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Solution


5630106082 - KIT REWORK BUSBAR RELAY [UFC200]

3479216300  -  MID Seal Plastic Binder

- select only if charger is equipped with MID Metering 

- choose quantity based on the amount of DC charging outputs 

 

IMPORTANT NOTE

Rework is done only on the CCS connectors, do NOT replace copper bars on the CHAdeMO side.

Figure 1. Parts which is the kit consisting off

1. Turn OFF the external power supply.

2. Check if no vehicle is plugged into any of the charging points and that there is no risk of voltage back feed. 

3. Open the left and right-side doors and lock them in place with their door latches.

4. Turn the charger off with the RCBO1 and pull out the main fuses from holders on the input.

5. Locate the Relays and busbars to be replaced - K11 and K14 CCS relays and busbars connected to it

6. Disconnect 2 wires marked as "DC+PU9-10" and "DC+PU11-12"

7. Disconnect the HV fuses from both positive polarity copper bars that are supporting the CCS charging sessions 

8. Dismantle the copper bars installed on the top of the relay K11 and K14

9. Replace Relay K11 and K14 for the ones from the kit

10. Place the new copper bars on the position of previous busbars and tighten the screws back with a torque rating mentioned in Figure Nr. 3

11. Install back the HV fuses on both new thicker copper bars

12. Place the heatsink on the top of the busbar as shown in Figure Nr. 2, tightening torque rating is 10Nm

13. Previously disconnected 2 wires marked as "DC+PU9-10" and "DC+PU11-12" must be connected to the busbar next to relays K11 and K14 (NOT the original position)

14. Make sure that all of the screws and bolts are properly tightened

15. Do the charging test

Figure 2. Detail of how the busbars are installed

Figure 3. Torque ratings 

 

 
 
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Delta, founded in 1971, is a global provider of power and thermal management solutions. Its mission statement, "To provide innovative, clean and energy-efficient solutions for a better tomorrow," focuses on addressing key environmental issues such as global climate change. As an energy-saving solutions provider with core competencies in power electronics and automation, Delta's business categories include Power Electronics, Mobility, Automation, and Infrastructure.
Keywords: rework, retrofit, kit, charger, UFC 200, distribution, change, update