PBC Faults Board Location

The illustrations below show the Power Block controller (PBCClosed Power Block Controller) board location, key cable connections, and cable connector pin maps used during troubleshooting.

Front View for Locating the Boards for PBC Faults

PBC Faults Board Location

PBC Faults Cable Location

PBC-J108

PBC-J109

PBC-P148

Circular connector on the Power Block DRYHEX.

PBC Faults

This section provides information on PBCClosed Power Block Controller faults, including fault characteristics, possible causes, and recommended troubleshooting steps.

PBC_FAN1_OVERCURRENT

Category

Fault Source

Fault Type

Criticality

Cooling

Dry zone fan bank 1

Hardware

Major

Fault Description

Fan 1 current consumption more than 4 A for 100 ms. Fan 1 is disabled and Power Block is set to derate to 50% of maximum available power.

Possible Causes

  • Short between wires due to a slice or a cut in insulation

  • Obstruction to fan fins

  • Internal fan failure

  • Connector broken leading to a short

Troubleshooting

  1. Confirm if connectors going to PBCClosed Power Block Controller and also to the fans are seated fully.

  2. Look for wiring continuity between PBCClosed Power Block Controller connector and Fan 1 connector.

    1. Measure continuity between M3 (Fan_PWR) and M4 (Fan_Ret) on P108 connector going to PBCClosed Power Block Controller.

  3. If there is a short detected between PWR and RET line, then replace the harness.

  4. If no short is measured, then replace the Dry zone fans to fix the issue.

  5. Contact ChargePoint if the issue still persists.

PBC_FAN2_OVERCURRENT

Category

Fault Source

Fault Type

Criticality

Cooling

Dry zone fan bank 2

Hardware

Major

Fault Description

Fan 1 current consumption more than 4 A for 100 ms. Fan 1 is disabled and Power Block is set to derate to 50% of maximum available power.

Possible Causes

  • Short between wires due to a slice or a cut in insulation

  • Obstruction to fan fins

  • Internal fan failure

  • Connector broken leading to a short

Troubleshooting

  1. Confirm if connectors going to PBCClosed Power Block Controller and also to the fans are seated fully.

  2. Look for wiring continuity between PBCClosed Power Block Controller connector and Fan 1 connector.

    1. Measure continuity between M1 (Fan_PWR) and M2 (Fan_Ret) on P108 connector going to PBCClosed Power Block Controller.

  3. If there is a short detected between PWR and RET line, then replace the harness.

  4. If no short is measured, then replace the Dry zone fans to fix the issue.

  5. Contact ChargePoint if the issue still persists.

PBC_FAN1_OPENCIRCUIT_DETECTED

Category

Fault Source

Fault Type

Criticality

Cooling

Dry zone fan bank 1

Hardware

Major

Fault Description

Fan 1 current consumption less than 0.3 A per 100 s. Fan 1 is disabled and Power Block is operational and will derate if Power Modules report overheating.

Possible Causes

Troubleshooting

  1. Confirm if connectors going to PBCClosed Power Block Controller and also to the fans are seated fully.

  2. Look for wiring continuity between PBCClosed Power Block Controller connector and Fan 1 connector.

  3. If no short is measured, then replace the Dry zone fans to fix the issue.

    1. Measure between M3 (Fan_PWR) on P108 connector (going PBCClosed Power Block Controller) to Pin 1 on P148 (going to DRY-HEXClosed Heat Exchanger.

    2. Measure between M4 (Fan_Ret) on P108 connector (going to PBCClosed Power Block Controller) and Pin 7 on P148 (going to DRY-HEXClosed Heat Exchanger).

    If continuity test in steps (a) and (b) passes, then replace DRY-HEXClosed Heat Exchanger for resolution. If steps (a) or (b) fail, then replace the harness.

  4. If the issue still persists after replacing DRY-HEXClosed Heat Exchanger, then contact ChargePoint if the issue still persists.

PBC_FAN1_SPEED_MISMATCH

Category

Fault Source

Fault Type

Criticality

Cooling

Dry zone fan bank 1

Hardware/Software

Major

Fault Description

Fan 1 not running at desired speed. 20% difference between commanded speed and speed feedback.

Power Block is operational and will derate if Power Modules overheat.

Possible Causes

Fan is not receiving responding to speed commands

Troubleshooting

  1. If Power Block operates without derating, then no change is necessary.

  2. If Power Block is derating, then contact ChargePoint for further steps.

PBC_FAN2_OPENCIRCUIT_DETECTED

Category

Fault Source

Fault Type

Criticality

Cooling

Dry zone fan bank 2

Hardware

Major

Fault Description

Fan 2 current consumption less than 0.3 A for 10 s.

Power Block is operational and will derate if Power Modules report overheating.

Possible Causes

Troubleshooting

  1. Confirm if connectors going to PBCClosed Power Block Controller and also to fans are seated fully.

  2. Look for wiring continuity between the PBCClosed Power Block Controller connector and the Fan 2 connector.

    1. Measure between M1 (Fan_PWR) on P1 connector (going to PBCClosed Power Block Controller) to Pin 6 on P148 (going to DRY-HEXClosed Heat Exchanger).

    2. Measure between M2 (Fan_Ret) on P1 connector (going to PBCClosed Power Block Controller) and Pin 2 on P148 (going to DRY-HEXClosed Heat Exchanger).

    3. Measure continuity between Fan_PWR and Fan_Ret.

  3. If continuity test in steps (a) and (b) passes, then replace DRY-HEXClosed Heat Exchanger for resolution. If steps ()a or (b) fail, then replace the harness.

  4. If issue persists after replacing DRY-HEXClosed Heat Exchanger, then contact ChargePoint for further steps.

PBC_FAN2_SPEED_MISMATCH

Category

Fault Source

Fault Type

Criticality

Cooling

Dry zone fan bank 2

Hardware/Software

Minor

Fault Description

Fan 2 not running at desired speed. 20% difference between commanded speed and speed feedback.

Power Block is operational and will derate if Power Modules overheat.

Possible Causes

Fan not receiving or responding to speed commands

Troubleshooting

  1. If Power Block operates without derating, then no change is necessary.

  2. If Power Block is derating, then contact ChargePoint for further steps.

RTD_DRYZONE_AMB_DISCONNECTED

Category

Fault Source

Fault Type

Criticality

Sensor

Dry zone RTD

Hardware

Major

Fault Description

Dry zone RTD disconnected.

Fault shown when the Dry zone RTD temperature goes above 100 °C for 10 s.

Power Block is allowed to run without any derate, unless power modules report higher temperatures and trigger derate.

Possible Causes

Troubleshooting

  1. Reseat connector P148 and confirm if it fixes the issue.

  2. Measure continuity between Pin J3 (T1_OUT) on P108 (going to PBCClosed Power Block Controller) and Pin 1 on P149. Also between Pin J4 (T1_RET) on P108 (going to PBCClosed Power Block Controller) and Pin 2 on P148.

  3. If no continuity, then issue might be a break in the feedback wire.

  4. Measure resistance across between Pin J3 and Pin J4 on P108.

  5. Contact ChargePoint if the issue persists.

RTD_DRYZONE_AMB_SHORTED

Category

Fault Source

Fault Type

Criticality

Sensor

Dry zone RTD

Hardware

Major

Fault Description

Dry zone RTD Shorted.

If the temperature is reading -40° C for more than 10 s.

Power Block is allowed to run without any derate, unless Power Modules report higher temperatures and trigger the derate.

Possible Causes

  • Short in RTD feedback wire

  • Slice or cut in wire shorting to GNDClosed Ground

Troubleshooting

  1. Reseat connector P148 and confirm if it fixes the issue.

  2. Measure continuity between Pin J3 (T1_OUT) on P108 (going to PBCClosed Power Block Controller) and Pin 1 on P149. Also between Pin J4 (T1_RET) on P108 (going to PBCClosed Power Block Controller) and Pin 2 on P148.

  3. If there is a short detected, then replace the harness to fix the issue.

  4. Measure resistance across between Pin J3 and Pin J4 on P108 to measure zero (if shorted).

  5. Contact ChargePoint if the issue persists.

PB_AC-IN_SURGE_OPEN

Category

Fault Source

Fault Type

Criticality

Sensor

Surge Arrestor

Hardware

Critical

Fault Description

AC-IN surge suppressor cartridge is open or failed. Fault reported every 1 s.

Possible surge event if this happens on a unit installed in the field and was operational for some time.

Might be faulty hardware or wiring if it is seen in a brand new install.

Possible Causes

  • Feedback wire compromised

  • Real surge event in the field

Troubleshooting

  1. Do a visual inspection of the surge cartridge - if REDClosed Route Enforcement Data then it's bad - replace the surge arrestor to fix the issue. Investigate if there was an actual surge event and inspect rest of the surge arrestors. If GREEN then it's good, continue to Step 2.

  2. To confirm the feedback wiring is good, measure continuity from Pin H4 (SURGE_NC_TRIP2) on P108 (going to PBCClosed Power Block Controller) to ACSRG1 (SURGE_NC_TRIP2) underneath the AC surge arrestor cartridge. Also, continuity between J1 (SURGE_NC_TRIP1) on P108 (going to PBCClosed Power Block Controller) and ACSRG2 (underneath the surge arrestor).

  3. If wiring is confirmed good, then replace the failed surge cartridges.

PB_DC-IN_SURGE_OPEN

Category

Fault Source

Fault Type

Criticality

Sensor

Surge Arrestor

Hardware

Critical

Fault Description

DC-IN surge suppressor cartridge is open/failed. Fault reported every 1 s.

Possible surge event if this happens on a unit installed in the field and was operational for some time.

Might be faulty hardware or wiring if it is seen in a brand new install.

Possible Causes

  • Feedback wire compromised

  • Real surge event in the field

Troubleshooting

  1. Do a visual inspection of surge cartridge - if REDClosed Route Enforcement Data then bad, if GREEN then good.

  2. To confirm the feedback wiring is good, measure continuity from Pin K2 (SURGE_COM_TRIP1) on P108 (going to PBCClosed Power Block Controller) to DCINSRG2 (underneath the DC-in surge arrestor cartridge). Also, continuity between G3 (SURGE_NC_TRIP1) on P108 (going to PBCClosed Power Block Controller) and DCINSRG2 (underneath the surge arrestor).

  3. If the wiring is confirmed good, then replace the failed surge cartridges.

PB_DC-OUT-A_SURGE_OPEN

Category

Fault Source

Fault Type

Criticality

Sensor

Surge Arrestor

Hardware

Critical

Fault Description

DC bus bar A surge suppressor cartridge is open or failed. Fault reported every 1 s.

Possible surge event if this happens on a unit installed in the field and was operational for some time.

Might be faulty hardware or wiring if it is seen in a brand new install.

Possible Causes

  • Feedback wire compromised

  • Real surge event in the field

Troubleshooting

  1. Do visual inspection of surge cartridge if REDClosed Route Enforcement Data then it's bad - replace the surge arrestor to fix the issue. Investigate if there was an actual surge event and inspect rest of the surge arrestors. If GREEN then it's good, continue to Step 2.

  2. To confirm the feedback wiring is good, measure continuity from Pin K1 (SURGE_COM_TRIP4) on P108 (going to PBCClosed Power Block Controller) to DCASRG1 (underneath the DC-out-B surge arrestor cartridge). Also, continuity between L1 (SURGE_NC_TRIP4) on P108 (going to PBCClosed Power Block Controller) and DCASRG2 (underneath the surge arrestor).

  3. If wiring is confirmed good, then replace the failed surge cartridges.

PB_DC-OUT-B_SURGE_OPEN

Category

Fault Source

Fault Type

Criticality

Sensor

Surge Arrestor

Hardware

Critical

Fault Description

DC bus bar B surge suppressor cartridge is open or failed. Fault reported every 1 s.

Possible surge event if this happens on a unit installed in the field and was operational for some time.

Might be faulty hardware or wiring if it is seen in a brand new install.

Possible Causes

  • Feedback wire compromised

  • Real surge event in the field

Troubleshooting

  1. Do a visual inspection of surge cartridge - if REDClosed Route Enforcement Data then it's bad - replace the surge arrestor to fix the issue. Investigate if there was an actual surge event and inspect rest of the surge arrestors. If GREEN then it's good, continue to Step 2.

  2. To confirm the feedback wiring is good, measure continuity from Pin L4 (SURGE_COM_TRIP3) on P108 (going to PBCClosed Power Block Controller) to DCBSRG1 (underneath the DC-Out-B surge arrestor cartridge). Also, measure continuity between K4 (SURGE_NC_TRIP3) on P108 (going to PBCClosed Power Block Controller) and DCBSRG2 (underneath the surge arrestor).

  3. If wiring is confirmed good, then replace the failed surge cartridges.

PB_48V-EXT_SURGE_OPEN

Category

Fault Source

Fault Type

Criticality

Sensor

Surge Arrestor

Hardware

Critical

Fault Description

48V_EXT surge suppressor cartridge is open or failed.

Possible surge event if this happens on a unit installed in the field and was operational for some time.

Might be faulty hardware or wiring if it is seen in a brand new install.

Possible Causes

  • Feedback wire compromised

  • Real surge event in the field

Troubleshooting

  1. Do a visual inspection of the surge cartridge - if REDClosed Route Enforcement Data then it's bad, if GREEN then it's good.

  2. To confirm the feedback wiring is good, measure continuity from Pin H3 (SURGE_COM_TRIP5) on P108 (going to PBCClosed Power Block Controller) to LVSRG1 (underneath the LVClosed Low Voltage Surge arrestor cartridge). Also, measure continuity between E4 (SURGE_NC_TRIP5) on P108 (going to PBCClosed Power Block Controller) and LVSRG2 (underneath the LVClosed Low Voltage surge arrestor cartridge)

  3. If wiring is confirmed good, then replace the failed surge cartridges.

PB_AC-IN_THERMAL_SW

Category

Fault Source

Fault Type

Criticality

Sensor

Thermal Switch

Hardware

Critical

Fault Description

Thermal switches on AC-IN terminals are open. Power Block is derated to 50% operation.

If the thermal switches open in derated condition or 3 times within 24 hours, then PBCClosed Power Block Controller shall lockout the Power Block.

Possible Causes

  • Feedback wire compromised

  • The thermal swich might be not making good contact with the bus bar

Troubleshooting

  1. To confirm the feedback wiring is good, measure continuity from Pin K3 (THER_SW1_RET) on P108 (going to PBCClosed Power Block Controller) to L1IN (ACIN TSWITCH - A15). Also, measure continuity between L3 (THER_SW1) on P108 (going to PBCClosed Power Block Controller) and L3OUT(ACIN TSWITCH - A15)

  2. If the wiring is confirmed good, then locate the thermal switch and confirm the seating on the bus bar. Also make sure the connectors on the switch are not loose. If everything seems good, then reach out to ChargePoint.

  3. If the continuity issue is located, then we might have to replace the harness after locating the exact point of break. Contact ChargePoint.

PB_DC-IN_THERMAL_SW

Category

Fault Source

Fault Type

Criticality

Sensor

Thermal Switch

Hardware

Critical

Fault Description

Thermal switches on DC-IN terminals are open. Power Block is derated to 50% operation.

If the thermal switches open in derated condition or 3 times within 24 hours, then PBCClosed Power Block Controller shall lockout the Power Block.

Possible Causes

  • Feedback wire compromised

  • The thermal switch might not be making good contact with the bus bar

Troubleshooting

  1. To confirm the feedback wiring is good, measure continuity from Pin L2 (THER_SW2) on P108 (going to PBCClosed Power Block Controller) to P47 (DCIN). Also, measure continuity between H2 (THER_SW2_RET) on P108 (going to PBCClosed Power Block Controller) and P51 (DCIN TSWITCH).

  2. If the wiring is confirmed good, then locate the thermal switch and confirm the seating on the bus bar. Also make sure the connectors on the switch are not lose. If everything seems good, then reach out to reach out to ChargePoint.

  3. If the continuity issue is located, then we might have to replace the harness after locating the exact point of break. Contact ChargePoint.

PB_DC-OUT-A_THERMAL_SW

Category

Fault Source

Fault Type

Criticality

Sensor

Thermal Switch

Hardware

Critical

Fault Description

Thermal switches on DC_OUT-A terminals are open. Power Block is derated to 50% operation.

If the thermal switches open in derated condition or 3 times within 24 hours, then PBCClosed Power Block Controller shall lockout the Power Block.

Possible Causes

  • Feedback wire compromised

  • The thermal switch might be not making good contact with the bus bar

Troubleshooting

  1. To confirm the feedback wiring is good, measure continuity from Pin C3 (THER_SW3_RET) on P108 (going to PBCClosed Power Block Controller) to J42 (DC_OUT-A). Also, measure continuity between C4 (THER_SW3) on P108 (going to PBCClosed Power Block Controller) and P43 (DC_OUT-A).

  2. If wiring is confirmed good, then locate the thermal switch and confirm the seating on the bus bar. Also make sure the connectors on the switch are not lose. If everything seems good, then reach out to ChargePoint for further steps.

  3. If the continuity issue is located, then we might have to replace the harness after locating the exact point of break. Contact ChargePoint for further steps.

PB_DC-OUT-B_THERMAL_SW

Category

Fault Source

Fault Type

Criticality

Sensor

Thermal Switch

Hardware

Critical

Fault Description

Thermal switches on DC_OUT-B terminals are open. Power Block is derated to 50% operation.

If the thermal switches open in derated condition or 3 times within 24 hours, then PBCClosed Power Block Controller shall lockout the Power Block.

Possible Causes

  • Feedback wire compromised

  • The thermal swich might be not making good contact with the bus bar

Troubleshooting

  1. To confirm the feedback wiring is good, measure continuity from Pin D4 (THER_SW4_RET) on P108 (going to PBCClosed Power Block Controller) to J45 (DC_OUT-B). Also, measure continuity between E1 (THER_SW4) on P108 (going to PBCClosed Power Block Controller) and P44 (DC_OUT-B).

  2. If wiring is confirmed good, then locate the thermal switch and confirm the seating on the bus bar. Also make sure the connectors on the switch are not loose. If everything seem good, then reach out to ChargePoint for further steps.

  3. If the continuity issue is located, then we might have to replace the harness after locating the exact point of break. Contact ChargePoint for further steps.

PB_DRYZONE_DOOR_OPEN

Category

Fault Source

Fault Type

Criticality

Sensor

Reed Switch

Hardware

Emergency

Fault Description

Dry zone door is open. PBCClosed Power Block Controller shuts down the Power Block in controlled manner (if happened during a session). PBCClosed Power Block Controller also commands to open the shunt trip breaker through Aux PS.

Possible Causes

  • Door is open

  • Reed sensor feedback is compromised

  • Sensor is misaligned with magnet or missing from its position

Troubleshooting

  1. Confirm if the Wetzone Front door is open.

  2. Look for the magnet and the sensor on the Wetzone door (Front Top door). Confirm the presence of both and that they are aligned with each other on closing the door. It need not touch each other but, as long as they are in the vicinity - 15 mm.

  3. Measuring continuity of the feedback wire from Reed1 Pin SP19 (Sensor wire on Main Door - covering Power Modules) going to Reed1 - Pin C4 on P198-109 on PBCClosed Power Block Controller. Also, continuity between SEP20 (on the sensor) and REED1_RET - Pin D4 on P198-109.

  4. If there is no continuity, then the feedback wire/harness is broken. Contact ChargePoint if the issue persists.

  5. If continuity is good, then use an external magnet and place it around the sensor. Check if the sensor feedback on chassis-shell changes when the magnet is around the sensor. If the feedback changes, then the sensor is bad and needs replacement.

PB_WETZONE_FRONT_DOOR_OPEN

Category

Fault Source

Fault Type

Criticality

Sensor

Reed Switch

Hardware

Emergency

Fault Description

Wet zone door is open. PBCClosed Power Block Controller shuts down the Power Block in controlled manner (if happened during a session). PBCClosed Power Block Controller also commands to open the shunt trip breaker through Aux PS.

Possible Causes

  • Door is open

  • Reed sensor feedback is compromised

  • Sensor is misaligned with magnet or missing from its position

Troubleshooting

  1. Confirm if the Dry zone is open.

  2. Look for the magnet and the sensor on the Dry zone door. Confirm the presence of both and that they are aligned with each other on closing the door. It need not touch each other but, as long as they are in the vicinity.

  3. Measuring continuity of the feedback wire from Reed2 Pin SP21 (Sensor wire covering Wetzone) going to Reed2 - Pin B2 on P198-109 on PBCClosed Power Block Controller. Also, continuity between SEP22 (on the sensor) and REED1_RET - Pin B3 on P198-109.

    If there is no continuity, then the feedback wire/harness is broken.

  4. If continuity is good, then use an external magnet and place it around the sensor. Check if the sensor feedback on chassis-shell changes when magnet is around the sensor. If the feedback changes, then sensor is bad and needs replacement.

PB_WETZONE_BACK_DOOR_OPEN_Shutdown

Category

Fault Source

Fault Type

Criticality

Sensor

Reed Switch

Hardware

Emergency

Fault Description

Wet zone door is open. PBCClosed Power Block Controller shuts down the Power Block in controlled manner (if happened during a session). PBCClosed Power Block Controller also commands to open the shunt trip breaker through Aux PS.

Possible Causes

  • Door is open

  • Reed sensor feedback is compromised

  • Sensor is misaligned with the magnet or missing from its position

Troubleshooting

  1. Confirm if the Wetzone Back door is open.

  2. Look for the magnet and the sensor on the Wetzone door (Back Top door). Confirm the presence of both and that they are aligned with each other on closing the door. It need not touch each other but as long as they are in the vicinity.

  3. Measuring continuity of the feedback wire from Reed3 (Sensor wire covering AUXPS) going to Reed3- Pin F3 on P108 on PBCClosed Power Block Controller. Also, continuity between Reed3_Ret and REED3_RET - Pin G1 on P108.

    If there is no continuity, then the feedback wire/harness is broken.

  4. If continuity is good, then use an external magnet and place it around the sensor. Check if the sensor feedback on chassis-shell changes when magnet is around the sensor. If the feedback changes, then sensor is bad and needs replacement.

PB_TILT_EXCEEDED_Shutdown

Category

Fault Source

Fault Type

Criticality

Sensor

Tilt Sensor

Hardware/Software

Emergency

Fault Description

Power Block tilted due to seismic effect or vehicle hitting the Power Block. The tilt angle should exceed 30 degrees for system shutdown.

PBCClosed Power Block Controller shuts down the Power Block in controlled manner. PBCClosed Power Block Controller also commands to open the shunt trip breaker through AUX PSClosed Auxilary Power Supply.

Possible Causes

Troubleshooting

  1. Visual inspection should confirm if this is an actual emergency event.

  2. If the visual inspection confirms if this is a wrongly reported tilt fault, it might be a non-calibrated/miscalibrated tilt sensor.

  3. Inspect if PBCClosed Power Block Controller is seated correctly. If tilted and not touching the chassis, then reseat and confirm if the issue goes away.

  4. Contact ChargePoint for further debugging the issue.

PBC_OVERTEMP_Warning

Category

Fault Source

Fault Type

Criticality

Sensor

Temperature Sensor

Hardware/Software

Major

Fault Description

PBCClosed Power Block Controller will report OverTEMP if PBCClosed Power Block Controller_PROCESSOR or PBCClosed Power Block Controller_BOARD_TEMP exceeds 100 °C for 10 s. The fault will clear on its own if both the temps are below 100 °C for 10 s.

Possible Causes

  • High dry-zone ambient temperature due to improper cooling

  • Miscalibrated sensor

Troubleshooting

  1. Possible that dry-zone cooling is not circulating the air, thus resulting in over temp around the PBCClosed Power Block Controller board. Confirm from logs if the fans and pumps are running fine and also if other FRUs are reporting temperature related faults.

  2. Compare with the ambient temperature and max. delta T of +15 °C. Replace the PBCClosed Power Block Controller if the difference between calculated versus observed is higher.

  3. Contact ChargePoint if this seems to be a spuriously reported over temperature warning.

PBC_48V_LOGIC_SUPPLY_LOSS_Shutdown

Category

Fault Source

Fault Type

Criticality

 

Voltage

Hardware

Critical

Fault Description

PBCClosed Power Block Controller reports this fault if the voltage drops below 40 V for more than 100 ms. PBCClosed Power Block Controller shuts down the Power Block in controlled manner (if happened during a session). PBCClosed Power Block Controller stores the snapshot of the failure.

Power Block is disabled if this event occurs 3 times within 24 hours.

Possible Causes

  • Issues with incoming 480 V

  • AUXPS failure

  • Harness failure

Troubleshooting

  1. Check if the AUXPS reports any faults. Confirm if the 48 V is seen on the AUXPS (in logs). If AUXPS is still outputting 48 V on its PBCClosed Power Block Controller channel, then jump to step 2. If AUXPS reports 48 V failure on PBCClosed Power Block Controller channel, then jump to step 3. Power down the system before proceeding to next steps.

  2. If 48 V is still seen on the PBCClosed Power Block Controller channel (on AUXPS), then there might be a break in the harness/wire carrying 48 V. Measure the continuity between Pin B6 on P195-01 (on AUXPS) and Pin A4 on P198-109 (on PBCClosed Power Block Controller). Also measure the continuity from Pin A6 on P195-01 (on AUXPS) and Pin A2 on P198-109 (on PBCClosed Power Block Controller). If there is a break in continuity, then we need to replace the harness.

  3. If the continuity in harness seems good and AUXPS does report 48 V dropping in the logs, then this might be related to incoming 480 V. Measure the incoming power quality to confirm if the incoming voltage is in +/- 10% of 480 V. Install Power Quality Monitor to confirm issues with 480 V. If any issues were found, then rectify them on the incoming side and then confirm if 48 V is back on the PBCClosed Power Block Controller channel.

  4. If 480 V looks good, continuity tests confirm good harness but, 48 V is not coming through to PBCClosed Power Block Controller, then replace AUXPS.

  5. If 480 V looks good, continuity tests confirm good harness and we can measure 48 V across pins G1 and H1 on P198-109 (on PBCClosed Power Block Controller), then replace PBCClosed Power Block Controller.

Loss_of_Comms_AuxPS

Category

Fault Source

Fault Type

Criticality

Communication

CAN Comms

Hardware/Software

Critical

Fault Description

This fault is reported if CAN communication is lost between AUX PSClosed Auxilary Power Supply and PBCClosed Power Block Controller. CAN heartbeat signal is monitored every 1 s and this fault is reported when 5 heartbeat signals are lost. PBCClosed Power Block Controller will terminate any ongoing session and then disable the Power Block.

Possible Causes

Troubleshooting

  1. If AUXPS fails, then we might lose CAN communication. Confirm from the logs if there are any AUXPS failures/faults reported. If yes, then replace AUXPS and confirm if CAN comms are back.

  2. If AUXPS is confirmed good, then we might have an issue with the harness carrying CAN data. Measure continuity between:

  3. If no short is measured, then replace the Dry zone fans to fix the issue.

    1. Pin C3 on P198-109 (on PBCClosed Power Block Controller) and Pin 5 on P195-10 ---- looks at CANH.

    2. Pin D3 on P198-109 (on PBCClosed Power Block Controller) and Pin 2 on P195-10 ---- looks at CANL.

    3. Pin E3 on P198-109 (on PBCClosed Power Block Controller) and Pin 6 on P195-10 ---- looks at CAN_GNDClosed Ground.

    4. Measure resistance across Pin 1 and Pin 4 on P195-10 - ideally should measure 120 Ω.

    If any of the above tests fail, then replace the harness.

  4. If continuity is good and AUXPS is confirmed good as well, then replacing PBCClosed Power Block Controller might resolve the issue. Contact ChargePoint for further steps.

Loss_of_Comms_CCB

Category

Fault Source

Fault Type

Criticality

Communication

CAN Comms

Hardware/Software

Critical

Fault Description

This fault is reported if CAN communication is lost between AUXPS and PBCClosed Power Block Controller. CAN heartbeat signal is monitored every 1 s and this fault is reported when 5 heartbeat signals are lost. PBCClosed Power Block Controller will terminate any ongoing session and then disable the Power Block.

Possible Causes

Troubleshooting

  1. If CCB fails, then we might lose CAN communication. Confirm from the logs if there are any CCB failures/faults reported. If yes, then replace CCB and confirm if CAN comms are back.

  2. If CCB is confirmed good, then we might have an issue with the harness carrying CAN data. Measure continuity between:

    1. Pin C3 on P198-109 (on PBCClosed Power Block Controller) and Pin 6 on P7 (of CCB) ---- looks at CANH.

    2. Pin D3 on P198-109 (on PBCClosed Power Block Controller) and Pin 7 on P7 (of CCB) ---- looks at CANL.

    3. Pin E3 on P198-109 (on PBCClosed Power Block Controller) and Pin 8 on P7 (of CCB) ---- looks at CAN_GNDClosed Ground.

    4. Measure resistance across Pin 10 and Pin 5 on P7 (on CCB) - ideally should measure 120Ω.

    If any of the above tests fail, then replace the harness.

  3. If continuity is good and CCB is confirmed good as well, then contact ChargePoint for further debugging.

Loss_of_Comms_PM

Category

Fault Source

Fault Type

Criticality

Communication

CAN Comms

Hardware

Critical

Fault Description

This fault is reports if CAN communication is lost between one or more Power Modules and PBCClosed Power Block Controller. CAN heartbeat signal is monitored every 1 s and this fault is reported when 1 heartbeat signal is lost. PBCClosed Power Block Controller will terminate any ongoing session and then disable the Power Block.

Possible Causes

Troubleshooting

  1. Power down the system and check if the module is fully seated and making proper connection to the mod-mate on the Power Block side.

  2. Confirm from logs or NOSClosed Network Operating System if there are any active critical faults on the Power Modules. If yes, then it is possible that the Power Modules have failed and need to be replaced. Replace the appropriate module and confirm if CAN communication comes back on that slot.

  3. If there are no active faults on the Power Module, visually inspect if any of the pins on the data connector are damaged. If any damage is found, then replace the module to resolve the issue.

  4. If all the above inspections do not show any obvious issues, then it could be the data connector on the mod-mate side that might have failed. Contact ChargePoint for further resolution steps.