Testing and maintenance of the self-checking function for charger faults

To test and maintain the self-check function for faults of electric vehicle chargers, the following steps can be followed:

First, test the self-checking function for faults

Indicator light status check

After plugging in the power supply, observe whether the indicator light lights up normally. During the charging process, the indicator light should light up normally, and after the charging is completed, it should smoothly turn green. If the indicator light does not light up or flashes abnormally, there may be a fault.

Pay attention to whether the charger has an alarm prompt. The fault is usually expressed by the flashing of the charging indicator light. You can refer to the charger manual to understand the specific meaning.

Output parameter detection

Output voltage detection: Use the voltage range of a multimeter to detect the output voltage. For instance, the normal output voltage of a 36V charger should be 42V, that of a 48V charger should be 56V, and that of a 60V charger should be 72V. If the output voltage is abnormal, there might be a problem with the charger.

Output current detection: Use the DC 20A current range of a multimeter to detect the output current. For example, the normal output current of a 36V/10Ah charger should be 1.8A, while that of a 48V/20Ah charger should be 2.8A. If the output current is too small or too large, there might be a fault with the charger.

Internal inspection

Open the charger's casing and carefully check for any unpleasant odors or burn marks inside. If there is a burnt smell or signs of burning are found, it indicates that there might be a problem with the charger.

Use the range of a multimeter to check the power cord of the charger. If the reading shows "1", it indicates that there is an open circuit problem.

Check whether there are any false soldered components near the high-voltage area on the circuit board, as well as whether the vibration damping capacitors at the output stage are damaged, and whether the components are open-circuited or falsely soldered.

Charging connection detection

Check whether the output plug of the charger is tightly inserted into the charging plug of the battery box, and whether the fuse of the battery box is open-circuited or the fuse socket has poor contact.

Check whether the L and N interfaces of the charging port maintain good contact. The temperature at the junction of the charging plug and the socket should be within the normal range, and the value of the temperature sensor should also be normal.

Second, maintenance of the self-checking function for faults

Daily maintenance

Regularly check whether the power connection of the charger is normal. The power cord connection should be firm and the power switch should be turned on.

Pay attention to the working environment of the charger. Avoid using it in high-temperature, humid or corrosive gas environments to prevent damage to the charger and affect the accuracy of the self-checking function for faults.

Avoid subjecting the charger to severe vibration or impact to prevent the internal components from loosening or being damaged, which may lead to the failure of the self-check function for faults.

Software update

Pay attention to the software update information of the charger and upgrade the software in a timely manner. Software updates may optimize the self-checking algorithm for faults and improve the accuracy and timeliness of fault detection.

Professional maintenance

If a malfunction of the charger is found during the self-check but cannot be resolved by oneself, professional maintenance personnel should be contacted promptly for inspection and repair. Professional maintenance personnel, with rich experience and specialized tools, can accurately determine the cause of faults and carry out repairs.

Regularly send the charger to a professional maintenance institution for comprehensive inspection and maintenance to ensure that the self-checking function for faults is always in good condition.