Debugging Engineer (Service Engineer)

Role Overview:
We are looking for a hands-on Service Engineer specialized in the repair and maintenance of Electric Vehicle (EV) chargers. The primary responsibility is to diagnose failed EV charging units (returned from the field or warranty) down to the component level, repair power boards and control boards, and restore them to fully functional condition. This role requires deep expertise in power electronics, switching topologies, and communication protocols used in EVSE (Electric Vehicle Supply Equipment).

Key Responsibilities (EV Charger Repair Focus):
1. Component-Level Repair: Diagnose and repair faulty EV charger PCBs by testing and replacing damaged power semiconductors (MOSFETs/IGBTs), drivers, controllers, and passive components.
2. Power Stage Troubleshooting: Isolate faults in the AC-DC PFC stage and DC-DC converter stage (LLC/Full-Bridge) using oscilloscopes and power analyzers.
3. Communication Troubleshooting: Resolve handshake failures between the EV charger and the vehicle's BMS by debugging CAN 2.0B communication lines, PWM pilot signals (CP/PP), and relay driver circuits.
4. Firmware Recovery/Updates: Flash and update firmware on 32-bit microcontrollers using IDEs or flashing tools to resolve software glitches or bugs reported in the field.
5. Load Testing & QC: Perform functional testing of repaired chargers using resistive load banks and EV simulator tools to ensure output voltage, current, and charging profiles meet specifications before dispatch.
6. Failure Analysis: Conduct Root Cause Analysis (RCA) on repetive failures and prepare detailed repair reports to share with the R&D/Design team for product improvement.
7. Inventory Management: Manage critical spare parts inventory (IGBT modules, gate drivers, capacitors, connectors) required for repairs.

Required Technical Skills (Must-Have for Repair)
1. Power Semiconductor Diagnostics:
a. Hands-on experience testing and replacing Power MOSFETs, IGBTs, Schoky Diodes, and BJTs using DMMs and component testers. Ability to check gate drive signals and switching waveforms.
2. Power Topology Knowledge (for tracing faults):
a. Must be able to read schematics and trace faults specifically in Flyback (aux supply), Half-Bridge, Full-Bridge, and LLC resonant converters.
3. Battery & Charging Profiles:
a. Deep understanding of CC/CV (Constant Current / Constant Voltage) and mulƟ-stage charging profiles to verify correct output behavior for Lead Acid, Li-ion, and LiFePO4 baƩeries when tesƟng repaired units.
4. CommunicaƟon Protocols (EV-Specific):
a. Expert in troubleshooƟng AutomoƟve CAN 2.0B (physical layer and data packets).
b. Knowledge of I2C, SPI, and RS485 for interfacing with internal sensors, displays, and metering ICs on the charger board.
5. Industry Safety Standards:
a. Awareness of safety clearance, creepage, and isolaƟon requirements as per UL, BIS, IEEE, IEC, and FCC standards to ensure repaired units pass safety cerƟficaƟon checks.
6. Test & Measurement Equipment:
a. Heavy proficiency in using:
o Oscilloscope (for switching node waveforms and ripple measurements)
o Power Analyzer (for efficiency and input/output power measurement)
o Logic Analyzer (for digital communicaƟon decoding)
o MulƟmeter, Clamp Meter, and Isolated DC Power Supplies