1 Control Power Verification Procedure
1.1 Pre-Measurement PrepAration
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Power Down:
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Turn OFF CP circuit breaker
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Connect all plugs on:
• Main PCBs (P1, R1, B1, E1, E2, Z1)
• DC-DC power units
• Optional function modules (if equipped)
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Power Up Sequence:
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Close switches/breakers listed in Table 1
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Turn ON CP breaker
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Measure voltages at designated test points
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2. Control Power Standards
2.2 DC Power Circuits
| Circuit | Breaker | Test Point | Standard | Tolerance | Signal Name |
|---|---|---|---|---|---|
| Brake System | CR1 | T2-15 ~ T2-13 | DC125V | ±5% | 79-1 ~ 00 |
| P1 Board Supply | CR2 | T2-06 ~ T2-13 | DC51V | ±5% | 420 ~ 400 |
| Safety Loop | CR3 | T2-17 ~ T2-13 | DC125V | ±5% | 79-2 ~ 00 |
| Car Top Station | CST | T2-01 ~ T2-13 | DC200V | ±5% | C200 ~ C00 |
| Hall Station | HST1 | T2-18 ~ T2-13 | DC125V | ±5% | H79 ~ H00 |
| Inverter Main | — | DCP ~ DCN | DC630V | 610-630V | — |
| Battery Charge | — | C1D-P01 ~ C1D-P03 | DC52V | ±5% | BP_PW ~ B00 |
2.3 Switchboard Power Supply
| Output | Connector | Pin | Standard | Tolerance |
|---|---|---|---|---|
| -12V | P1 POWIN | P01-P04 (-12V~GND) | DC-12V | ±10% |
| +12V | P1 POWIN | P03-P04 (+12V~GND) | DC+12V | ±10% |
| +5V | P1 POWIN | P05-P04 (+5V~GND) | DC+5V | ±5% |
2.4 AC Power Circuits
| Circuit | Breaker | Test Point | Standard | Tolerance | Signal Name |
|---|---|---|---|---|---|
| Fans/Lights | — | T6-01 ~ T6-03 | AC220V | 220-230V | LG1 ~ LG2 |
| Lighting | LIH | LT-07 ~ LT-08 | AC220V | 220-230V | L10D ~ L20D |
| LIGHT | LT-03 ~ LT-04 | AC220V | 220-230V | L10 ~ L20 | |
| PL | LT-05 ~ LT-06 | AC220V | 220-230V | L10A ~ L20A |
3 Critical Measurement Notes
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Inverter DC Bus:
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Must stabilize between 610-630V within 30s of power-up
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If <600V: Check rectifier module and pre-charge circuit
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Battery Circuit:
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Verify 52V±5% before connecting batteries
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Low voltage may indicate charger PCB failure
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Safety Loop Voltages:
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79-1/79-2 to 00: Consistent DC125V ensures relay operation
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5% deviation requires immediate investigation
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4 Troubleshooting Voltage Anomalies
| Symptom | Likely Cause | Verification Steps |
|---|---|---|
| DC51V (CR2) out of range | • CR2 breaker contact resistance • P1 board overload | 1. Measure voltage at breaker output 2. Disconnect P1 to isolate |
| +5V exceeding ±5% | • Switchboard regulator failure • Short circuit on P1 | 1. Check POWIN pins for debris 2. Measure current draw |
| AC lighting voltage low | • LIGHT breaker thermal damage • Neutral line corrosion | 1. Thermographic scan of breakers 2. Tighten LT terminal blocks |
5 Maintenance Recommendations
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Quarterly Checks:
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Clean DC bus capacitor vents
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Torque test all power terminals (T2/T6/LT series)
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Annual Procedures:
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Replace electrolytic capacitors over 5 years old
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Calibrate switchboard outputs with reference meter
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Safety Notice:
‼️ Always discharge DC bus capacitors to <30V before servicing (measure DCP-DCN)
