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.
3
Maintenance instructions 06.2023
4Repair Group 00 - Technical data