The Failure Causes and Solutions for EV Charging Module

The EV charging module may encounter the following six common failure conditions during operating: module protection, module failure, unequal current distribution, communication interruption, half-load output, and voltage output failing to reach the set voltage. The following is a detailed analysis and the solutions.

EV Charging Module Protection

Fault phenomenon:

The module enters protection mode due to input and output overvoltage, undervoltage, overheating, etc. Specific fault situations can be confirmed by referring to the fault codes in the communication protocol.

Possible failure causes:

1) Abnormal AC input voltage (too high/too low).

2) Poor cabinet sealing or poor airflow design, leading to inadequate heat dissipation.

3) High room temperature causing module overheating protection.

Solutions:

1) Please check if the input voltage is normal.

2) Please ensure the cabinet has good ventilation and optimize the heat dissipation environment.

3) Please lower the room temperature to avoid the module entering protection mode due to overheating.

EV Charging Module Failure

Fault phenomenon: 

The module shuts down due to output overvoltage or IGBT overcurrent failure.

Possible failure causes:

1) The input part of the module is abnormal, the input voltage is too high or too low, causing the module to stop working

2) The CAN Communication between the module and the external controller is interrupted, causing the module to stop working

3) The module's own device failure causes the module to work

Solutions:

1) Disconnect the AC power and restart the module to check if it returns to normal.

2) If it is an overvoltage fault, first disconnect the power, then adjust the voltage adjustment potentiometer counterclockwise to the minimum (a slight "click" sound can be heard when at the minimum), and then reset the output voltage.

EV charging module Unbalanced current

Fault phenomenon

The output current of multiple parallel modules is uneven.

Possible failure causes:

1) Please check whether the parallel communication lines between the modules are connected and whether they are connected correctly.

2) Please check the specific value of the module load current. It is not recommended to test the current sharing data under light load.

Abnormal communication between the EV charging module and the external controller

Fault phenomenon: 

The module does not respond to the instructions of the external controller

Possible failure causes:

1) Whether the module communication protocol matches the external controller.

2) Whether the communication line between the module and the external controller is connected correctly.

3) The CAN communication method requires a matching resistor of 120 ohms (instructions in the manual).

4) Whether the external controller sets the instructions correctly, point-to-point instructions, group broadcast instructions, and full broadcast instructions.

Solution:

1) Set the module value and group according to the actual situation. This is also a factor that affects the operation of the module. The manual has instructions.

2) The content description of the restricted part designed in the communication protocol does not recommend customers to change the data privately.