ICS-200B Service Manual
Contents
1. peeenwaepmoiS o Hem rey cone pum 1 7 3 mmas wes amp 3 s o oae emer 1 S RAD ISI Terminal QC e RAD QC ___ Eu 1 mecs Bipcmww piwRd ume 1 u 2 meer wpn bek mam ___ 1 m p a me o ionen Green O 1 u 1 me BipCmww pHue Same ___ 2 5 2 mecs B eCoww piYelw Samp 2 7 2 mec sam 2 pw uer pueCmew pmGuy 2 ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 Table 4 2 is included as reference in case ICS 200 B mounting hardware is misplaced during servicing Use this table as a guide when replacing nuts bolts washers etc Table 4 2 Mounting Hardware ICS 200 B Enclosure to Wall 2 1 2 Long Hex Head Lag Screw Zinc Qty 4 B 1 4 Seal Bonding Washer Qty 4 C 3 4 Water Tight NEMA Fitting Qty 1 Single Enclosure to Post A Single Support Post Package Qty 1 Dual Enclosure to Post A Single Support Post Package Qty 1 B Dual Support Accessory Package Qty 1 Single Support Post Package A Post with Base Qty 1 e 5 8 11 Hex Nut Zinc Qty 8 e 5 8 Washer Qty 8 B Base Cover Qty 2 16 32 x 1 2 Flat Head Phillips Screw Qty 4 C Mounting Plate Qty 1 D Single Support Bracket2. ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 11 Table 5 1 Symptoms Based Protection and Service for Trouble Shooting Designator Action Announcement Condition Section dl ree Protection Blinking Ground Fault 4 5 5 Present 54 5 6 5 5 5 12 5 11 System Failure 07 since time Contactor Driver 5 16 System Failure 08 since fime RTC Not Counting 5 i 2 Service Static Electric Vehicle Connection Fault Pilot Voltage Out Of Since time Specifications No Activity After Service Power Configuration Case 2 5 15 Any any System Not 5 10 Responding Table 5 2 Symptoms Based Data Log for Trouble Shooting Data Log Condition Section Petes Cale 00 Contactor Stuck Open _ 156 ___06 __ GFCICirevitry 154 08 RTC NotCounting 153 09 __ NoWDT Resets 517 1 9 7 5 3 8 System Failure 05 since time Configuration Case 1 5 13 System Failure 06 since time Circuitry 5 14 5 1 Ground Fault Error The ground fault system is capable of automatic re closure The protection designator will blink and the EV cable will be de energized during a ground fault condition After the ICS 200 has attempted to re start the charging cycle several times it will cease re closure and the designator will remain ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 12 statically lit
3. AC Power and PCB Power 4 Remove power supply from the snap top stand offs posts 5 When replacing the power supply make sure the green terminal is BETWEEN the power supply and the metal mounting post ONLY replace power supply with compatible type Use Table 8 1 to determine if the replacement power supply is compatible with the ICS 200 B wiring harness Currently there are two groups of compatible power supplies used in the ICS 200 B If the replacement power supply is in the same group as the original power supply then they are compatible Table 8 1 Power Supply Compatible Part Number Manufacturer Use 40 3003 Figure 8 5 Power Supply Connections GREEN Q TERMINAL O Ss QI COCO AX SNAP TOP STANDUFFS u p 5 M K CO POWER WHITE BLACK mumm BLACK Sms RED mmm RED mmm ORANGE mmm 2 0 09 ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 26 9 Using the Data Switch Before attempting to collect the data log using the Data Switch it is important that copies of the EVI Data Log Sheet in section 10 are available for recording the announced information on 9 1 Initiating the Data Log Announcement The data switch is used to gather ICS 200 eve
4. Qty 1 E Top Cap Single has 3 flanges Qty 1 F 3 4 Conduit Assembly Qty 1 G 1 4 20 x 1 0 Torx 27 Screw Qty 10 H 1 4 Seal Bonding Washer Qty 10 I 1 1 8 Plug Qty 1 Dual Support Accessory Package A Mounting Plate Qty 1 B Dual Support Brackets Qty 2 C Top Cap Dual has 2 flanges Qty 1 D 3 4 Conduit Assembly Qty 1 E 1 4 20 x 1 0 Torx T 27 Screw Qty 10 F 1 4 Seal Bonding Washer Qty 10 ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 5 Trouble Shooting Table 5 1 are intended to help with determining which ICS 200 component may be malfunctioning in a failed unit After establishing the possible source of problem use the procedures in section 6 Inspecting Components to check component for failure Step 1 Use Trouble Shooting section to focus on possible component failure Step 2 Use Inspecting section to verify the suspect component has failed The ICS 200 has many features to help diagnose problems However to take advantage of these features it is necessary to LOOK LISTEN and GET the DATA LOG Often times simply making a conscious effort to take note of what the unit is trying to say will point directly to the problem area Look at the FRONT panel make note of which designators are lit e If the unit is making an announcement make note of exact message e Press the STOP BUTTON Listen to the announcement
5. Replacing Components 8 1 Opening the Enclosure 1 Remove and retain 2 4 15 Torx left side Figure 8 1 2 Swing box open by pulling on the left side 3 When replacing screws on the door DO NOT OVER TIGHTEN Figure 8 1 Opening Service Door 8 32 TORX HEAD SCREW wb REQUIRES T 15 TORX DRIVER ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 22 Figure 8 2 Opening Service Panel N OPTIONAL I Pl L1 RED 1 9 GROUND TWO POWER IN OPTIONS DO NOT REMOVE OTHER KNOCK OUT ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 in PORT 0 EG 23 8 2 Printed Circuit Board Turn circuit breaker off verify no power is applied Open the enclosure as described in section 8 1 Pull each corner of the PC board gently off the 4 Snap top standoffs Pull PCB off the header approximately a inch this will pull it away from connector Pull PCB out holding by the metal head sink on top Remove Push Button connector cable from back side of board When replacing pop back on posts When replacing REMEMBER TO CONNECT Push Button connector cable on back side
6. ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 27 10 EV Data Log Sheet Use the following tables to record the error information from the ICS 200 Table 10 1 First Message Sequence Durability Constraint kilo watt hours 4 charged reduce cable tension Table 10 2 Second Message Sequence ma Number Chius 5 ee a failure is wej o oo failure is fat oo failure 14870 Jat To Clear The Log Press stop to cancel set failure to zero announced Press the STOP button to continue normal operation without clearing the error log Press CHARGE NOW to continue Press stop to cancel set failure to zero will be announcement again Press STOP to abort Press CHARGE NOW again to clear the error log ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 28
7. Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 10 12 22 22 27 28 29 23 24 25 27 1 About This Document 1 1 Scope A summary of how to access records and interprets the ICS 200 verbal diagnostics for the purpose of service Information about what to do given certain failures and symptoms 1 2 Comments The service manuals intent is to lend a hand to maintenance personnel in diagnosing and repairing filed units Also to assist in establishing when a suspicious behavior is not a failure The ICS 200 includes an internal diagnostics data logging system which is maintained by the backup battery Often times problems can be determined by analyzing this data log ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 5 2 Abbreviations and Terms Like any market the Electric Vehicle products have their own set of new terminology Table 2 1 will help you understand some of the terms associated with Electric Vehicles and EVI s ICS 200 product series Table 2 1 List of Abbreviations and Terms Charging Station general term for the ICS 200 product also EVSE HBCD or PCS Conductive Coupling A mechanical and electrical interconnecting scheme for the purpose of transferring electrical energy using conductive contacts which are physically mated A high power switching device similar to a relay Its purpose is to provide control of EV cable energization Data
8. Switch Small device which connects to the ICS 200 s FICS adapter port used for ICS 200 data gathering EVSE Electric Vehicle Service Equipment general term for the ICS Excessive Pressure A pulling force on the cable when experience by the system FICS Adapter Field Installation and Configuration System a device which Ground Fault Circuit Interrupter device which detects small EM amounts of ground current in an AC system and is capable of de energizing the contactor if a threshold current is present GFCI Coil Ground Fault Coil a toroid sensor through which the L1 and ORI E conductos are routed Home Based Connection Device general term for the ICS 200 product also EVSE Charging Station or PCS maximum of 240V AC 48Amps M Load Management a controlling mechanism by which the utility can govern when electric energy will be consumed by Magma Software used in conjunction with the FICS Adapter for LIN Printed Circuit Board the circuitry card inside of the ICS 200 5 L PC PC PE Power Control Station general term for the ICS 200 product also EVSE Charging Station or HBCD EVSE functionality A pulse width modulated signal used to communicate information between the EVSE and the EV ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 Pull free The mechanism by which a cable is allowed to disengage from a connection d
9. announcer will then periodically repeat the error message including the time of the first occurrence of the failure The delivered units are configured to attempt re closure 5 times with 15 minute intervals in between Actions to Take 1 Ifthere is a ground fault present on the EV this is a normal operation 2 Usethe PET to test the ICS 200 s ground fault circuitry Suspected Components 1 Ground Fault Coil 2 Black and White wires from the ground fault coil to the PCB connector 3 Circuitry on the PCB 5 2 Service Ground Not Preset If the ground from the service panel is not present and there are no other paths to earth ground the system will cease charging and enter a service required failure mode Conductive charging stations require a bonded ground as a primary means of providing personal safety See the document Proper Service Connection in the service pack Actions to Take 1 6 6 Inspection for Proper Ground Suspected Components 1 Improper service connection 2 8 Green bonding wire from the junction box into the internal ground block 3 Small green wires on the internal ground block 5 3 Real Time Clock Not Counting The ICS 200 charging cycles are based on the internal clock it must operate correctly for proper operation The internal clock incorporates a battery backup capable of 10 years of non powered operation Actions to Take 1 6 5 Inspecting PCB Suspected Components 1 Circuitry on the PCB I
10. of board New PCB s MUST BE PROGRAMMED with a new configuration see section 7 QyucAc s Figure 8 3 Removing Hold Board ONLY By Metal Heat Sink Other Side LED s must face out Pull header off approximately 1 2 gt smi Pull each corner on the board gently the 4 Snap top standoffs ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 24 8 3 1 Turn circuit breaker off verify no power is applied Open the enclosure as described in section 8 1 Carefully observe the placement of wires illustrated in Figure 8 4 Remove the 8 power wiring first Remove the quick connects DO NOT GRIP BY THE WIRES Remove and retain 4 48 32 nuts When replacing the contactor carefully observe the placement of wires Di uU qe R3 Figure 8 4 Wiring Connections for Contactor ae ag or ya E lt E m oO 2 a LX 8 38 NUTS m xL 22103 K WHITE YELLOW RAN BLA L1 IN YELLOW Le ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 8 4 Power Supply Replacement 1 Turn circuit breaker off verify no power is applied 2 Openthe enclosure as described in section 8 1 3 Remove the two connectors
11. unit at the circuit breaker Open the enclosure as described in section 8 1 Make sure the Anderson connectors are firmly seated Check for matching colors Anderson internal contacts may come loose Check the internal contacts by gently pulling the wires Check the internal contacts by gently pushing the wires into the plastic holders It is possible for the contact crimps to fail Check for failed contacts by measuring the resistance from inside the connector to the other end of the wire wherever it lands 6 5 Inspecting PCB 1 Open the enclosure as described in section 8 1 2 Look for the heart beat a blinking read light at the bottom of the PCBG 3 Turn off the power to the unit at the circuit breaker 4 Make sure the PCB is firmly seated into the connector 5 Inspect the PCB for physical damage such as blown up parts or debris 6 6 Inspection for Proper Ground 1 Openthe junction box 2 The following measurements should be read From To Approximate Neutral if used 120VAC Neutral if used 120VAC Neutral if used Less than 15 ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 20 7 Programming New Using Magma When a new PCB is installed in an ICS 200 B it must programmed to the configuration of the previously installed PCB It is necessary to use Magma and the FICS adapter to accomplish this task As is often the case a failed PCB will still communicate properl
12. CS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 13 5 4 Venting Fan Failure The ICS 200 incorporates circuitry for monitoring the proper operation of the venting fan If the venting fan is required but not operating properly the unit will disallow charging and enter this failure mode The venting fan is powered from L1 and Neutral The venting fan must be serviced Actions to Take 1 Usethe PET to test the ICS 200 s charging with FAN operation 2 When powered by the ICS 200 check the venting FAN Suspected Components 1 Circuitry on PCB 2 Improper wiring in the junction box 3 Improper or no Neutral write from the service panel 5 5 EV Cable Pulled Free The ICS 200 can detect when the EV cable has been pulled free from the unit The unit will not operate until the cable is re installed Actions to Take 1 Inspect the pull free plate for problems 2 Inspecting Anderson Connectors Suspected Components 1 Circuitry on PCB 2 small GREY Anderson connector in the pull free mechanism 5 6 Contactor Open Failure 00 The ICS 200 can detect when the EV connector is not energized when it should be This condition is a result of a failed power contactor The unit will not operate until the contactor is repaired Actions to Take 1 6 1 Inspecting Fuses 2 6 2 Inspecting Contactor Suspected Components 1 Blown fuse 2 Disconnected or loose quick connect on the cont
13. FOR PROPER GROUND 21 ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 2 7 PROGRAMMING NEW USING MAGMA 8 REPLACING COMPONENTS 8 1 OPENING THE ENCLOSURE 8 2 PRINTED CIRCUIT BOARD 8 3 CONTACTOR 8 4 POWER SUPPLY 9 USING THE DATA SWITCH 9 1 INITIATING THE DATA LOG ANNOUNCEMENT 9 2 RECORDING THE DATA LOG 9 3 CLEARING THE DATA LOG 10 EVI DATA LOG SHEET ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 22 23 23 25 26 27 28 28 28 28 29 Table 2 1 3 1 3 2 Table 4 1 Table 4 2 Table 5 1 Table 5 2 Table 7 1 Table 7 2 Table 8 1 Table 9 1 Table 10 1 First Message Sequence Table 10 2 Second Message Sequence Figure 8 1 Removing Beauty Cover Figure 8 2 Opening Back Service Panel Figure 8 3 Removing PCB Figure 8 4 Wiring Connections for Contactor Figure 8 5 Power Supply Connections Table of Tables List of Abbreviations and Terms Required Equipment Extended Service Equipment ICS 200 B Spare Parts Kit Co Mounting Hardware ICS 200 B Symptoms Based on Protection and Service for Trouble Shooting Symptoms Based on Data Log for Trouble Shooting Installing a New PCB Installing a New PCB if the Old One Does Not Work Power Supply Compatible Group 1 Starting the Data Log Table of Figures ICS 200B Service
14. ICS 200B Service Manual EVI Inc Electric Vehicle Infrastructure Inc Copyrighted Material Revision History SERVICE MANUAL 01 DOC Date Revision Author Comment 3 23 1998 1 0a Jason France First Draft 3 30 1998 1 0b Jason France Changes from first presentation to Table 5 2 added comments to the 10 EV Data Log Sheet 1 11 1999 1 0c Mickey Oros First Draft for B unit ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 Table of Contents 1 ABOUT THIS DOCUMENT 5 1 1 SCOPE 5 1 2 COMMENTS 5 2 ABBREVIATIONS AND TERMS 6 3 SERVICE EQUIPMENT 8 4 SPARE PARTS KIT 9 5 TROUBLE SHOOTING 11 5 1 GROUND FAULT ERROR 13 5 2 SERVICE GROUND NOT PRESET 13 5 3 REAL TIME CLOCK NOT COUNTING 13 5 4 VENTING FAN FAILURE 14 5 5 EV CABLE PULLED FREE 14 5 6 CONTACTOR OPEN FAILURE 00 14 5 7 CONTACTOR CLOSED FAILURE 01 15 5 8 ELECTRIC VEHICLE CONNECTION FAULT 15 5 9 EV CABLE TENSION 15 5 10 SYSTEM NOT RESPONDING 16 5 11 PILOT 12V CIRCUITRY FAILURE 03 16 5 12 PILOT 12V CIRCUITRY FAILURE 04 16 5 13 CONFIGURATION CASE 1 FAILURE 05 17 5 14 GFCI CIRCUITRY FAILURE 06 17 5 15 CONFIGURATION CASE 2 17 5 16 CONTACTOR DRIVER FAILURE 07 18 5 17 NO WDT TRIPS 18 5 18 EXCESSIVE EV CURRENT 18 6 INSPECTING COMPONENTS 19 6 1 INSPECTING FUSES 19 6 2 INSPECTING CONTACTOR 19 6 3 INSPECTING POWER SUPPLY 20 6 4 INSPECTING ANDERSON CONNECTORS 20 6 5 INSPECTING PCB 20 6 6 INSPECTION
15. S 200 Release tension on the EV cable Actions to Take 1 Inspect the cable for inadvertent sources of strain 2 Inspect the Excessive Strain PCB s optical sensors for debris 3 Inspect the pull free plate for problems Suspected Components 1 Excessive Strain 2 Loose broken wires on the Excessive Strain 3 Circuitry on the Main PCB ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 15 5 10 System Not Responding In the unlikely event the ICS 200 were to discontinue responding at all power the system down using the circuit breaker for 10 seconds then re apply power The ICS 200 incorporates circuitry that maintains a condition of safety even if the internal CPU were to malfunction Actions to Take Press the STOP button and check for announcement Check for service power to the junction box 6 1 Inspecting Fuses 6 3 Inspecting Power Supply 6 5 Inspecting PCB pour Suspected Components 1 No power from service 2 Power supply failed 3 Noconnection to front panel 4 Circuitry on the Main PCB 5 11 Pilot 12V Circuitry Failure 03 The ICS 200 can detect when the EV pilot signal positive voltage sensing circuitry is not functioning correctly The unit will not operate until the circuitry is repaired Actions to Take 1 Use the PET to test the ICS 200 2 Inspecting Anderson Connectors Suspected Components 1 The small BLUE Anderson connector in t
16. actor 3 Contactor s energizing coil or contacts has gone bad 4 Circuitry on the PCB ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 14 5 7 Contactor Closed Failure 01 The ICS 200 can detect when the EV connector is energized when it should not be This condition is a result of a failed power contactor The unit will not operate until the contactor is repaired Actions to Take 1 6 1 Inspecting Fuses 2 6 2 Inspecting Contactor Suspected Components 1 Blown fuse 2 Disconnected or loose quick connect on the contactor 3 Contactor s energizing coil or contacts has gone bad 4 Circuitry on the PCB 5 8 Electric Vehicle Connection Fault The ICS 200 can detect when the EV is manipulating the pilot incorrectly This condition is a result of a failed ICS 200 pilot driver circuit connection or EV pilot circuitry Inspect the connector and try to re enter a charging cycle Actions to Take 1 Inspect the EV s inlet for debris 2 Inspect the EVSE connector for debris 3 Inspecting Anderson Connectors 4 Use the PET to test the ICS 200 Suspected Components 1 The small BLUE Anderson connector in the pull free mechanism 2 Circuitry on the PCB 5 9 EV Cable Tension It is important not to pull too hard on the EV cable The ICS 200 is equipped with a pull free system which allows the EV cable to come out of the unit under conditions which may cause damage to the EV or the IC
17. evice when it experiences certain forces Switching Power Supply the electronics package inside of the ICS 200 which converts AC power to power for the printed circuit board batteries which vent hazardous gases will be charged VA phrases for the communication of system status ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 3 Service Equipment Table 3 1 Required Equipment SAE wrench set or equivalent Phillips head screwdriver and T 15 amp 27 Torx wrench Data Switch and blank data log sheets DMM or Digital Multi meter capable of measuring RMS AC Volts DC Volts and resistance PET Portable EVSE Tester available from EVI Spare Parts Kit available from EVI Table 3 2 Extended Service Equipment FICS Adapter Field Installation and Configuration System available from EVI Laptop running Windows 95 or 3 11 800x600 screen 8MB Free serial port Magma Software loaded onto laptop available from EVI or http www evil com ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 4 Spare Parts Kit Stock one set of the items listed in Table 4 1 for each 100 units installed in the field for optimum service capabilities Table 4 1 ICS 200 B Spare Parts Kit Eg AN S EN a C P N Order F3 ences Rx 1 1 mam Detection Module POR aes aw i 1 1 1 vamos Growers ____ 1 S 1 pom
18. he circuit breaker 5 Usethe DMM to measure the voltage on the contactors energizing coil across the 2 yellow wires 6 When the contactor is off this should read about 0 7 When the contactor is on this should read over 200 VAC 8 Turnon the power to the unit at the circuit breaker 9 Usethe DMM to measure the voltage on the contactors input 10 Measure across the Red and Black number 8 coming from the conduit 11 This should always read 200 VAC 12 Use the PET or EV to put the ICS 200 into the charging mode 13 Listen to hear the contactor close 14 Use the DMM to measure the voltage on the contactors output 15 Measure across the Red and Black number 8 going to the Anderson connectors 16 When the contactor is off this should read about 0 VAC 17 When the contactor is on this should read over 200 VAC ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 19 6 3 Inspecting Power Supply Refer to Figure 8 5 Open the enclosure as described in section 8 1 Use the DMM to measure the AC voltage on the Power Supply s input Measure across the two black wires This should read over 200 VAC Use the DMM to measure the DC voltage on the Power Supply s output to chassis ground The following measurements should be read si UA Bom From To Approximate DC Voltage 15 VDC Red 5 VDC Red 5 VDC A 9 up9tuUwRwcf Inspecting Anderson Connectors Turn off the power to the
19. he pull free mechanism 2 Short in the wiring harness 3 Circuitry on the Main PCB 5 12 Pilot 12V Circuitry Failure 04 The ICS 200 can detect when the EV pilot signal negative voltage sensing circuitry is not functioning correctly The unit will not operate until the circuitry is repaired Actions to Take 1 Use the PET to test the ICS 200 2 Inspecting Anderson Connectors Suspected Components 1 The small BLUE Anderson connector in the pull free mechanism 2 Short in the wiring harness 3 Circuitry on the Main PCB ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 16 5 13 Configuration Case 1 Failure 05 The ICS 200 requires certain internal programmable registers to be set to the correct values If the values are incorrect they will be re programmed automatically This condition is only a problem if it persists Actions to Take 1 6 5 Inspecting PCB Suspected Components 1 Circuitry on the Main 5 14 GFCI Circuitry Failure 06 The ICS 200 can detect when the ground fault sensing circuitry is not functioning correctly The unit will not operate until the circuitry is repaired This circuitry is used each time the EV is connected Actions to Take 1 Usethe PET to test the ICS 200 s ground fault circuitry Suspected Components 1 Ground Fault Coil 2 Black and White wires from the ground fault coil to the PCB connector 3 Green wire from the PCB connector
20. nt and usage information Table 9 1 Starting the Data Log Insert the Data Switch into the FICS port located inside on the PC board Press and HOLD the Data Switch button Press and HOLD the Start and Stop button Release the Data Switch button Continue to HOLD the Start and Stop buttons until unit begins to speak As soon as kilo watt hours is spoken release the Start and Stop buttons Record spoken information into the EVI Data Log Sheet EOS aid Rare 9 2 Recording the Data Log The data log announcement will follow the form listed in section 10 In each place where the sheet is blank there ICS 200 will speak a number Write the numbers down as they are spoken Note that the numbers which are longer than 2 digits are spoken in groups of two digits For example the number 12345 will actually be spoken 01 23 45 Simply record the groups of 2 digits as they are heard and make sense of the numbers after the data log is done 9 3 Clearing the Data Log After announcement of the durability constraints and error log Press stop to cancel set failure to zero will be announced Press the STOP button to continue normal operation without clearing the error log Press CHARGE NOW to continue Press stop to cancel set failure to zero will be announcement again Press STOP to abort Press CHARGE NOW again to clear the error log The durability constraint counts cannot be cleared from the front panel
21. t when the EV is drawing more current than the branch circuit is configured to handle This safety feature is programmable using Magma This condition is only a problem if it persists Actions to Take 1 6 5 Inspecting PCB 2 Check the EV current coil a small toroid which has the red L1 passing through it Suspected Components 1 Circuitry on the Main PCB ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 18 6 Inspecting Components Table 5 1 is intended to help with determining which ICS 200 component may be malfunctioning in a failed unit After establishing the possible source of problem use the procedures in section 6 Inspecting Components to check component for failure Step 1 Use Trouble Shooting section to focus on possible component failure Step 2 Use Inspecting section to verify the suspect component has failed 6 1 Inspecting Fuses Turn offthe power to the unit at the circuit breaker 2 Open the enclosure as described in section 8 1 3 Check the fuses by gently pulling on them 4 UseaDMM measure the resistance of each FUSE 5 fuses should read about 0 ohms of resistance 6 Replace any fuses which are blown 6 2 Inspecting Contactor 1 Turn off the power to the unit at the circuit breaker 2 Openthe enclosure as described in section 8 1 3 Check the quick connects and wires connected to the contactor by gently pulling on them 4 Turn on the power to the unit at t
22. through the GFCI coil to the internal grounding block 4 Circuitry on the PCB 5 15 Configuration Case 2 The ICS 200 has 4 programmable sub systems Embedded Software On site and Load Management Factory and Voice Data Bank When the service power is applied to the system these 4 memories will be checked for integrity and compatibility If this failure occurs it is most likely the ICS 200 has been programmed incorrectly If the unit has not been recently programmed the system must be repaired Actions to Take 1 6 5 Inspecting PCB 2 Re program the unit using Magma Suspected Components 1 Circuitry on the Main PCB ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 17 5 16 Contactor Driver Failure 07 The ICS 200 can detect when the EV connector is energized when it should not be This condition is a result of a failed driver circuitry The unit will not operate until the contactor is repaired Actions to Take 1 6 5 Inspecting PCB 2 6 2 Inspecting Contactor Suspected Components 1 Circuitry on the Main PCB 2 Contactor s energizing coil or contacts has gone bad 5 17 No WDT Trips The ICS 200 can detect when its either of its two CPU monitoring circuits has failed The unit will not operate until the contactor is repaired Actions to Take 1 6 5 Inspecting PCB Suspected Components 1 Circuitry on the Main PCB 5 18 Excessive EV Current The ICS 200 can detec
23. y with the Magma software In this case use the steps outlined in Table 7 1 If a failed board will not respond at all to the Magma software use the steps outlined in Table 7 2 Table 7 1 Installing a New PCB Before removing failed PCB From Magma go to File gt Download Parameters From ICS Check all three Paramsets Click on Download Wait for download to complete this takes about 1 minute Now Magma holds the configuration of the original PCB Save the configuration into a file Select File gt Save As Choose a file name and do not forget it 10 Change the PCB as described in section 8 2 11 Load the saved configuration 12 Select File gt Open 13 Choose the file name from step 9 then click on OK 14 Select File gt Upload Parameters To ICS 15 Check the three Paramsets OSLM Factory and NVRAM 16 Click on Upload 17 Wait for upload to complete this takes about 2 minutes 3909 I ON 2 Table 7 2 Installing a New PCB if the Old One Does Not Work Change the PCB as described in section 8 2 Load the configuration Select File gt Open Choose the file name based on the EVI part number desired Select File gt Upload Parameters To ICS Check the three Paramsets OSLM Factory and Click on Upload Wait for upload to complete this takes about 2 minutes ON Cv s a Ese ICS 200B Service Manual Electric Vehicle Infrastructure Inc Copyrighted Material 1 19 99 21 8
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