Replace charge controller (Wall V4)

Version

Revision 1

Used in

Serial number starts with 6240 or 6241

Parts needed

EV-PCB-CONTROLBOARD-1

Tools needed

Hex 7
Small flat screwdriver
Flat screwdriver
Hex 8
Cutting pliers
Allen 2.5

Charger Overview

Charger overview

Replacement Instructions

Untighten the 2 nuts at the back of the front plate and remove the front plate Place the front plate aside [Hex 7]
Disconnect the CP and PP line of the socket to the relay board. Push in the openings of the connector to release the ferrules. [Small flat screwdriver]
Disconnect the solenoid wires from the relay board. Push in the openings of the connector to release the ferrules. The red and black wire coming from the power supply (between CP/PP connector and solenoid connector) do NOT need to be disconnected [Small flat screwdriver]
Disconnect the phases, PE and neutral cables of the socket to the relay board Push in the openings of the charging controller to release the ferrules. [Flat screwdriver]
Disconnect the cable from the display board Connector is very fragile, pay attention not to damage it.
Remove the right panel from the casing - untighten the 2x M4 locknuts (no need to fully remove them). Panel fits into 2 slots on the casing so it needs to be pivoted to be removed. Be careful not to damage the electronics while untightening the top locknut. [Hex 7]
Release the MID from the DIN rail mounting : Insert a small screwdriver in the bottom hook and pull the hook downwards. MID can be removed from DIN rail mounting by rotating the MID, first releasing bottom side and then top side. Removing MID from DIN rail will allow reaching the charge controller board. Pay attention not to force/damage any cables from MID during the operation. [Small screwdriver]
Disconnect the antenna from the charge controller. Disconnect the Wifi and 4G cables from the charge controller. [Hex 8]
Disconnect the display board cable (2x 7p) from the charge controller
Cut the cable tie holding the cables together on the side of the MID. [Cutting pliers]
Disconnect the 12P relay board cable from the charge controller
Disconnect the LED cable from the charge controller
Remove the charge controller from the casing : Untighten the 4x M4 screws. Replace by the new charge controller and retighten the 4x M4 screws. [Allen 2.5 - Torque : 2.5 N.m]
Reconnect the LED cable
Place the MID back onto the DIN rail. Start by placing the top side of the MID; then rotate the DIN rail downwards and push the hook at the bottom of the MID towards the DIN rail with a small screwdriver. [Small screwdriver]
Reconnect the 2x7p display cable onto the charge controller
Reconnect the 12p connector onto the charge controller
It is recommended to reuse a tie wrap to secure the different cables together (leave out the antenna cables which is the most fragile)
Reconnect the antenna. Start with the Wifi cable (left side) and assemble the 4G cable afterwards (right side) - 4G cable is marked with the mention “LTE” Be careful during assembly, connectors are very fragile. [Hex 8 - Torque : 1.5 N.m]
Place the panel back into the unit and retighten the 2x M4 locknuts. [Hex 7 - Torque : 2.5 N.m]
Reconnect the display board. Connector is very fragile, pay attention not to damage it; when connected it cable side should hook onto the connector from the board.
Connect the solenoid wires to the relay board following the colour code (blue, red, yellow, white). Start from the back of the casing (blue wire). Wires just need to be pushed in the connector Check all cables are properly secured.
Connect the CP & PP line from the socket to the charging controller by pushing them in the connector (follow CP and PP mention on the relay board) Check all cables are properly secured.
Connect the phases, PE and neutral wires from the socket to the relay board by pushing them in the connector. Sequence from bottom of the unit to top is PE (yellow, neutral (blue), L3 (grey), L2 (black), L1 (brown) Check all cables are properly secured. When done, place the cables so they don’t prevent closing of the unit.
Place back the front panel and retighten the 2 nuts of the front plate [Hex 7]