ABB

ABB — field brand hub

ABB DCFC tickets in this corpus cluster on Terra 54 (dual-standard CCS/CHAdeMO) and Terra 184 (higher power, liquid-cooled). Both speak OCPP to whatever CSMS the site runs; HMI strings and ABB Connected Services still matter for board-level work. Name the family and the gun before you condemn a power module.

When this OEM shows up / cabinet vs dispenser

Terra 54 is a compact dual-standard package: CCS and often CHAdeMO share the cabinet. Faults that hit only CHAdeMO while CCS stays Available are connector/CAN/lock path — not a full power-stage condemnation. Terra 184 separates high-power modules and cooling more clearly; cable/coolant issues can look like “module fault” until you prove flow and isolation.

Gun / SECC / latch side: CCS latch fail, CHAdeMO no-start, isolation at CableCheck, temp sensor open on the connector path.

Power / cooling / grid side: coolant flow low, power module imbalance, grid undervoltage, OCPP disconnect under peak load, energy register anomalies.

HMI / controller side: frozen Fault banner, boot loop after FW flash — often recoverable without module RMA if you preserve logs first.

Photograph the display code, connector number, and whether the peer gun still works before opening covers. Do not condemn a power module because CableCheck failed once in the rain. On dual-standard pads, always record which gun faulted — see /guides/chademo-legacy and /guides/ccs-handshake-basics.

How faults typically present

HMI

• Terra fault banner + service-menu code (ABB-T54-* / ABB-T184-*).
• HMI frozen on Fault while Controllers still heartbeat to Connected Services — photograph before reboot.
• Boot loop after flash: do not keep power-cycling; capture version and USB/log dump if entitled.

OCPP / Connected Services

• StatusNotification Faulted with ABB vendorErrorCode / info — log verbatim.
• Peak-hour OCPP disconnect with energy still flowing briefly, then stall Unavailable: backhaul or modem path, not always a power module.
• Energy register jump: metering path — separate from isolation (/guides/metering-payment).
• Heartbeat alive with stale Faulted status: use /guides/ocpp-faulted-triage.

Physical cues

• Latch not seating, glycol at holster (184), CHAdeMO lock motor noise, water at cable glands, E-stop daisy-chain chatter.

Ranked common failure patterns

Terra 54

1. Isolation error before charge — Cable/gun IR, wet connectors, or true bus isolation. Swap known-good cable before stack RMA. Entry: /entries/abb-abb-t54-iso-isolation-error-before-charge. Stage map: /entries/protocol-ccs-h03-cable-check-isolation-fail.

2. CCS connector latch fail — Debris, bent latch, actuator, or feedback. Prove cable + vehicle before SECC board swap. Entry: /entries/abb-abb-t54-ccs-ccs-connector-latch-fail. If latch is fine but SLAC dies: /entries/protocol-ccs-h01-ccs-slac-timeout, /entries/protocol-ccs-h02-sdp-failed-secc-not-responding.

3. CHAdeMO side no start — Lock, CAN, or vehicle profile; do not swap CCS parts for CHA codes. Entry: /entries/abb-abb-t54-cha-chademo-side-no-start. Related: /entries/protocol-cha-h01-chademo-can-timeout, /entries/protocol-cha-h02-chademo-connector-lock-fail.

4. Grid undervoltage trip — Upstream PQ / feeder before module blame. Idle voltage lies — measure under load. Entry: /entries/abb-abb-t54-grid-grid-undervoltage-trip. Guide: /guides/site-power-quality-basics.

5. HMI frozen on Fault — Soft hang; pull Connected Services event first, then controlled reset per OEM. Entry: /entries/abb-abb-t54-hmi-hmi-frozen-on-fault. Stuck Faulted after reboot: /entries/protocol-ocpp-f01-statusnotification-stuck-faulted-after-reboot.

6. Boot loop after FW flash — Incomplete flash, media, or config; preserve logs for OEM. Entry: /entries/abb-abb-t54-fw-boot-loop-after-fw-flash.

7. Temp sensor open circuit — Harness/connector before condemning thermal plant. Entry: /entries/abb-abb-t54-sens-temp-sensor-open-circuit.

Terra 184

1. Coolant flow low — Filter, airlock, pump, sensor spoof (flow=0 with pump audible). Never run the pump dry “for a minute” to test. Entry: /entries/abb-abb-t184-cool-coolant-flow-low. Guide: /guides/liquid-cooling-loops. Airlock after fill: /entries/site-generic-cool-air-airlocked-loop-after-fill.

2. Power module imbalance — Confirm which stage and current-share before full bank swap. Entry: /entries/abb-abb-t184-pm-power-module-imbalance.

3. OCPP disconnect after peak — Cellular/Ethernet under load; prove RSSI and CSMS path. Entry: /entries/abb-abb-t184-com-ocpp-disconnect-after-peak. Related: /entries/protocol-ocpp-f02-heartbeat-timeout-to-csms, /entries/protocol-net-c01-dns-resolution-failure-to-csms.

4. E-stop loop intermittent — Loose mushroom, daisy-chain aux, moisture in enclosure. Entry: /entries/abb-abb-t184-estop-e-stop-loop-intermittent.

5. Energy register jump — Meter CRC / mid-meter path, not isolation. Entry: /entries/abb-abb-t184-met-energy-register-jump. Related: /entries/protocol-met-01-energy-meter-crc-error.

Log sources / tools

Source	What you pull
Terra HMI / service menu	Fault banner, gun ID, coolant/flow, module map
ABB Connected Services	Event timeline, FW, serial
OCPP CSMS	StatusNotification, MeterValues, Heartbeat gaps
IR gun / DMM / megger	Latch heat, PE, IR, phase voltages
Known-good CCS / CHAdeMO cable	Moves fault with cable vs stack

For cooling tickets: level, pressure/flow, pump run sound, and photos of fittings after any cable swap. Insulation testing only inside OEM procedure and LOTO.

Field checklist (first 15 minutes)

1. Photo HMI + connector ID + peer gun status.
2. Terra 54 or Terra 184? One gun or whole cabinet?
3. Weather / recent cable or coolant work?
4. Pull OCPP StatusNotification for the stall window.
5. If ISO/CCS: dry + known-good cable before opening HV.
6. If cooling (184): level, leaks, filter, pump sound — then bleed procedure.
7. If soft-offline: ping path to CSMS, DNS, cert dates — not antenna first.

When to escalate

Electrician / site power — Undervoltage / phase events matching Terra grid codes; feeder or transformer issues during multi-stall peaks; E-stop daisy-chain or fire-panel inhibit outside the cabinet.

Network / CSMS — Peak OCPP disconnects with healthy power stage; wrong chargePointIdentity / URL after board work; meter discrepancies that are host/CSMS mapping, not hardware; Authorize rejects with healthy energy path (/entries/protocol-ocpp-f03-authorize-rejected-invalid-idtag).

ABB OEM — Confirmed module imbalance after share/grid proven; coolant pump/sensor with OEM fill procedure already followed; boot-loop / FW latch with Connected Services package attached; SECC/latch actuator confirmed after known-good cable and vehicle.

Do not escalate “CHA no start” as a CCS latch RMA, or coolant flow low as a module imbalance without flow evidence. Payment-only failures belong to the PED/billing stack, not the Terra power stage (/entries/ingenico-pay-to-payment-terminal-timeout).