeguards that also prevent any
accidentally touching on your part, for example if
you trip. For installations under 1,000 V, you can
use insulating cloths, hoses or moulded sections for
covering. When working with the doors open, the
appropriate protective clothing for electrical work
must be worn (helmet, safety goggles, gloves, safe-
ty footwear).
4 Legal texts and regulations, air
conditioning systems
4.1 Provisions and directives
◆The laws and regulations listed below apply to the Federal
Republic of Germany, other or additional laws or regulations
may apply in other countries.
◆The effects of climate change can now be felt worldwide. Cli-
mate protection is therefore one of the most important tasks
facing humanity. However, this task poses huge challenges
to everyone involved.
◆What is known as the Kyoto Protocol defines global climate
protection objectives, among other things. In addition to re-
duction targets for carbon dioxide, this protocol also includes
reduction targets for fluorinated greenhouse gases, e.g. for
the refrigerant R134a, due to its high global warming poten-
tial.
◆Goods that were type-tested before 2011 may only be
placed on the market with refrigerant R134a up until 31 De-
cember 2016 (this applies only to EU countries, different reg-
ulations may apply outside the EU). Since 1 January 2017,
only goods whose refrigerant circuit is filled with a refrigerant
with a global warming potential of less than 150 may be
placed on the market in EU countries. Refrigerant R1234yf
complies with the requirements of Regulation (EC) No.
706/2007.
Many relevant laws have been adopted for the automotive in-
dustry, for example at European level. At national level, the Cli-
mate Protection Regulation Concerning Chemicals, for exam-
3
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10 Repair Group 00 - Technical data

ple, came into force in the Federal Republic of Germany on 1
August 2008 in order to define European legislation more pre-
cisely.
In the European Community, various regulations and directives
on the handling of refrigerants have been adopted, such as:
◆Regulation (EC) No. 1005/2009
◆Regulation (EC) No. 2037/2000
◆Regulation (E) No. 517/2014
◆Regulation (EC) No. 706/2007
◆Regulation (EC) No. 307/2008
◆EU Directive 2006/40/EC
In the Federal Republic of Germany, additional regulations on
refrigerants have been enacted, such as:
◆Climate Protection Regulation Concerning Chemicals,
Closed Substance Cycle Waste Management Act (KrWG),
◆TRG (Technical Regulations for Compressed Gases)
Refrigerant R1234yf is currently not listed in the various laws
and regulations. Due to its chemical composition, however, it
must be assumed that it will be included in a revision of the rel-
evant laws and regulations. Therefore, the laws and regulations
that apply to refrigerant R134a must also be observed and com-
plied with when using refrigerant R1234yf.
Maintenance and repair work on the air conditioning system re-
frigerant circuit
Repair and service work on the air conditioning system refriger-
ant circuit may only be carried out by persons who can verify
their relevant expertise in accordance with Regulation (EC) No.
307/2008 (applies to countries in which this regulation applies,
different regulations or laws may apply in other countries).
In general, however, the following applies:
Operation, repair, decommissioning, obligation to accept returns
◆It is forbidden during operation, repair work and decommis-
sioning to allow substances that contain refrigerants, contra-
ry to the state of the art, to escape into the atmosphere.
◆Records of the quantity used during operation and mainte-
nance should be kept so that the responsible authority can
be presented with a proof of use on request, if necessary. At
present, it is no longer necessary to keep a verification sheet
in the EC due to a European Parliament Regulation from
2005 Other regulations may apply in countries that do not
belong to the EC.
◆Distributors of substances and preparations mentioned
above are obliged to accept returns of these substances and
preparations after use or to approve a third party for such
purposes.
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4 Legal texts and regulations, air conditioning systems 11

◆Maintenance work and the decommissioning of goods con-
taining refrigerants specified in the regulations referred to
and the withdrawal of the substances and preparations refer-
red to in these regulations may only be carried out by per-
sons with the necessary skills (expertise) and technical
equipment.
Closed Substance Cycle Waste Management Act (KrWG), and
preparation and disposal of contaminated refrigerant and refrig-
erant oil
The respective applicable rules and regulations of the country in
question must be observed here.
4.2 Charging refrigerant circuit with differ-
ent refrigerants
Air conditioning systems that were developed and designed for
refrigerant R1234yf may not be filled with other refrigerants, e.g.
R134a.
According to the current legal situation, goods that were type
tested with refrigerant R1234yf may not be filled with refrigerant
R134a.
4.3 Occupational health and safety
◆Regulations on general occupational health and safety in ac-
cordance with VBG (German employer's liability insurance
association), e.g. VGB 20 accident prevention regulations for
“refrigeration systems, heat pumps and cooling devices” and
VGB 1 “general regulations and obligations of the company”
“and obligations of the policyholder”.
◆Observe workplace-related operating instructions.
◆Repair and service work on the air conditioning system re-
frigerant circuit may only be carried out by persons who can
verify their relevant expertise in accordance with Regulation
(EC) No. 307/2008 (applies to countries in which this regula-
tion applies, different regulations or laws may apply in other
countries).
5 Storage of the mobile charging
station
5.1 General safety rules
The general safety rules for storing energy storage units and
energy storage devices apply.
Storage locations must be assessed for adequacy in consulta-
tion with local authorities and must be approved if necessary.
Observe country-specific regulations.
The storage location must be suitable according to the applica-
ble regulations and must be equipped as specified in the regu-
lations.
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12 Repair Group 00 - Technical data

A risk assessment of the storage location is essential.
A fire safety concept/accident concept must be developed ⇒
“Handling critical high-voltage batteries” on page 3.
Condition
● If present: The packaging must have openings in the area of
the ventilation grilles to prevent a flammable atmosphere in-
side the system. This also applies if the mobile charging sta-
tion is still its original packaging ex works.
● The device must not be stored in direct sunlight.
● The mobile charging station and the isolator switch, CB2, of
the 12-V backup battery, BAT, must be switched off. See:
●⇒ Initial setup
● “Store free from frost” as negative temperatures can damage
the built-in 12-V backup battery, BAT.
● Maintain a room temperature of +10°C to +30°C as con-
stantly as possible.
● Storage with other combustible substances is not permitted.
● The storage room must be well ventilated when batteries are
being charged.
● When charging batteries in storage rooms, it is essential to
follow the instructions of the battery manufacturer as gases
may form during charging.
● This information is only valid for undamaged battery systems
in a flawless state.
● Regular checking of the correct state of the battery systems
over the entire storage period must be ensured and docu-
mented in the service schedule. See:
◆⇒ “Storing the mobile charging station” on page 14
◆⇒ “Checking, storing and charging the mobile charging sta-
tion” on page 15
◆⇒ “Checking the 12-V backup battery, BAT” on page 59
Maintenance instructions 06.2023 3
5 Storage of the mobile charging station 13

5.2 Storing the mobile charging station
Carrying out maintenance after three months of storage is recommended. The limit for the required
check is six months.
- Observe the general
safety rules.
qSee: ⇒ “General
safety rules” on
page 12
- The high-voltage bat-
teries should have a
charge level (SoC) of
30% when the mobile
charging station is
put into storage. A
2% SoC loss per
month is expected by
the supplier if the
temperature and hu-
midity conditions are
met. The optimal stor-
age temperature
range is 10 to 30°C.
- While the mobile
charging station is
being stored, a
charge-discharge cy-
cle may be required.
This depends on the
total storage time.
qSee: ⇒ “Checking,
storing and charging
the mobile charging
station” on
page 15.
- After a maximum of six months, the condition of the batteries
of the mobile charging station must be checked. To do this,
switch on (start up) the mobile charging station and read the
SoC for charging points A and B in the additional display and
operating unit, HMI.
- If the charge level is below 30%, the system must be con-
nected to the mains (via CEE plug) and charged to at least
80%. The recharging must then be documented and the next
check date (a maximum of six months later) must be speci-
fied. The 12-V backup battery, BAT, is automatically charged
too.
- See: Commissioning / connecting to the mains via CEE plug
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14 Repair Group 00 - Technical data