RAK 108 14.3.2016 Chago Pro ENG Installation instruction Operation instruction 1
Contents Ensto Chago Pro 3 Safety Instructions 3 Delivery Contains 3 Order Sets 4 Installation Accessories 5 Installation 8 Before Installation 8 Ground Mounting Installation 8 Ground Mounting on Concrete 8 Ground Mounting on Ground Mounting Frame 10 Ground Mounting on Unimi Concrete Foundation 12 Wall Mounting Installation 14 Supply Connection 15 Commissioning 16 Commissioning Standalone Charging Point 16 Programming RFID Tags 16 Clearing the RFID Card Memory 16 Commissioning Online Charging Point 17 SMS Commands 19 Maximum Current Setting 19 User Instructions 19 User Interfaces 19 Charging with RFID 20 Start Charging with RFID 20 Stop Charging with RFID 20 Charging with Pushbutton 20 Start Charging with Pushbutton 20 Stop Charging with Pushbutton 20 During Charging 20 Maintenance / Preventive Maintenance Instructions 21 Installation / Commissioning Checklist 22 Introduction 22 Before Installation 22 Checking the Installation 22 Technical Information 24 Electrical connections 24 Design and mechanics 24 Features 25 Safety features 25 Connectivity and Communication 25 Warranty 25 EVF200 Dimension Drawing 26 EVF100 Dimension Drawing 27 EVF200 Internal Circuit 28 EVF100 Internal Circuit 30 Troubleshooting 32 2
Ensto Chago Pro Ensto Chago Pro (EVF) is a solution for the charging of one or two electric vehicles. It is engineered especially for fast AC charging (22kW/3x32A), but the station can be equipped also with domestic sockets (1x16A). Especially the durability, ease of use and maintenance are considered in the design of Chago Pro. Modularity makes it possible to build up Chago Pro according to customer s needs and also upgrade the charging station afterwards. Mode 3 compatible EV charging 3-color LED indicates the charging point s status User identification via RFID tag or mobile phone / app Optionally compartment for domestic socket Type F/E/G with or without lockable hatch Diverse variety of communication and connectivity options: GPRS/2G and RS485 (default). Ethernet, 3G, Wi-Fi (optional with EVI500 advanced controller) Hinged maintenance compartment allows easy access to electrical components Compatible basic charging modules allows modularity based on customer s needs Safety Instructions Chago Pro must be installed by a qualified person. Read the instruction manual before installation and usage of the charging station. The instruction manual must be stored in a safe location and be available for future installation and service. Follow the guidelines in the instruction manual when installing and using the charging station. The installation must be done according to the local safety regulations, restrictions, dimensioning, codes and standards. The information provided in this manual in no way exempts the user of responsibility to follow all applicable codes and safety standards. Delivery Contains EVF charging station Installation and Operation instruction Note! The delivery does not include any installation accessories. Please order needed accessories based on following order sets. 3
Order Sets Order accessories depending on mounting method. Ground mounting on concrete Please order suitable anchor bolts separately from a local supplier. EVTL32.00: Ground mounting box, cable entry from bottom Ground mounting on ground mounting frame or EVTL28.00: Ground mounting frame Ground mounting on Unimi concrete foundation EVF200/100 Charging station EVTL34.00: Ground mounting box, cable entry from top Unimi Concrete Foundation, see www.unimi.se Wall mounting EVTL31.00: EVF200/100 Charging station Wall installation kit including installation rail and box 4
Ø 14 Installation Accessories Order numbers and dimensions. Ground Mounting Box EVTL32.00 EVTL32.00 is a ground mounting box with cable entry from bottom. M8 91 63 46 Cable entry 182 576 415 Cable glands M40x1.5 182 110 Ø 14 Ground Mounting box EVTL34.00 EVTL34.00 is a ground mounting box with cable entry from top. 330 Cable entry 100 M8 17 (133) 80 (120) 360 110 269 38 3 39 112 Cable route Cable glands M40x1.5 262 415 574 5
Ground mounting frame EVTL28.00 EVTL28.00 is a whole set as shown on the picture. M12 110 415 578 415 Ø115 184 110 92 380 490 8 86 63 289 6
Wall installation kit EVTL31.00 EVTL31.00 is a wall installation kit including installation rail and box 360 90 1385 80 50 580 580 (51.5) 320 80 1261.5 (45) 100 105 366 105 576 269 Cable glands M40x1.5 100 330 7
Installation Before Installation Remove the package around the EVF. Remove the film protecting the metal parts only after the installation is finished. When selecting the installation location, take into consideration the minimum space needed for operating and maintenance. 1000 mm in front of the maintenance space 150 mm around the charging point 150 180 1000 Ground Mounting Installation Ground Mounting on Concrete Items needed: 1 pcs Ground Mounting box EVTL32.00 or EVTL34.00 4 pcs Anchor bolts M12 Washers Nuts Make sure that the materials used for the concrete foundation and the installation procedures follow local building regulations and safety standards. Dig a pit for the concrete foundation. The pit floor should be trampled and horizontal. Put cable and possible drain pipes in place. Fill the pit with concrete. Let the concrete solidify, make sure the surface stays solid and level during the process. 8
Cable protection pipe 0110 415 110 Installation Steps 1. Drill a hole in the concrete for the anchor bolts. For more information see the anchor bolt instructions. Use the ground mounting box as a jig. 2. Put the anchor bolts in place and tighten the anchor bolt nuts. 3. Adjust nuts and washers on the anchor bolts horizontally. M12 Horizontal adjustment 150 (64) 86 Washer upper surface measured from ground level 43 (EVTL32.00) 38 (EVTL34.00) Anchor bolt Concrete Select anchor bolts depending on the thickness and strength of the concrete 4. Place the ground mounting box on the concrete. 5. Attach the mounting box to the anchor bolts using suitable washers and nuts. 6. EVTL32.00: Pull the supply cable(s) and possible data cable through the ground mounting box cable gland(s) approx. 400 mm measured from the upper surface of the mounting box. EVTL34.00: Pull the supply cable(s) and possible data cable through the ground mounting box cable gland(s) and further through the mounting box cable hole approx. 400 mm measured from the upper surface of the mounting box. 7. Tighten the cable gland. Close the unused cable entries with cable gland plugs. 9
Ground mounting box EVTL32.00 Use EVTL32.00 holes as a drilling jig 8. EVTL32.00: Remove the supply cable sheath at the length of max. 200 mm. EVTL34.00: Remove the supply cable sheath beginning from the cable gland exit. 9. Open the maintenance door. 10. Remove the nuts and washers from the ground mounting box. 11. Lift the EVF on the ground mounting box and pull the supply cable(s) and possible data cable through the cable hole. 12. Bolt the EVF in place using washers and nuts you removed from ground mounting box. 13. Cut the supply cable leads in different lengths and strip them at the length of 25 mm. 14. Connect the supply cable leads to the power connectors. 15. Ensure that the PE is connected to the EVF. 16. Switch on F0, F1, F2 (if present) and QF1. 17. Close the maintenance door. Ground Mounting on Ground Mounting Frame Items needed: 1 pcs Ground mounting frame EVTL28.00 1 pcs Ground mounting box EVTL32.00 or EVTL34.00 Make sure that the materials used for the concrete foundation and the installation procedures follow local building regulations and safety standards. Plan the installation depth so that the top surface of the ground mounting frame is not below the ground surface. Dig a ca 490 mm deep hole in the ground. The pit floor should be trampled and horizontal Place the ground mounting frame in the hole. Put cable and possible drain pipes in place. Pour concrete over the frame and pipes. Let the concrete solidify, make sure the surface stays solid and level during the process. 10
Installation Steps 1. Remove the upper nuts and washers on the top of the ground mounting frame bolts. 2. Place the mounting box on the mounting frame. 3. Adjust the the nuts on the mounting frame bolts so that the top surface of the mounting box is horizontal. 4. EVTL32.00: Pull the supply cable(s) and possible data cable through the ground mounting box cable gland(s) approx. 400 mm measured from the upper end of the mounting box. EVTL34.00: Pull the supply cable(s) and possible data cable through the ground mounting box cable gland(s) and further through the mounting box cable hole approx. 400 mm measured from the upper end of the mounting box. 5. Tighten the cable gland. Close the unused cable entries with cable gland plugs. 6. EVTL32.00: Remove the supply cable sheath at the length of max. 200 mm. EVTL34.00: Remove the supply cable sheath beginning from the cable gland exit. 7. Open the maintenance door. 8. Lift the EVF on the mounting box and pull the supply cable(s) and possible data cable through the cable hole. 9. Bolt the EVF in place using the washers and nuts you removed from the mounting frame bolts. 10. Cut the supply cable leads in different lengths and strip them at the length of 25 mm. 11. Connect the supply cable leads to the power connectors. 12. Ensure that the PE is connected to the EVF. 13. Switch on F0, F1, F2 (if present) and QF1. 14. Close the maintenance door. 80 (EVTL34.00) 46 (EVTL32.00) Ground mounting box EVTL32.00 or EVTL34.00 min. R900 M12 Thread bar (25) 400 Ground level Ground mounting frame EVTL28.00 (800) Cable protection pipe Concrete 415 ~500 Ø110 11
Ground Mounting on Unimi Concrete Foundation This installation example describes the installation procedure using a concrete foundation supplied by Unimi - Solutions. Items needed: 1 pcs Ground mounting box EVTL32.00 or EVTL34.00 (Ensto) Please order the following items from www.unimi.se 1 pcs Concrete foundation Chago Pro, product code 100-1 1 pcs Cover plate 1 pcs Ensto EVF compatible adapter element, product code 100-13 Installation Steps Figure 1 Prepare trenching for cable conduits and the concrete foundation to necessary depths. Add gravel to the bottom of the trench, to such thickness that the top of the foundation will reach desired level when lifted into the hole. Note! Consider the possible paving materials when setting the level. Cover the unused conduit openings with plugs accompanying the foundation. Lift the foundation into the installation hole, the attachment bar embedded in the foundation can be used as a lifting point. The attachment bar should be oriented to allow attachment of the EVF into desired position. Lay the cable conduits into the trenches and install conduits to relevant inlets. Pull electric cables through the conduits into the foundation. Figure 2 Tighten the foundation to its place by filling the excess space outside the foundation with gravel. Set the final layer of gravel so that the top of the foundation will be flush with ground or the final paving material. Always place a cover plate on the foundation if the EVF charging station is installed in a separate session than the foundation. 1 2 3 Figure 3 When starting the installation of the EVF charging station remove the cover plate. 12
Figure 4 Place the adapter element on the foundation and tighten the captive screws, 3 pcs. Remove the upper nuts and upper pair of washers from the adapter element. (Ensure there is one polyamide washer on each side of the mounting box.) Pull the supply cable and possible data cable through the hole in the center of adapter approx. 450 mm measured from the upper surface of the adapter. 4 Figure 5 Place the mounting box on the adapter element. Bolt the mounting box in place using the washers and nuts you removed from the adapter element. (Ensure there is one polyamide washer on each side of the mounting box.) Hint: to make it easier to ascertain that the mounting box is levelled, first flip it upside down and position the nuts under it so that it becomes levelled and then flip it over again and tighten the upper nuts and washers. EVTL32.00: Pull the supply cable(s) and possible data cable through the ground mounting box cable gland(s). EVTL34.00: Pull the supply cable(s) and possible data cable through the ground mounting box cable gland(s) and further through the mounting box cable hole. Tighten the cable gland. Close the unused cable entries with cable gland plugs. Bolt the EVF in place 5 6 Figure 6 Open the maintenance door. Lift the EVF on the mounting box and pull the supply cable(s) and possible data cable through the cable hole(s). Bolt the EVF in place using suitable washers and nuts. EVTL32.00: Remove the supply cable sheath at the length of max. 200 mm. EVTL34.00: Remove the supply cable sheath beginning from the cable gland exit. Cut the supply cable leads in different lengths and strip them at the length of 25 mm. Connect the supply cable leads to the power connectors. Ensure that the PE is connected to the EVF. Switch on F0, F1, F2 (if present) and QF1. Close the maintenance door. 600 450 Ø15 250 395 Ø115 (x4) 13
Wall Mounting Installation Items needed: 1 pcs Wall mounting kit EVTL31.00 Screws or bolts Washers Nuts Self drilling screws and sealing washers Attach the top part of the EVF to the wall bracket with adhesive tape Secure the EVF with screws Installation rail Install to wall with 6 pcs screws / bolts Ø 16 Pull the cable leads through the mounting box hole Remove the cable sheath beginning from the cable gland exit Mounting box Bolt the EVF on the mounting box Supply cable direction 14
Installation steps 1. Ensure that the wall is robust and stable. The mounting surface must be flat and vertical. 2. Prepare the wall for installation and select the screw / bolt type depending on the wall type. Excercise extreme caution when drilling holes in the wall. 3. Install the wall mounting kit EVTL31.00 on the wall using 6 pcs of suitable screws / bolts, washers and nuts. 4. Adjust the installation rail so that the mounting box is perpendicular to the ground. 5. Pull the supply cable(s) and possible data cable through the cable gland(s) on wall mounting bracket roof approx. 2 m. 6. Alternative cable entry is from mounting box sides. 7. Pull the supply cable(s) and possible data cable through the cable gland(s) on the mounting box. 8. Tighten the cable glands. Close the unused cable entries with cable gland plugs. 9. Remove the supply cable sheath, beginning from the cable gland exit. 10. Open the maintenance door. 11. Lift the EVF on the mounting box and pull the supply cable leads through the cable hole. 12. Bolt the EVF in place. 13. Attach the top part of the EVF to the wall mounting bracket with adhesive tape (included the delivery). 14. Drill 2 pcs holes through the EVF enclosure and top bar of the wall mounting bracket. 15. Secure the EVF to the wall bracket with self drilling screws and sealing washers (included the delivery). 16. Cut the supply cable leads in different lengths and strip them at the length of 25 mm. 17. Connect the supply cable leads to the power connectors. 18. Ensure that the PE is connected to the EVF. 19. Switch on F0, F1, F2 (if present) and QF1. 20. Close the maintenance door. Supply Connection The voltage and current ratings including cables and line protector dimensioning must comply with national regulations. System dimensioning must be done by a qualified electrical designer. N L1 L2 L3 PE Possible supply connections: Use separate supply cables for each charging point Use one supply cable and chain internally to the charging points 15
Commissioning Before commissioning the EVF must be installed according to the installation instruction. NOTE! When commissioning the EVF with two charging points do the same steps on each side. More details on installation and commissioning checklist on page 22-23. By default all EVF stations are in Standalone mode. In this mode no SIM card is required. If the EVF is going to be used in Online mode, first follow the steps in the chapter Commissioning Standalone Charging Point to make sure the basic functionality is working. Commissioning Standalone Charging Point 1. Open the maintenance door. 2. Switch F0, F1, F2 (if present) and QF1 ON. 3. Check that EVI100 s PWR LED turns to green and GSM LED starts blinking red once per second. EVI100 is searching for a GSM network. EVF s indicator LED is blinking red. After a while the GSM LED turns off and EVF s indicator LED turns green. 4. EVF is now ready for use with any RFID tag. Programming RFID Tags RFID tags are programmed to the charging point RFID card memory with the following sequence: 1. Open the maintenance door. 2. Trip the MCB (F1). The charging point indicator light changes from solid green to solid red. 3. Within 5 seconds from tripping the MCB, show and keep the RFID tag on the RFID reader for 5 seconds. The charging point indicator light blinks red. 4. Remove the RFID tag from the RFID reader. The charging point indicator light turns solid red. 5. The charging point is now in teach mode. 6. Show an RFID tag to the RFID reader. The charging point indicator light blinks red as a confirmation that the RFID tag is programmed to the RFID card memory. 7. Continue step 6 until all RFID tags are programmed. You can program up to 20 RFID tags to the RFID card memory. 8. The teach mode exits automatically after 60 seconds or with exit sequence according to steps 9-10. 9. Activate the MCB (F1). Charging point indicator light turns solid green. 10. If the MCB does not trip again within 5 seconds, the charging point exits the teach mode. 11. Close the maintenance door. 12. The charging point can be now operated with only the programmed RFID tags. Any of the programmed RFID tags can stop charging started with same or any other of the programmed RFID tags. Clearing the RFID Card Memory 1. Open the maintenance door. 2. Trip the MCB (F1). The charging point indicator light changes from solid green to solid red. 3. Within 5 seconds from tripping the MCB, show and keep the RFID tag on the RFID reader for 5 seconds. The charging point indicator light blinks red. 4. Remove the RFID tag from the RFID reader. The charging point indicator light turns solid red. 5. The charging point is now in teach mode. 6. Reactivate and trip the MCB (F1) four times within 5 seconds. The charging point indicator light is red when the MCB trips and green when the MCB is activated. 7. The RFID card memory is cleared. The charging point indicator light is solid red. 8. Activate the MCB. The charging indicator light turns to solid green. 9. Close the maintenance door. 10. Any RFID tag can stop charging started with same or any other RFID tag. 16
Commissioning Online Charging Point Before the charging point can be used online for electric vehicle charging it must be configured to work with local GSM network settings and server address. The information in the table below is prerequisite for commissioning the charging point in Online mode. The charging point SIM card must be mini SIM (2FF). The charging point uses GPRS data transfer functionality and there must be a 2G network available. SIM card must also include SMS and call services. SIM cards PIN query must be disabled (No PIN). Typical amount of GPRS data is 10MB/month depending on connectivity settings. Note! Advanced controller, EVI500: If EVI500 is in use please follow EVI500 commissioning instructions. Information IP address or the DNS address of the server Description This can be given in numerical (62.183.177.161) or in textual (someserver.com) format. Maximum length of this parameter is 30 characters. Server s TCP listening port Port number must be in range of 1 32000. GPRS Access Point Name (APN) of the GSM network Country code of the mobile network (CC) The name depends on the used GSM operator and SIM card. Maximum length of this parameter is 40 characters. Some of the incoming phone calls are presented in national format and the device converts it to an international form to ease the comparison with numbers saved in the server. Commissioning of Online charging point is done with the following sequence: 1. Open the charging point s maintenance hatch. 2. Switch F0 OFF. 3. Disable SIM card s PIN query by using a mobile phone. 4. Insert the SIM card into the EVI100 controller s SIM card slot with the contacts up and the angled corner to the right. 5. Switch F0 ON. 6. Check that EVI100 s PWR LED is turning green and GSM LED starts blinking red once per second. EVI100 is searching for a GSM network. Charging point s indicator LED is blinking red. After a while the GSM LED starts blinking every three seconds. EVI100 is connected to a GSM network. Finally charging point s indicator LED turns into green. 7. Start charging point configuration: Configuration is done with an SMS using the in advance gathered information according to the table above. The SMS format is as follows: SETTINGS IP PORT APN CC Example of settings message: SETTINGS 62.183.177.162 10090 internet +358 8. Send the configuration SMS to the charging point s SIM card phone number. After a couple of seconds you should receive the following SMS: Asetukset talletettu Settings saved Data sparad 17
9. If you receive the following SMS check that the configuration SMS is in correct format: Virhe komennossa Error in input Felaktigt kommando 10. If you do not receive any reply, check that the phone number is right. If the setting message still does not go through, switch F0 OFF, remove the SIM card, place it to your mobile phone and wait until all the SMS messages have been received. Then place the SIM card back to the EVI100 controller and turn the power ON. Go back to point 7. 11. Reset the charging point by switching F0 OFF and back ON or by sending SMS reset to the SIM card number. Wait a couple of minutes. 12. Check the setting configuration of the station by sending configuration SMS (with no parameters) to the SIM card phone number: SETTINGS After a couple of seconds you should receive the following SMS: SW: A383 ID: 000091 IP: 63.183.176.162 PORT: 9001 APN: internet GSM CC: +358 Where Parameter SW is the software version on EVI100 controller. Parameter ID is the identification number of the charging point. Parameter IP is the IP address of the server. Parameter PORT is the port number of the server. Parameter APN is access point name of the GPRS network. Parameter GSM CC is the mobile network country code. 13. Check the communication status by sending SMS context (with no parameters) to the SIM card phone number. CONTEXT Wait for the response message and check that the reply is as follows Settings: Yes Send started: Yes Gprs opened: Yes Socket opened: Yes Server reply: Yes Operator: *operator depends on the SIM card* Signal (dbm): *indicates received GSM signal strength* 14. This step is only valid in case you are using Ensto Chago Server (EVS). Login to the server s Web UI. When the charging point is configured and the settings are correct, and the context reply is as above, then the charging point can be found by pressing the Configure New Charging Points based on their IMEI code. The IMEI code can be found on the sticker on the EVI100 controller, e.g. 351777044451373. Move the charging point to the correct charging point group and change the settings if required. Finally press the Save Changes button. 18
SMS Commands The charging point supports the following SMS text message commands. SMS command Parameters Purpose Example settings Ask: no parameters Set: server address server port GPRS APN Mobile Country Code Ask and set GPRS and server settings context n/a Ask GPRS and server connection status Ask: settings Set: settings my.evs.com 2000 internet +44 context reset n/a Reboot EVF reset charge n/a Start charging charge stop n/a Stop charging stop Maximum Current Setting As default maximum charging current is 32A per phase according to the nominal value of charging point. Please see charging point type marking. When using back-end system like Ensto Chago Server, the maximum charging current may be adjusted (such as 16 A or 25 A per phase). The given rating must be done by following the system dimensioning. User Instructions User Interfaces The indicator LED light at the top of the charging point shows the status of the charging point to the user and other persons around the charging point. LED signal lights will show the status of the charging point as described below: Charging point status LED light LED operation Charging point free and ready to use Green Stable RFID read, user login ongoing Green Flashing User login fail, access denied Red Stable User loggin passed, charging allowed Green Waving While connecting the cable Green Flashing twice Vehicle connected, charging not started Green Waving Charging ongoing < 100mA current taken Blue Waving Charging ongoing > 100mA current taken Blue Stable Error state Red Stable 19
Charging with RFID You must have an unique RFID tag to identify that you has a permission to access the charging point. Start Charging with RFID When the charging point is free and the indicator light shows green, you can start a charging event. Show the RFID tag to the RFID reading area. When the RFID tag is read, the charging point will verify the user. If the user login is failed, the indicator light turns to red. If the user login is passed, the indicator light turns to waving green. Now you are logged in to the charging station. Plug in the electric vehicle for charging. The indicator light turns to stable blue. The RFID reading area Pushbutton (optional) Stop Charging with RFID Show the RFID tag to the RFID reading area. When you stop the charging event, the indicator light turns to waving green and you are able to unplug the charging cable. After you have unplugged, you are logged out from the charging point and the charging point is free for the next user. Charging with Pushbutton If the charging station is equippped with a pushbutton, you can start / stop charging by pressing the pushbutton. Start Charging with Pushbutton When the charging point is free and the indicator light shows green, you can start a charging event. Press the pushbutton to start charging. The indicator light turns to waving green. Plug in your electric vehicle. The indicator light turns to stable blue. Stop Charging with Pushbutton Press the pushbutton to stop charging. Unplug your electric vehicle. During Charging During charging the indicator lights will function in the following way If the charging current is below 100mA, the indicator light is waving blue (ie. the cable unplugged from the electric vehicle, the electric car is fully charged). If the charging current is over 100mA, the indicator light is stable blue (ie. charging ongoing). If there is a malfunction during charging, the indicator light will be set to stable red. 20
Maintenance / Preventive Maintenance Instructions 1 x per year WARNING! Danger of electrical shock or injury. Turn off power before working inside the device or removing any components. X MAINTENANCE ACTION Retighten all screws (electric components). Retighten all screws (mounting frame + body). Check the Mode 3 socket and if needed change it (burn or parts damage) (socket cost not under warranty). Check the Mode 2 socket and if needed change it (burn or parts damage) (socket cost not under warranty). Check the sealings, replace the damaged sealings. Gently kick the station with the hand to create vibration to ensure no bad contact / connection exist (wire or PCB). Gently pitchnut the EVI controller to create vibration to ensure no bad contact / connection exist (wire or PCB). Create fail (e.g: RCD OFF) and charge (with RFID card) to check all the LED states / color (green, blue, red) and RFID reader is functioning. Press the RCD test button to test it trips properly. If equipped with RCD auto reset; press RCD test button and wait the auto reset. If equipped with Surge Protection Device (SPD); check that the Over Current Protective Device (OCPD) has not operated and that the SPD is still in a servicable condition. If equipped with MID meter; look at the MID module and check it is proper. Test available electricity at the sockets (Mode 2 + Mode 3) use Mode 3 tester if needed. All the contacts (L1, L2, L3 must be tested). With Mode 3 tester, test the functioning of Mode 3 (from green to blue). Check the tightness of the PE-cable screw that is connected to the frame, the screw is located above the supply connectors. Test voltage between PE and N (must be less than 10 volt). Test PE quality (must be less than 3 Ohms). SW update if needed (if in contract). Restart the station from F0, ensure it will restart properly. 21
Installation / Commissioning Checklist Introduction This checklist is a guidance for ensuring both mechanical and electrical installation as well as commissioning of the Ensto Chago EVF charging stations. Before Installation Read the product specific installation instructions before performing any actions. Note! Only trained electrician may perform the installation in accordance with the applicable local and national electrical rules and standards. Checking the Installation Go through the visual, mechanical and electrical installation when the charging station is un-powered. CATEGORY X ITEM NOTES Overall look Mechanical installation Electrical installation Ordered material has been received. Protective plastic wrapping have been removed. No scratches or damages may be seen. Charging station is fixed properly on the ground / wall Foundation surface is solid and level Unit does not swing All screws on mounting frame and body are tightened. Maintenance door opens and closes smoothly. Charging station s power supply capacities meet electrical planning (cable size, MCB ). Gently kick the charging station with the hand to create vibration to ensure no bad contact / connection exist (wire or PCB). Gently pitchnut the EVI controller to create vibration to ensure no bad contact / connection exist (wire or PCB). Check tightness of the PE-cable screw that is connected to the frame. Power supply cables (L1, L2, L3, N and PE) are properly connected. Insulation of power supply cables is intact (L1, L2, L3, N and PE) Voltage between PE and N is less than 10 V PE quality is less than 3 Ω Please see details on installation instructions. Retighten, if needed. Review local electrical design plan. The screw is located above the supply connectors. Please see details on installation instructions 22
Operational check Optional features Ready for use Commissioning has been done according to the installation instructions All the LED states / color (green, blue, red) and RFID reader is functioning. Available electricity at the sockets (Mode 2 + Mode 3). All the contacts (L1, L2, L3) must be tested. Verify then when charging point LED is green, there is no power at the socket contact (L1, L2, L3, N). With tester, test the functioning of Mode 3 (from green to blue). Press the RCD test button to test it trips properly. RCD auto reset: Press RCD test button and wait the auto reset. MID meter: Look at the MID module and check that it is proper. Latest SW in use (if bought) Correct functioning mode Standalone Online Installation instruction is available for maintenance (behind maintenance door). User instruction is available for the user. Reset the station, be sure it restart properly. Please see details on installation instructions Create fail (e.g. RCD OFF) and charge (with RFID tag) Use mode 3 tester, if needed. 23
Technical Information Electrical connections Nominal voltage Nominal current Nominal frequency Rated power supply Supply connections and terminals 230 Vp-n / 400 Vp-p 3 32 A (Mode 3 socket) / 1 x 16A (Domestic socket) AC 50 Hz EVF100: 22kW: 1x 3x32A EVF200: 22kW per charging outlet: 2x 3x32A OR 44kW: 1x 3x63A Optionally: Dynamic load management (DLM) based on available power supply Static current limitation on back-office system (EVS) L1, L2, L3, N, PE Cu 2.5-50 mm², Al 6-50 mm² Tightening torque Nm: 4 Nm (2.5-4 mm²), 12 Nm (6-50 mm²) Design and mechanics Material / color Enclosure class IK class Operating temperature Directive Standard Painted aluminum and stainless steel Two basic colors: RAL9016S Traffic White RAL7021 Anthracite IP54 IK10 EVI100: -30... +50 oc EVI500 (optional): -20... +50 oc LVD directive 2006/95/EC EMC 2004/108/EC RoHS 2011/65/EC EN61439-1 EN61439-3 Operation and communication according to IEC 61851-1 Approvals / Markings CE, FI 24
Features No. of simultaneous users Connection to car Lockable lid for Mode 3 socket Lockable lid for Domestic socket Charging status indication User access & control Energy measurement EVF100: 1 user EVF200: 2 users Default: Mode 3 charging, Type 2 / Type 3 Option: Mode 2 charging, Type F / E / G Option: for T2 or T2S sockets only Option LED: Blue = Charging Green = Available Red = Malfunction Standalone mode: Default: Free use, RFID Online mode: Option: RFID reader (ISO/IEC 1443A / B, ISO/IEC 15693) Option: Mobile like SMS, call, app (through communication interfaces) Option: Remote control (through communication interfaces) Default: Current transformers (per charging point) Option: MID class kwh metering (per charging point) Safety features Over-current protection (MCB) Residual current protection (RCD) Automatic reset of RCD and RCD remote test Automatic release for Mode 3 socket in case of sudden power outage Surge, overvoltage protection Low control voltage 24 VDC Default Default: Type A Option: Type B Option Option Option Default Connectivity and Communication Connectivity Communication Default: GPRS (2G), RS485 (via EVM) Option: Ethernet, 3G, Wi-Fi (EVI500) Default: Ensto proprietary protocol Option: OCPP 1.5 or via EVS as OCPP gateway Warranty Warranty conditions, see www.ensto.com. 25
EVF200 Dimension Drawing Chago Pro with two charging points. Note! Domestic sockets optional. 176 575 46 1375 1329 180 579 110º 180 490 (90º 507mm) 26
EVF100 Dimension Drawing Chago Pro with one charging point. The side of the charging point can be placed on the right or the left side based on customer request. Note! Domestic sockets optional. 176 572 576 345 510 46 1375 (1329) 1227 27
EVF200 Internal Circuit The circuit diagram varies depending on selected product configuration. black red blue red green Antenna Antenna Board 28 Supply Connectors
black red blue red green Supply Connectors Antenna Antenna Board EVI500 29
EVF100 Internal Circuit The circuit diagram varies depending on selected product configuration. For EVF100 only one side is equipped. Supply Connectors 30
blue red green 31
Troubleshooting Charging station is off, no lights on Issue Mains voltage does not exist in supply connector L1. Circuit breaker F0 is off. 24V power unit has no LED on. EVI100 controller has not PWR LED on. Corrective action Ensure proper power supply. Turn F0 on. Ensure power supply to 24V power unit; if ok replace the power unit. Ensure power supply to EVI100; if ok replace EVI100. Signal light is blinking red Issue Station is starting up after power loss. Corrective action Wait for 2 minutes. Signal light is steady red Issue Residual current device (RCD) has tripped. Circuit breaker (MCB) has tripped. EVI100 controller has SIM card in and controller s GSM LED is blinking once in 3 seconds. EVI100 controller has SIM card in and controller s GSM LED is blinking once in 1 second. Station is connected to EVM master controller but station is not visible in EVM. Station is connected to EVM master controller and station is disabled in EVM. Station is connected to back-end via EVM but station is not visible in back-end. Station is tilted more than 10 degrees from vertical position. Corrective action Reset RCD. Reset MCB. Enable station in back-end e.g. EVS. Disable PIN code query on SIM card. Ensure SIM card has GPRS data subscription. Ensure connection SMS has correct data. Ensure that GSM signal strength is good. Ensure back-end system is online and ready for connection. Ensure correct cable connections. Enable station in EVM. Ensure back-end system is online and ready for connection. Move station to straight vertical position. Station reacts to RFID tag by blinking red signal light Issue Corrective action RFID tag is not authorized. Use authorized RFID tag. 32
Signal light is steady red, charging cable inserted Issue Charging event has been stopped without removing Mode 3 cable. Corrective action Option 1: Open the maintenance door. Switch F0 off for 5 seconds, switch it on again and simultaneously gently pull charging cable out from the socket. Option 2: If equipped with Mode 3 lock release functionality, turn off the power from F0 and pull charging cable out from the socket. Option 3: Turn off the power. Switch Mode 3 lock manually into open position. Signal light is blinking green and then turns red for few seconds Issue Station is in on-line mode and authorization was attempted before blinking. Station is in stand-alone mode and authorization was attempted before blinking. Corrective action Ensure authorization token (RFID, phone no.) is allowed in back-end. Ensure authorization token (RFID) is programmed into station. Signal light is waving blue Issue Charging cable is connected to station and EV vehicle is properly connected. Station is in on-line mode and no charging cable is connected. Corrective action Ensure that vehicle battery is not full. Ensure that vehicles s charging timer is not activated. Wait until stop timer elapses (delay depends on backend settings). Stop charging from back-end. Stop charging with service key. Signal light is green but station do not react to RFID tag Issue RFID tag is not positioned correctly to station s RFID reader. RFID tag is not compatible with station. RFID tag is broken. EVI100 controller has SIM card in and controller s GSM LED is blinking once in 1 second: connection to back-end server has been lost and EVI100 is trying to reconnect. Corrective action Position tag correctly to the reader. Use compatible tag meeting the specifications in station manual. Replace tag. Wait until GSM connection is working again. If the situation continues, contact the mobile network service provider. 33
Charging cable is locked in Mode 3 socket outlet Issue Unexpected fault has occurred while power is on. Power is off. Corrective action Option 1: Open the maintenance door. Switch F0 off for 5 seconds, switch it on again and simultaneously gently pull charging cable out from the socket. Option 2: If equipped with Mode 3 lock release functionality, turn off the power from F0 and pull charging cable out from the socket. Option 3: Turn off the power. Switch Mode 3 lock manually into open position. Open the maintenance door. Switch Mode 3 lock into open position. Note! If the station has a Mode 3 Lock Release functionality, then during power cut the Mode 3 lock opens automatically. Ensto Chago Oy Kipinätie 1, P.O. Box 77 FIN-06150 Porvoo, Finland Tel. +358 20 47 621 Customer service: chago.support@ensto.com chago.support@ensto.com www.ensto.com 34