Why Repairing EV Charging Electronics Is Profitable
A 150 kW DC fast charger costs 80,000–220,000 PLN new. Replacing a single IGBT power module or CCS/CHAdeMO controller costs 18,000–45,000 PLN for the part alone. Acore regenerates these components for 2,500–9,500 PLN — with a full 12-month warranty. Every day of downtime for a highway fast charger means 1,500–6,000 PLN in lost revenue for the operator. Acore diagnoses and repairs within 2–7 business days from receipt.
Types of EV Equipment We Repair
1. DC Fast Charging Stations (50 kW – 400 kW)
High-power DC chargers are the most complex and expensive electronics in EV infrastructure. We repair power modules, CHAdeMO/CCS Combo 1 & 2/GB/T communication controllers, power management systems, and network interfaces (OCPP 1.6/2.0.1). Supported brands: ABB Terra HP/DC, Tritium Veefil-RT, Efacec QC45/HV350, BTC Power, Delta Electronics, Schneider Electric EVlink DC, Kempower, Siemens SICHARGE UC.
2. AC Wallboxes (7.4 kW – 22 kW)
Smart AC chargers contain advanced control electronics: EVCP (Electric Vehicle Communication Processor), GFCI modules, smart-charging systems with WiFi/Ethernet/4G and OCPP. We repair: Webasto Next/Live/Lite, Mennekes AMTRON Charge Control 22, ABB Terra AC, Schneider EVlink Home/Pro, Zaptec Go/Pro, Alfen Eve Single/Double, Delta AC Mini, EVBox Elvi/BusinessLine.
3. On-Board Chargers (OBC)
The OBC converts AC grid power to DC for the traction battery. We repair OBC units from: Renault Zoe 22 kW, BMW i3/i5/iX, Hyundai Ioniq 6, VW ID.4/ID.3, Nissan Leaf, Kia EV6, Porsche Taycan. Major OBC suppliers: Brusa NLG664/NLG6, Continental OBC, Vitesco OBC, Valeo SiC OBC 22 kW, Delta Automotive.
4. Industrial Chargers for Forklifts and AGVs
Industrial 24V/48V/80V/96V chargers for lithium and lead-acid batteries. We repair: Fronius Selectiva, Delta-Q IC Series/Quiq, Hoppecke sun|power, Hawker, Zivan NG/TG. Common faults: damaged MOSFET/IGBT transistors, microprocessor controllers, CAN BMS interlock circuits, shunt resistors.
Fault Codes and Common Failures
| Component | Error Code / Symptom | Root Cause | Repair Cost | New Part Cost |
|---|---|---|---|---|
| IGBT Power Module (DC Fast Charger) | FAULT_IGBT_OC, FAULT_DC_BUS_OV | Blown Infineon FF600R12ME4 or Semikron SKM400GB12T4 IGBT | 2,500–5,500 PLN | 18,000–35,000 PLN |
| CCS Combo / CHAdeMO Controller | CCS_COMM_FAULT, PLC_LINK_ERROR, CP_STATE_ERR | Damaged PLC modem (QCA7000/7005), CP pilot signal failure | 1,200–3,500 PLN | 8,000–22,000 PLN |
| PFC Module (Power Factor Correction) | PFC_FAULT, AC_INPUT_FAIL, THD_ERROR | Damaged SiC MOSFETs (Wolfspeed C3M0065090J), PFC diodes, DC-link capacitors | 1,800–4,200 PLN | 12,000–28,000 PLN |
| EVSE / EVCP Controller (wallbox) | ERROR_CP_VOLTAGE, GFCI_TRIP, RELAY_WELD | Damaged STM32/NXP MCU, RCMU sensor fault, welded SSR relay | 600–2,200 PLN | 3,500–12,000 PLN |
| OBC – LLC Converter (vehicle) | OBC_FAULT_OT, OBC_ISO_FAIL, OBC_CAN_TIMEOUT | Damaged SiC GaN LLC transistors, burnt LLC transformer, CAN isolator failure | 1,500–4,500 PLN | 9,000–28,000 PLN |
| Auxiliary LVPS (24V/12V AUX) | AUX_POWER_FAIL, MCU_UNDERVOLTAGE | Failed electrolytic capacitors, LDO regulator, flyback MOSFET | 400–1,400 PLN | 3,000–8,000 PLN |
| OCPP / 4G / Ethernet Communication Module | OCPP_OFFLINE, BACKEND_UNREACHABLE, NETWORK_FAIL | Damaged SIM800/EC21 (Quectel) module, Ethernet PHY chip, eMMC flash failure | 500–1,800 PLN | 2,500–7,000 PLN |
Supported Stations – Full Brand List
ABB Terra HP/DC/AC, Tritium Veefil-RT/PK/DC-X, Efacec QC45/HV350, Kempower T/S-Series, Webasto Next/Live/Lite, Mennekes AMTRON, Zaptec Go/Pro, Alfen Eve, Schneider EVlink, Delta Electronics, Siemens SICHARGE UC/D, Wallbox Pulsar/Supernova, EVBox Elvi/BusinessLine, ChargePoint CPF50, Blink IQ 200, Tritium Pilot, BTC Power 50/150, EFACEC QC200 Ultra.
Downtime Economics
| Station Location | Sessions/day | Revenue/day | 7-day downtime loss | Acore repair time |
|---|---|---|---|---|
| Motorway service area (150 kW) | 80–150 | 4,000–8,000 PLN | 28,000–56,000 PLN | 3–5 days |
| Shopping centre (50 kW) | 25–60 | 1,200–3,000 PLN | 8,500–21,000 PLN | 2–4 days |
| Hotel parking (22 kW) | 10–20 | 300–700 PLN | 2,100–4,900 PLN | 2–3 days |
| Logistics fleet depot | 30–80 vehicles | 3,000–12,000 PLN | 21,000–84,000 PLN | 1–3 days |
FAQ
- How much does repairing a 150 kW DC power module cost?
- Repair of an IGBT 150 kW module at Acore costs 2,500–5,500 PLN. A new module from ABB/Tritium/Kempower costs 18,000–45,000 PLN — a saving of up to 88%. Turnaround: 3–5 business days from receipt.
- Can a wallbox be repaired after a lightning strike or power surge?
- Yes — surges typically damage: the GFCI circuit, WiFi/Ethernet communication module, EMC capacitors, and auxiliary voltage regulators. Post-surge wallbox repair typically costs 600–2,200 PLN. Turnaround: 1–2 days.
- Do you repair on-board chargers (OBC) fitted in electric vehicles?
- Yes — we repair OBC from Renault Zoe, BMW i3/i5, VW ID.3/ID.4, Hyundai Ioniq 5/6, Kia EV6. Most common fault: OBC_FAULT after thermal runaway or grid voltage spike. Repair cost: 1,500–4,500 PLN.
- What does CP_STATE_ERR / CP_VOLTAGE_ERROR mean on an ABB Terra station?
- This error indicates incorrect voltage on the Control Pilot (CP) signal per IEC 61851. Root cause: damaged EVCP controller, burnt 1kΩ CP resistor, state A/B/C/D/E/F detection circuit failure. Repair: 1,200–2,800 PLN.
- Do you support OCPP 2.0.1 and ISO 15118 Plug and Charge?
- Yes — we support all OCPP versions (1.5, 1.6J, 2.0, 2.0.1) and ISO 15118-2 including Plug and Charge (PnC) and V2G. We also perform firmware updates if the controller is on an outdated version.
- Do you offer on-site diagnosis for failed charging stations?
- On-site service within 30 km (Knurów, Gliwice, Rybnik, Tychy, Zabrze) is available within 1–2 business days, Mon–Fri 8:00–16:00. For more distant locations we coordinate courier pickup of the module.