S1B /2011. EVlink - QC. Electric Vehicle Quick Charging Station Installation Manual 09/2011 S1B

Transcription

1 EVlink - QC S1B /2011 EVlink - QC Electric Vehicle Quick Charging Station Installation Manual 09/2011 S1B

2 The information provided in this documentation contains general descriptions and/or technical characteristics of the performance of the products contained herein. This documentation is not intended as a substitute for and is not to be used for determining suitability or reliability of these products for specific user applications. It is the duty of any such user or integrator to perform the appropriate and complete risk analysis, evaluation and testing of the products with respect to the relevant specific application or use thereof. Neither Schneider Electric nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information contained herein. If you have any suggestions for improvements or amendments or have found errors in this publication, please notify us. No part of this document may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission of Schneider Electric. All pertinent state, regional, and local safety regulations must be observed when installing and using this product. For reasons of safety and to help ensure compliance with documented system data, only the manufacturer should perform repairs to components. When devices are used for applications with technical safety requirements, the relevant instructions must be followed. Failure to use Schneider Electric software or approved software with our hardware products may result in injury, harm, or improper operating results. Failure to observe this information can result in injury or equipment damage Schneider Electric. All rights reserved. 2 S1B /2011

3 Table of Contents Safety Information About the Book Chapter Overview of EVlink Quick Charging Stations Technical Characteristics Access to the Charging Station Compartments Installing the Charging Station Connecting the Charging Station Commissioning Troubleshooting Assistance Protecting the Environment S1B /2011 3

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5 Safety Information Important Information NOTICE Read these instructions carefully, and look at the equipment to become familiar with the device before trying to install, operate, or maintain it. The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure. PLEASE NOTE Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material. A qualified person is one who has skills and knowledge related to the construction and operation of electrical equipment and its installation, and has received safety training to recognize and avoid the hazards involved. S1B /2011 5

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7 About the Book At a Glance Document Scope The purpose of this manual is to describe and explain the following operations relating to quick charging stations: Installing the quick charging station Electrical connection Commissioning Troubleshooting assistance This manual is aimed at installers of quick charging stations. NOTE: Commissioning the bank card pay station is not described in this document. For information about this, please contact Schneider Electric, who supply the charging station. Validity Note This manual is valid for quick charging stations and their catalog numbers are listed in the table below. Quick charging stations differ according to: Their Human Machine Interface (HMI) Their user identification system Their Ethernet communication system Catalog Numbers Human Machine Interface User Identification Ethernet Communication QC001 Touch screen Wired QC002 Screen + keypad Wired QC003 Touch screen Wired + wireless QC004 Screen + keypad Wired + wireless QC005 Touch screen RFID tag Wired QC006 Screen + keypad RFID tag Wired QC007 Touch screen RFID tag Wired + wireless QC008 Screen + keypad RFID tag Wired + wireless QC009 Touch screen Bank card Wired QC010 Screen + keypad Bank card Wired QC011 Touch screen Bank card Wired + wireless QC012 Screen + keypad Bank card Wired + wireless Related Documents Title of Documentation EVlink - Installation conditions for charging stations EVlink specific to each electric vehicle manufacturer Instruction sheet Site configuration - EVlink QC Instruction sheet Receipt, Handling, Storage - EVlink QC Reference Number DOCA0007 S1B54009 S1B54010 You can download these technical publications and other technical information from our website at User Comments We welcome your comments about this document. You can reach us by at techcomm@schneider-electric.com. S1B /2011 7

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9 EVlink - QC Quick Charging Station Installation Manual S1B / What s in this Chapter? This chapter contains the following topics: Topic Page Overview of EVlink Quick Charging Stations 10 Technical Characteristics 15 Access to the Charging Station Compartments 16 Installing the Charging Station 19 Connecting the Charging Station 23 Commissioning 26 Troubleshooting Assistance 28 Protecting the Environment 33 S1B /2011 9

10 Overview of EVlink Quick Charging Stations Introduction Users of electric vehicles may need to recharge their vehicle s battery very quickly. The 50 kw charging power of EVlink quick charging stations allows compatible vehicles to be recharged in less than 20 minutes. Depending on the options selected, EVlink quick charging stations offer the following functions: User-charging station dialog: touch screen or screen with keypad for displaying the residual charge and the recharging setpoint Charging management: Socket locked during charging Emergency stop button Data transmission: Wired connection (Ethernet TCP/IP) or wireless connection for transmitting data concerning operation, status, activation/deactivation of the charging station, etc. Bank card pay station, adapted to suit different countries Authorized user RFID tag reader: management of the list of authorized users by a remote server Description of DC Quick Charging Stations A 120 A DC socket B Wireless communication antenna (depending on the catalog number) C Human Machine Interface (HMI) (see details on next page) D Control compartment E Power compartment F Emergency stop button G Pedestal 10 S1B /2011

11 Description of the Human Machine Interface The various HMI parts are shown in the diagrams below. HMI Touch screen HMI Touch screen With RFID tag reader HMI Touch screen With bank card pay station HMI Screen + keypad HMI Screen + keypad With RFID tag reader HMI Screen + keypad With bank card pay station A LCD touch screen B RFID tag reader C Bank card pay station screen + keypad D Bank card reader E Paper roll access flap lock F Ticket exit slot G Button to go back to the welcome screen H LCD screen I Context-sensitive navigation buttons S1B /

12 Description of the Control Compartment The control compartment is accessed via the side doors of the quick charging station. For more information, see the procedure illustrated in (see page 16). The control compartment parts are shown in the diagram below. The charging station shown here includes a bank card pay station and a wireless communication module. A Wireless communication module (depending on the catalog number) B PLC C Ethernet gateway D Removable terminal blocks for the power compartment fans E Bank card pay station (depending on the catalog number) F Bank card pay station printer (depending on the catalog number) G Document holder containing the wiring diagrams H Metering panel with energy meter (depending on the catalog number) I Power connection block J Main switch K Control connection block L Surge arrester M Earthing braid connection block 12 S1B /2011

13 Description of the Power Compartment The power compartment is accessed via the back of the quick charging station by removing 2 panels. For more information, see the procedure illustrated in (see page 17). The power compartment parts are shown in the diagram below. A DC charging cable outlet B Smoothing capacitor C Converter compartment heating and ventilation thermostat D Converters E Toroidal chokes F Control compartment G DC power supply protection MCBs H Transformer compartment ventilation thermostat I Isolation transformer J Anti-harmonic filter S1B /

14 Weight and Dimensions Quick charging stations weigh between 600 and 700 kg depending on the catalog number. 14 S1B /2011

15 Technical Characteristics Environmental Characteristics Characteristic Value Degree of protection IP IP54 Degree of protection IK IK10: charging station IK3: Human Machine Interface Operating temperature -30 C to +50 C Line Supply Characteristics Characteristic Value Connection 400 V AC 3P + neutral Frequency Hz +/- 10% Earthing system TT or TN Power 58 kva Power factor > 0.95 THDI < 13% DC Charging Station Characteristics Characteristic Value Maximum output current 120 A DC Maximum output voltage 500 V DC Maximum output power 50 kw Communication protocol CHAdeMO Connection socket Yazaki 120 A Charging mode Mode 4 according to IEC Certification marking Complies with IEC 61851, Electric vehicle conductive charging system (IEC and IEC ). Complies with IEC 62196, Plugs, socket-outlets, vehicle couplers and vehicle inlets - Electric vehicle conductive charging system (IEC and IEC ). Complies with IEC 61439, Low-voltage switchgear and controlgear assemblies (IEC and IEC ). Complies with CHAdeMO protocol. Complies with European Directive 1999/5/EC (charging station with optional RFID tag reader). S1B /

16 Access to the Charging Station Compartments Access to the Control Compartment Use the keys supplied with the charging station to open the control compartment: A Bespoke key for the outer door. B Standard key for the inner door. 16 S1B /2011

17 Access to the Power Compartment DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Turn off all power supplying this equipment before working on the equipment. Always use an appropriate voltage detection device to confirm the absence of voltage. Failure to follow these instructions will result in death or serious injury. 2 panels weighing around 15 kg each must be removed in order to gain access to the power compartment. S1B /

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19 Installing the Charging Station Preparation Before installing the quick charging station, check the following points: All site configuration work has been completed and the charging station base (catalog number VNSCHN100007) is in place. For more information, please refer to the Instruction sheet Site configuration - EVlink - QC (catalog number S1B54009). The charging station has been unpacked, with the charging cable socket plugged into its outlet. For more information, please refer to the Instruction sheet Receipt, handling, storage - EVlink - QC (catalog number S1B54010). Running Cables in Sheaths Run the cables in sheaths as shown in the diagram below: Item Sheath for Minimum Sheath Diameter Cable Characteristics Minimum Cable Length A Power cable 110 mm 5 x 35 mm² copper minimum (cross-section to be defined a/c to cable length) + Unsheathed 25 mm² copper braid for interconnecting mechanical earths 0.5 mm B Control cable 40 mm 7 x 2.5 mm² (cable obligatory if a remote emergency stop is used) C Communication cable 40 mm Ethernet cable Telephone cable for the bank card pay station (depending on the catalog number) 0.5 mm 3 m S1B /

20 Installation Procedure for the Charging Station Step Action 1 Release the charging station from the transport pallet: 1 and 2 Remove the plastic covers from all 4 corners of the charging station. 3 Undo all 4 M10 screws fixing the charging station to the transport pallet. 2 Clear the passages in the charging station pedestal for handing with a forklift truck: 1 Undo all 4 screws fixing the front and rear fascia strips to the charging station pedestal. 2 Take off the front and rear fascia strips. 3 Open the control compartment (see page 16). 20 S1B /2011

21 Step Action 4 Remove the cable gland plate to free up space for the cable sheaths when installing the charging station on its base. 5 Close the control compartment. 6 Lift the charging station with a forklift truck, setting the forks to their maximum spread because the center of gravity A of the charging station is eccentric. 7 Position the charging station on the base frame. S1B /

22 Step Action 8 Fix the charging station on the base frame with the 4 x M10 nuts and washers supplied. 9 1 Replace both charging station pedestal fascia strips. 2 Tighten all 4 screws fixing the front and rear fascia strips to the charging station pedestal. 3 and 4 Replace the plastic covers on the charging station feet. 10 Open the control compartment to replace the cable gland plate. For all information concerning the charging station, please refer to the relevant section (see page 23). 11 Close the control compartment. 22 S1B /2011

23 Connecting the Charging Station Upstream Protection of the Charging Station Power Circuit The charging station power circuit must be protected upstream by: A thermal-magnetic MCB rated 125 A curve D A 300 ma RCD rated 125 A type A Connection in the Control Compartment All the charging station connections are made in the control compartment. Wiring Diagram You can find the charging station wiring diagram in the document holder located in the control compartment. Please refer to it when connecting the charging station. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Wear suitable personal protective equipment and follow the currently applicable electrical safety instructions. Only qualified personnel can install and maintain this equipment. NEVER work alone. Turn off all power supplying the charging station before working on it. Check that all current and voltage sources have been disconnected before carrying out visual inspections, testing or maintenance work on this equipment. Before closing the doors and refitting the casing, carefully inspect the working area to ensure that no tools or other items have been left inside the equipment. Always use a properly rated voltage sensing device to confirm that all power is off. If this equipment is to remain in good working order it must be installed, handled and operated correctly. Failure to follow basic installation instructions can lead to injury and can damage the charging station. Failure to follow these instructions will result in death or serious injury. S1B /

24 Connection Blocks A B C Power terminal block Earthing braid Control terminal block Power terminal block connection characteristics: Stripping length: 10 mm Stranded cable without cable end with a cross-section of 35 mm² Tightening torque: N m Tool required: size 6 Allen key Control terminal block connection characteristics: Stripping length: 8 mm Stranded cable without cable end with a cross-section of 2.5 mm² Tightening torque: N m Tool required: 2.5 flat screwdriver Power Terminal Block The 5 x 35 mm² minimum power cable (cross-section to be defined a/c to cable length) is connected to the XP terminal block at the bottom of the control compartment. Power Terminal Block Marking XP1 XP2 XP3 XP4 XP5 Terminal Assignment N L1 L2 L3 NOTICE COMPLY WITH THE PHASE ROTATION ORDER Connect the power cable in accordance with the charging station wiring diagram to ensure the phase rotation order is as indicated. Check the phase rotation order with an appropriate tool. Failure to follow these instructions can result in equipment damage. 24 S1B /2011

25 Earthing Braid Use a 25 mm² unsheathed copper earthing braid to connect the mechanical earths. The earthing braid has a pierced cable lug to allow passage of a screw. The braid is fixed to the control compartment frame. Control Terminal Block The control connections are connected to the XB terminal block at the bottom of the control compartment. Control Terminal Block Marking XB11-XB12 XB13-XB14 XB15-XB16 Terminal Assignment Remote emergency stop Remote emergency stop Reserved The control terminal block is used to connect an emergency stop button with 2 NC (normally closed) contacts. Ethernet Communication Cable The Ethernet communication cable is connected directly to the Ethernet switch. It must have a category 6 RJ45 connector. It must be at least 3 m long in the charging station so it can reach the Ethernet switch using the existing trunking. Communication Cable for the Bank Card Pay Station (Depending on the Catalog Number) For charging stations with a bank card pay station, the telephone cable must be linked to the pay station. The telephone cable must have a category 6 RJ11 connector. It must be at least 2 m long in the charging station so it can reach the pay station using the existing trunking. For more information about the bank card pay station, refer to the corresponding manufacturer documentation. S1B /

26 Commissioning Commissioning Procedure The steps below describe how to commission the charging station. Each step is listed below. Step Description 1 Control compartment checks 2 Plugging the charging cable socket into its outlet 3 Power-up Control Compartment Checks Turn ON all protection devices. Retrieve the charging station wiring diagram from the document holder. Socket Outlet Check Plug the charging cable socket into its outlet before powering up the charging station. Refer to the socket usage label. The socket outlet indicator lights up when the socket is locked. NOTE: The socket outlet is locked when the charging station is powered up. To unlock the socket outlet, turn off all power supplying the charging station. Power-Up Step Action 1 In the control compartment: Close all the MCBs. Activate the main switch: The charging station is energized, the self-test sequence starts. 2 On the front of the charging station, check that the screen shows the self-test sequence is running correctly: The self-test sequence lasts about 30 seconds. 3 At the end of the self-test sequence, if all the tests are successful, the next page is displayed for 10 seconds: 4 The welcome page is then displayed: the charging station is ready for operation. 26 S1B /2011

27 Step Action 5 If a problem is detected during the self-test sequence, a message is displayed on the screen. Consult Troubleshooting Assistance (see page 28). S1B /

28 Troubleshooting Assistance Information Available to the Repairer The available information is in the form of HMI fault page messages, on the front of the charging station. If necessary, get in touch with your Schneider Electric contact. Fault Page The fault page displays faults detected by the charging station. The fault page is exited Automatically, reverting to the welcome page if there is no longer a fault Manually, by pressing the Back button. A fault message consists of the following information, presented in the form of a table: Column Description Message Describes the fault if it is a touch screen Fault number if it is a screen with keypad See the list of faults (see page 29). Date Date the fault occurred Time Time the fault occurred Access to the Fault Page The table below shows the pages from which you can access the fault page, depending on the type of charging station. Page Charging Station with Touch Screen Charging Station with Screen and Keypad Failure of self-tests Press Restart tests. Welcome Press the Restart button. Charging station out of order Press the top left-hand corner of the screen for 5 seconds. Press the Back and > buttons simultaneously for 5 seconds. Press the top left-hand corner of the screen for 5 seconds. Press the first and third buttons from the left simultaneously for 5 seconds. 28 S1B /2011

29 Description of the Fault Page Touch Screen Screen and Keypad A Messages scroll up B Messages scroll down C Display of the previous fault page D Display of the next fault page E Acknowledgment of all messages F Goes back to the previous page, end of consulting fault messages G Fault message display zone The color of each fault message indicates the fault status: Message Color Red Green Yellow Fault Status Active: The fault detected is present and has not been acknowledged. Acknowledged: The fault detected is present and has been acknowledged. Not acknowledged: The fault detected has disappeared before being acknowledged. List of Faults The table below lists faults and their consequences: Charging stops Charging is prevented from restarting The fault number appears on the fault page of charging stations with a keypad, the description of the corresponding fault appears on the fault page of touch screen charging stations. Fault Number Fault Description Effect on Charging Charging Stopped Charging Prevented T-01 Fault PLC CPU T-02 Nom0200 comm board 1 fault T-03 Nom0200 comm board 2 fault T-04 Input board fault T-05 Output board fault T-06 Fault comm bank card reader T-07 Fault comm RFID reader T-08 Fault comm with GSM&GPRS module T-09 Fault comm with XBT T-10 Fault comm with Power Meter PM9C T-11 Discordance conf Bank card payment T-12 Discordance conf Tag payment T-13 CB protect open (QF4) T-14 CB protect open (QF2 / QF3) T-15 DC CB open (QF11-13 / QF21-23) S1B /

30 Fault Number Fault Description Effect on Charging Charging Stopped Charging Prevented T-16 Emergency stop (S1) T-17 Trip lightning protect (F1) T-18 Trip aux lightning protect (F2) T-19 CB trip (QF1) T-20 Trip AC 63A CB (QF2) T-21 Trip Transfo CB (QF4) T-22 Trip DC CB (QF11-13/QF21-23) T-23 Fault insulation (P2) T-24 Fault temp transfo (BT1) T-25 Fault ventilation (QFA2) T-26 Fault On battery power (U1) T-27 Fault Loss 12V (K7) T-28 Fault conv 1 Digital input (U1) T-29 Fault conv 2 Digital input (U2) T-30 Fault Bank Terminal T-31 Fault in one of the buttons T-32 Reserved T-33 Fault comm with AC/DC conv-1 T-34 Fault temp of AC/DC conv-1 T-35 Over-voltage in AC/DC conv-1 T-36 Over-current in AC/DC conv-1 T-37 Loss 1 Voltage AC/DC conv-1 T-38 Loss 3 Voltage AC/DC conv-1 T-39 Emergency stop of AC/DC conv-1 T-40 Fault DPH conv 1 T-41 Fault BLIC conv 1 T-42 Fault BTRIP conv 1 T-43 Fault CPU Watchdog conv 1 T-44 Fault calibration conv 1 T-45 Fault current sensor conv 1 T-46 Fault unknown conv 1 T-47 Fault softcharge timeout conv 1 T-48 Fault MODBUS config param conv 1 T-49 Fault comm with AC/DC conv-2 T-50 Fault temp of AC/DC conv-2 T-51 Over-voltage in AC/DC conv-2 T-52 Over-current in AC/DC conv-2 T-53 Loss 1 Voltage AC/DC conv-2 T-54 Loss 3 Voltage AC/DC conv-2 T-55 Emergency stop of AC/DC conv-2 T-56 Fault DPH conv 2 T-57 Fault BLIC conv 2 T-58 Fault BTRIP conv 2 T-59 Fault CPU Watchdog conv 2 T-60 Fault calibration conv 2 T-61 Fault current sensor conv 2 T-62 Fault unknown conv 2 T-63 Fault softcharge timeout conv 2 T-64 Fault MODBUS config param conv 2 T-65 Fault battery charger 30 S1B /2011

31 Fault Number Fault Description Effect on Charging Charging Stopped Charging Prevented T-66 Fault battery incompatibility T-67 Fault battery malfunction T-68 Fault non-zero voltage step 29_3 T-69 Network volt. out of range +/-10% T-70 Voltage imbalance T-71 Current imbalance T-72 Fault under-voltage T-73 Fault over-voltage T-74 Fault comm PWM T-75 Fault PWM Initialization T-76 Bit 1 of 21 PWM register T-77 Bit 6 of 21 PWM register T-78 Bit 3 of 21 PWM register T-79 Bit 5 of 21 PWM register T-80 Bit 2 of 21 PWM register T-81 Bit 4 of 21 PWM register Fault Acknowledgement All faults detected and indicated must be acknowledged manually using the ACK All button on the screen. Detected faults disappear from the fault page when the fault has disappeared and been acknowledged. The charging station is out of order as long as at least one fault is present and not been acknowledged. Intervention During the Warranty Period During the warranty period, any attempt to repair the charging station by anyone other than authorized Schneider Electric personnel will render the warranty null and void. If a fault persists, contact the Schneider Electric Customer Care Center. Schneider Electric Customer Care Center The Schneider Electric Customer Care Center is available to answer all your technical questions about EVlink charging stations. Country Contact Details Germany Schneider Electric Deutschland Address: Gothaer Strasse 29, D Ratingen Telephone: Fax: de-schneider-service@de.schneider-electric.com Belgium Schneider Electric Belgium nv/sa Address: Dieweg 3, 1180 Brussels Telephone: Fax: customer.service@be.schneider-electric.com Spain Schneider Electric Spain Address: C/Bac de Roda N 52 - Edificio A, Barcelona Telephone: Fax: es-sat@es.schneider-electric.com France Schneider Electric Industries SAS Address: 35 rue Joseph Monier, Rueil Malmaison Telephone: Fax: centre-service-client@fr.schneider-electric.com S1B /

32 Country Contact Details Italy Schneider Electric S.p.A. Direzione Commerciale Italia Address: Via Circonvallazione Est, Stezzano (BG) Telephone: Fax: it-webmaster@it.schneiderelectric.com United Kingdom Schneider Electric Ltd Address: University of Warwick Science Park Sir William Lyons Road Coventry CV4 7EZ Telephone: Fax: gb-customerservices@gb.schneiderelectric.com You can find the contact details for the Schneider Electric Customer Care Center in other countries on the website 32 S1B /2011

33 Protecting the Environment Recycling Packaging The packaging materials from this equipment can be recycled. Please help protect the environment by recycling them in appropriate containers. Thank you for playing your part in protecting the environment. End-of-Life Recycling At end of life, the products in the EVlink range have been optimized to decrease the amount of waste and valorize the components and materials of the product in the usual end of life treatment process. The design has been achieved so as components are able to enter the usual end of life treatment processes as appropriate: depollution if recommended, reuse and/or dismantling if recommended so as to increase the recycling performances and shredding for separating the rest of materials. S1B /

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36 S1B54439 Schneider Electric Industries SAS 35, rue Joseph Monier CS30323 F Rueil Malmaison Cedex As standards, specifications and designs change from time to time, please ask for confirmation of the information given in this publication. 09/2011