EV Charging Stations - Planned Preventative Maintenance - Must Know

EV Charger Planed Preventative Maintenance (PPM)

With the rapid increase of electric vehicles in Western Australia, EV charging stations are becoming a crucial part of many business operations. While these installations represent valuable infrastructure, maintenance best practices are still evolving as the technology becomes more widespread. We are finding a number of EV charges are functioning out of spec or not at all and as such provide the following guidance for maintaining your systems.

Understanding Your EV Charging Station

EV charging stations are relatively sophisticated electrical equipment operating under demanding conditions. Unlike traditional electrical installations, these units handle high power transfers, complex communications, and frequent connection/disconnection cycles. Understanding the basic signs of deterioration can help prevent unexpected downtime.

Why should you implement an EV Charger Planned Preventive Maintenance Routine?

A well-maintained charging station will:

• Operate more efficiently

• Have a longer service life

• Provide consistent charging speeds

• Maintain safety compliance

• Reduce unexpected downtime

 Planned Preventative Maintenance ensures that routine tasks are done when required.

Basic Inspection Guide – EV Charger Checks by the Owner/Operator

While professional testing requires qualified electricians, regular visual inspections are valuable and may provide early intervention for issues as they arise. We recommend that customers create a weekly checklist covering the following non-intrusive checks.

NOTE: Do not open covers or remove inspection hatches that may expose internal equipment.

Physical Inspection

• Check cables for wear or damage

• Inspect connector condition and ensure no damage is present

• Verify housing integrity

• Check display functionality

• Monitor indicator lights

Operational Checks

• Record typical charging durations

• Monitor successful connection rate

• Document any error messages

• Observe charging behavior

• Check emergency stop function

Environmental Factors

• Clear surrounding debris, rubbish or build up

• Ensure adequate ventilation

• Check drainage patterns

• Inspect weather protection and look for signs of water ingress

• Monitor nearby vegetation

Detailed Inspection – Professional EV Charger Preventative Maintenance

A professional testing routine completed by a licensed electrical contractor remains essential for safety and compliance. We recommend a preventative routine at least once a year. LECE provides comprehensive testing and maintenance services, with the help of our Fluke FEV300 EV Charging Station Test Adapter, we:

• Test for possible presence of dangerous voltage to earth

• Perform Cable Simulation simulating current capabilities of charging cables

• Perform Vehicle Simulation testing various charging states

• Simulate PE error (Earth fault)

• Test in accordance with ASNZS 3000:2018, AS/NZS 3760:2010, IEC TS 61439-7, IEC/EN 61851-1 and IEC/HD 60364-7-722

• Check the IP integrity of the cabinet

• Clean/remove debris dust and contaminants

• Test RCDS

• Thermographic inspection of internal equipment

Regular maintenance isn't just about preventing failures - it's about protecting your investment, ensuring public safety, and continuing reliable service for your customers or staff.

When should you get professional assistance?

Early warning signs may indicate and situations that may require immediate professional attention:

• Repeated circuit breaker trips

• Significant performance reduction

• Persistent error messages

• Visible equipment damage

• Unusual operational sounds or odors

• Following severe weather events

• After any electrical incidents

• Decreased charging speeds

• Intermittent charging failures

• Unexpected error messages

• Unusual operational sounds

• Physical damage to cables or connectors

• Overheating during charging sessions

• Circuit breaker trips

• Communication failures

Professional Support

Remember. We strongly recommend inspection at least once every 12 months.

When was yours last tested?

For expert assistance or to arrange a professional inspection, contact LECE at service@lecegroup.com.au or (08) 9477 3894.

References

-       AS/NZS 3000:2018 (Wiring Rules)

-       AS/NZS 51769:2019 (Electric Vehicle Supply Equipment)

-       https://www.fluke.com/en-au/product/electrical-testing/installation-testers/fev300#