Summary of Contents for CAR-connect LDC.22-500
- Page 1 Operating manual Mobile high-voltage DC charger LDC.22-500 41.CC.2210.3042_BA_V00_EN...
- Page 2 TRANSLATION OF THE ORIGINAL OPERATING MANUAL All rights reserved. All text, images and graphics are subject to copyright and other intellectual property laws. Copyright 2020 CAR-connect GmbH. Image sources Symbols for warnings, prohibitions, mandatory actions and standards are taken from publicly accessible sources, such as the Internet.
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Page 3: Table Of Contents
Contents Contents Contents ..........................3 Introduction ....................... 6 Preliminary information ......................6 Validity of the declaration of conformity .................. 6 Manufacturer specifications ...................... 6 Safety.......................... 7 Warning levels ..........................7 Important safety instructions ..................... 8 Safety functions .......................... 9 2.3.1 Emergency stop button ..................... - Page 4 Contents Contents Operation ......................... 25 Preparing the power supply connection ................25 Startup ............................26 Initial startup ..........................27 5.3.1 Cold start ......................... 27 5.3.2 Warm start ........................28 5.3.3 Setting the contrast ......................28 5.3.4 Startup after long downtimes ..................29 5.3.5 Self-test ...........................
- Page 5 Contents Contents 5.11 Maintenance..........................46 5.11.1 Inspection and maintenance intervals ................46 5.11.2 Authorized inspection and maintenance personnel ............47 5.11.3 Inspection and maintenance areas on the product ............47 5.11.4 Inspection and maintenance table .................. 48 5.11.5 Tightening torques ......................50 5.11.6 Replacing wearing parts ....................
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Page 6: Introduction
Our portfolio also includes measurement and diagnostic technology for the entire vehicle and battery analysis equipment. With extensive experience in software and hardware development, CAR-connect is your dependable partner at every production stage, from prototyping to series production. -
Page 7: Safety
This operating manual is only valid for the following product: Item number 22103042 Designation Mobile high-voltage DC charger LDC.22-500 Warning levels This chapter provides information about the warning levels used in this operating manual. DANGER Failure to observe the safety instructions WILL result in death or serious injury! -
Page 8: Important Safety Instructions
Safety Important safety instructions This chapter contains the safety instructions that must be observed when handling the product. DANGER Danger of fatal electric shock! The electrical voltage in the product is lethal and will cause death by electric shock! Liquids and moisture may cause short circuits! •... -
Page 9: Safety Functions
Safety CAUTION Risk of damaging individual wires! When bending or coiling the DC charging cable, you can damage individual wires if the bending radius is too small. • When coiling or laying the DC charging cable, maintain a bending radius of at least 22 cm! •... - Page 10 Safety The product is equipped with an emergency stop button. Pressing the emergency stop button causes the following to happen: The contactors in the DC charger are opened, immediately interrupting the electrical connections to the power supply from the AC/DC converters and to the vehicle. A signal is sent to the controller, which makes it impossible to resume charging by resetting the emergency stop button.
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Page 11: Intended Use
Safety Intended use The high-voltage DC charger is a mobile workshop cart for rapidly charging traction batteries in electric vehicles in the workshop. The high-voltage DC charger is used to charge traction batteries with direct current in charging mode 4. The high-voltage DC charger has a GB/T charging plug, dynamic power adjustment and control and protection functions that make it suitable for all the conventional electric vehicles available on the market. -
Page 12: Note To The Grid Operator
Safety Note to the grid operator In some countries, you may require a permit from the energy utility to operate electric vehicle charging stations. • Contact your grid operator before starting up the product. • Have the grid operator or an electrician check your home’s connection to see if it is suitable for operating an electric vehicle charging station. -
Page 13: Transport And Storage
Transport and storage Transport and storage Transport on receipt of goods The product has been packed securely and ready for use in a multi-piece heavy duty cardboard box on a disposable pallet. Immediately check the condition of the product and the completeness of the package. Document any damage or signs of a customs inspection and contact the carrier or manufacturer immediately. -
Page 14: Unpacking The Product
Transport and storage Unpacking the product The packaging consists of a two-part cardboard box. The lower half is firmly attached to a disposable pallet. Inner packaging within the cardboard box protects the product. CAUTION Risk of injury due to heavy product! Lifting the product can lead to back injuries. - Page 15 Transport and storage Remove the inner packaging. Unfold the front opening of the heavy duty cardboard box. Grasp the product by the handle and pull it out of the heavy duty cardboard box in the horizontal position. Stand the product upright. When in the vertical position, the product’s own weight engages the parking ...
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Page 16: Transporting The Product At The Place Of Use
Transport and storage Transporting the product at the place of use The product is mounted on wheels that allow it to be easily transported to the place of use or storage. Observe the following warnings when transporting the product to the place of use: CAUTION Risk of crushing and bruising! -
Page 17: Adjusting The Parking Brake
Transport and storage 3.3.2 Adjusting the parking brake This adjustment ensures that the parking brake securely locks the wheels as soon as the product is upright. Requirement: The product must be disconnected from the power supply and from the vehicle. •... -
Page 18: Ambient Conditions At The Place Of Use
Transport and storage Ambient conditions at the place of use CAUTION Overheating! If excessive heat is produced, the DC charger automatically switches off! • Do not expose the product to direct sunlight! • Ensure that the ventilation grilles are always clear while the product is in operation! •... -
Page 19: Product Description
Product description Product description Scope of delivery Immediately check the condition of the product and the completeness of the delivery. If anything is missing or defective, please contact the manufacturer immediately. (1) High-voltage DC charger (2) USB stick with operating manual 41.CC.2210.3042_BA_V00_EN... -
Page 20: Design
Product description Design Product design: (1) Emergency stop button (2) Service port (3) LC display with membrane keypad (4) GB/T charging plug (5) Power supply plug (6) Handle (7) Rubber cushion (8) Wheels 41.CC.2210.3042_BA_V00_EN... -
Page 21: Symbols And Connections
Product description Symbols and connections The product is equipped with the following stickers: Position Description Function Quick start guide The nonverbal quick start guide describes the steps needed to charge a traction battery. The quick start guide is not a substitute for reading the operating manual! Warranty seal Opening the product or damaging or removing the... - Page 22 Product description The following symbols and information are shown on the product stickers: Symbol Meaning Electrical hazard! Read the operating manual! The serial number is used in conjunction with the manufacturer part number to identify the product. The “AC” and “Phase (~)” markings indicate that the product must be connected only to alternating current sources.
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Page 23: Displays And Controls
Product description Displays and controls The product is equipped with the following displays and controls: Position Description Function Emergency stop • Immediately interrupts all hazardous currents. button The exact function of the emergency stop button is described in the “Safety” section. LC display with •... -
Page 24: Technical Data
Product description Technical data Rated data Values Manufacturer number 22103042 Power supply 3P/N/PE | AC 323 V – AC 437 V | 50/60 Hz | 22 kW | plug: CEE 32 (red) connection Permitted grid design TT/TN grid Power supply 32 A/phase | RCD 30 mA connection circuit breaker... -
Page 25: Operation
Operation Operation This section provides information about the following activities: Preparing the power supply connection • Startup • • Initial startup • Starting charging • Finishing charging Using the LC display • Troubleshooting • Cleaning • • Storage • Disposal •... -
Page 26: Startup
Operation A safe and suitable power supply connection that complies with the applicable standards is required to ensure that the traction battery can be charged safely. The following illustration of a power supply connection is provided as an example and may differ from your particular situation. -
Page 27: Initial Startup
Operation Initial startup This section explains the actions you must perform when starting up the product for the first time. Follow the general safety instructions. Insert the three-phase plug all the way into the three-phase socket. Observe the keying on the plug! The high-voltage DC charger starts up automatically once connected to the power ... -
Page 28: Warm Start
Operation 5.3.2 Warm start You can carry out a warm start of the high-voltage DC charger when the charger is switched off but connected to the power supply. Press and hold the “On” button. The message “Switching on” and a progress bar appear on the LC display. ... -
Page 29: Startup After Long Downtimes
Operation If the LC display is easy to read or if you do not achieve a better setting with the following step, exit this setting by pressing function key F1 (cancel). Change the contrast by pressing function keys F2 (down) and F3 (up) within the limits 0 to 20. -
Page 30: Starting Charging
Operation If malfunctions are detected during the self-test, they are indicated on the LC display (see the “Troubleshooting” section). At the end of a successful self-test, the messages “Connect vehicle” and “Ready” appear on the LC display in alternation. You can now begin the charging process. -
Page 31: Setting The Auto-Off Function
Operation 5.4.2 Setting the auto-off function To conserve energy, you can set the DC charger to automatically switch off after a specified time. Requirement: The DC charger must be switched on (see the “Cold start” and “Warm start” chapters). • Charging must not be active. -
Page 32: Finishing Charging
Operation Insert the GB/T charging plug all the way into the socket on your vehicle. Make sure that the locking mechanism engages. The message “Preparing charging” appears on the LC display. If necessary, start the charging process on the vehicle as described in the operating manual from the vehicle manufacturer. -
Page 33: Canceling The Charging Process
Operation 5.5.2 Canceling the charging process WARNING Danger of fatal electric shock! Product components may produce sparks and electric arcs! • Never disconnect high-voltage plug connections while under load! • Finish the charging process before disconnecting the plug connections! CAUTION Risk of damage! In rare cases, the GB/T charging plug may still be locked after charging is finished. - Page 34 Operation Press and hold the unlock button. Remove the GB/T charging plug from the charging socket on your vehicle. Charging has now been canceled. 41.CC.2210.3042_BA_V00_EN...
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Page 35: Using The Lc Display
Operation Using the LC display 5.6.1 Function keys The function keys F1 to F4 are arranged below the LC display. You can use the function keys to navigate through the menu on the LC display, make settings and change parameters. Each function key is assigned a situation-specific function, which is shown on the LC display directly above the respective function key. -
Page 36: Menu Structure
Operation 5.6.2 Menu structure The figure below shows the menu structure and how you can navigate within it. The individual parameters are described in the tables below. The “Configuration parameters” menu is not available while charging is active. Main menu Operating parameters Charging time nsulation... -
Page 37: Main Menu
Operation 5.6.3 Main menu From the main menu, press function keys F2 to F4 to access the following submenus. Exit the submenu by pressing function key F1 (exit). Function Assignment Function Display the operating parameters. The operating parameters are used to monitor the charging process (see the “Operating parameters”... -
Page 38: Configuration Parameters
Operation Parameter Values Meaning Unit Charge Status of the charging process. phase Charging end voltage Voltage Current voltage at the output of the high- voltage DC charger Maximum possible charging current of the Current high-voltage DC charger Current charging current of the high-voltage DC charger Output Temperature at the DC output of the high-... -
Page 39: Information Parameters
Operation Parameter Meaning Unit Factory setting Device power limit Power Maximum state of charge SoC limit Maximum charging time Charging time Time after which the high-voltage DC Auto-off charger switches off automatically after charging is finished Menu language German Language Contrast of the LC display Contrast °C... - Page 40 Operation Parameter Meaning Unit Total mating Total number of connector mating cycles cycles Number of mating cycles for the DC plug Mating cycles Cold starts Number of device starts by connecting the power supply plug Number of starts from standby mode Warm starts AC relay cycles Number of closing cycles for the AC relay...
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Page 41: Restoring The Factory Settings
Operation 5.6.7 Restoring the factory settings In isolated cases or if the product is used in other workshops, it may be necessary to reset the high-voltage DC charger to the factory settings. Carry out a cold or warm start (see the “Cold start” or “Warm start” section). As soon as the message “Connect vehicle”... -
Page 42: Troubleshooting
Operation Troubleshooting The DC high-voltage charger outputs the following types of message on the LC display: Warning messages: These messages, if disregarded, will cause the product to lock, • which can then only be reset by the manufacturer. Always carry out the instructions in the warning messages immediately or contact the manufacturer (see the “Warning messages”... - Page 43 Operation The table below provides information about the steps you can take to resolve these faults. It may be necessary to finish charging first (see the “Finishing charging” section). If the fault messages cannot be resolved, contact the manufacturer immediately. Message Meaning Corrective action...
- Page 44 Operation Message Meaning Corrective action GB/T temp. fault The permissible By the operator: temperature was • Check the number of mating cycles exceeded at the for the GB/T charging plug. GB/T charging plug. Replace the GB/T charging plug if necessary. •...
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Page 45: Cleaning
Operation Cleaning DANGER Danger of fatal electric shock! The electrical voltage in high-voltage systems is lethal and will cause death by electric shock! • Disconnect the product from all power sources before cleaning the product! Observe the safety instructions! Use only a dry cloth to clean the product. Storage Store the product in a dry and dust-free location when not in use. -
Page 46: Maintenance
Operation 5.11 Maintenance Follow the safety instructions! Test the product at regular intervals to ensure proper functioning. WARNING Danger of electric shock! The electrical voltage in the product is dangerous and can cause serious injury or death from electric shock! •... -
Page 47: Authorized Inspection And Maintenance Personnel
Personnel with this qualification level have the professional training necessary to recognize and avoid hazards that can arise from high-voltage systems. CAR-connect Activities marked with this abbreviation may only be carried out by the manufacturer. 5.11.3 Inspection and maintenance areas on the product The figure below shows the areas on the product that are subject to inspections and maintenance. -
Page 48: Inspection And Maintenance Table
Operation 5.11.4 Inspection and maintenance table The following table provides information about the inspections and maintenance to be carried out on the product, the corresponding intervals and the persons authorized to do Area Activity Person Interval Visual inspection Check all stickers on the product to ensure that they are present, legible and not damaged. - Page 49 Operation Area Activity Person Interval Visual inspection Inspect the plugs and electrical cables for damage. Wear inspection Inspect the plugs and electrical cables for wear. Check the number of mating cycles shown on the LC display (see the “Information parameters” section).
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Page 50: Tightening Torques
Operation 5.11.5 Tightening torques The following table shows the maximum permissible torques for all screw connections. Observe the maximum torques when fastening components. Screw size Torque 2 Nm 3.5 Nm 6 Nm 16 Nm 5.11.6 Replacing wearing parts This section explains how to replace wearing parts. Certain wearing parts can be replaced only by the manufacturer or an electrician. - Page 51 Operation Preparing the product Before you can replace wearing parts, you have to prepare the product. Disconnect the product from the power supply and from the vehicle. Lift the product onto a workbench and make sure that it cannot slip. If necessary, set the product on a soft pad to protect if from scratches.
- Page 52 Operation Replacing the upper filter mat Remove the screws from the top cover. Remove the top cover. Replace the filter mat. Reattach the top cover using the screws. You have successfully replaced the upper filter mat. Replacing the lower filter mat Remove the screws from the bottom cover.
- Page 53 Operation Replacing the support bracket pads Always replace both support bracket pads at the same time! Remove the screws from the support bracket pads. Replace the support bracket pads and fasten the new pads with the screws. You have successfully replaced the support bracket pads. ...
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Page 54: Help
Help Warranty CAR-connect GmbH grants a warranty period of 24 months from the date of purchase. The warranty is valid for demonstrable defects in functional material and workmanship. Further information on the warranty conditions can be found in the terms and conditions on the manufacturer’s website. - Page 56 CAR-connect GmbH Am Egelingsberg 8 38542 Leiferde, Germany Phone: +49 53 73 / 92 197 – 0 Fax: +49 53 73 / 92 197 – 88 info@car-connect.cc www.car-connect.cc Translation of the original operating manual. Subject to technical changes.
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