Circontrol Raption 150 Compact CCS Service Manual
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Circontrol Raption 150 Compact CCS Service Manual

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Raption 150 Compact
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  • Page 1 Raption 150 Compact Service Manual...
  • Page 3 C O P Y R I G H T I N F O R M AT I O N This document is copyrighted, 2022 by Circontrol, S.A. All rights are reserved. Circontrol, S.A. reserves the right to make improvements to the products described in this manual at any time without notice.

  • Page 5: Table Of Contents

    How to service your Raption 1 — So, Hello! A - Important safety instructions B - Work in a safe environment C - Personal Protective Equipment (PPE) D - Recommended tools 2 — Features A - Overview B - Dimensions C - Components overview 3 —...
  • Page 6 Raption 150 Compact Service Manual 5 — Other components A - Heater system B - Ventilation system C - RFID reader D - DC meter E - Uninterruptible power supply (UPS) F - Power supplies G - Contactors H - Teltonika RUT 240 6 —...
  • Page 7 8 — Maintenance A - CCS holder adjustment 9 — Annexes 10 — Technical data 11 — Need help?
  • Page 8 It is mandatory to follow the basic security information supplied in this manual to ensure safe and proper installation. Failure to follow safety instructions may involve personal injury, equipment damage and danger of death. CIRCONTROL is not responsible for events arising from such breach. THE FOLLOWING SYMBOLS ARE USED FOR IMPORTANT...

  • Page 9: So, Hello

    • Use only Circontrol supplied spare parts. • Never handle electrical equipment when hands, feet, or body are wet or perspiring, or when standing on a wet...

  • Page 10: B - Work In A Safe Environment

    Raption 150 Compact Service Manual Work in a safe environment It is recommended to be very cautious and work safely to control all potential electrical hazards. So, the safety rules shown below classify the work to be done depeding on the present electrical risk, that helps to control risks of injury or death from workplace hazards.
  • Page 11 Work without voltage It is essential to carry out the following steps in order to successfully perform the required tests: Disconnect the installation from its source. Check for absence of voltage. Test preparation by placing all the necessary measuring instruments and closing the doors totally or partially (as much as possible).

  • Page 12: C Personal Protective Equipment (Ppe)

    Raption 150 Compact Service Manual Personal Protective Equipment (PPE) It is mandatory that all technical employees wear the following Personal Protective Equipment (PPE). It must be used for any electrical task such as the described above. INSULATING SAFETY SHOES INSULATING GLOVES Class 0: 1000V Dielectric boots recommended Class 0: 1000V AC/1500V DC...

  • Page 13: D Recommended Tools

    Recommended tools LAPTOP SWITCH MULTIMETER ALLEN TOOLS MULTI-TOOL TORX-TOOLS USB-RS485 SCREW DRIVERS ETHERNET CABLE RATCHET WRENCH...
  • Page 14 Raption 150 Compact Service Manual Overview 1- Cover 2- CCS light beacon 3- CCS holder 4- CCS connector 5- Handle 6- RFID reader 7- Card payment 8- Touch screen 9- Air inlet Unit 10- CHAdeMO light 11- CHAdeMO holder 12- CHAdeMO beacon connector 13- Power M.

  • Page 15: Features

    Features Dimensions 1290 1140 Measures in mm...

  • Page 16: C Components Overview

    Raption 150 Compact Service Manual Components Overview Inside the Charge Point it is possible to differentiate four main parts. In the upper part there are the electronic boards, the electrical protections and the electrical actuators. In the medium low part there are located the power modules. Next to them on the left, there is the power input supply section.
  • Page 17 — E L E C T R O N I C B OA R D S , E L E C T R I C A L P R O T E C T I O N S , E L E C T R I C A L AC T UAT O R S - D O O R O P E N I N G - Step 1 Locate the tab in the mid left of this part and...
  • Page 18 Raption 150 Compact Service Manual 1 A — E L E C T R O N I C B OA R D S , E L E C T R I C A L P R O T E C T I O N S , E L E C T R I C A L AC T UAT O R S - O U T E R L A Y E R C O M P O N E N T O V E R V I E W - 7 10 7 11...
  • Page 19 1 B — E L E C T R O N I C B OA R D S , E L E C T R I C A L P R O T E C T I O N S , E L E C T R I C A L AC T UAT O R S - I N N E R L A Y E R C O M P O N E N T O V E R V I E W - 7 10 7 11...
  • Page 20 Raption 150 Compact Service Manual 2 — P O W E R M O D U L E S Are assembled power modules of 25kW in Raption 51, Raption 52 and Raption 100. Power modules layout (view from left side):...
  • Page 21 1- Power module 25kW 2- Power module 25kW 3- Power module 25kW (U120.1) (U121.1) (U121.2) 4- Power module 25kW 5- Power module 25kW 6- Power module 25kW (U122.1) (U123.1) (U123.2) Upper power modules 8- Lower power modules (U122.1 / U123.1 / U123.2) (U120.1 / U121.1 / U121.2)
  • Page 22 Raption 150 Compact Service Manual 3 — C I R C U I T B R E A K E R 1- Temporary overvoltage fuse 2- Molded Case terminal 80A Circuit Breaker (F102.1 / F102.2 / (Q101.1) F102.3) 3- Miniature circuit 4- Rotary handle for breaker 2P 16A MCCB...
  • Page 23 4 — D O O R S Right door Left door 1-Beacon light CCS 2- Mechanical 3- CCS holder 4- Heater/Fan (H330.1) connector locking (CN301.1) (R115.1) 5-Beacon light CHA 6- CHA holder 7- Router 8- Switch (H430.1) (CN401.1) (N241.2) (N235.1) Note: Depending on the model, the components can vary.
  • Page 24 Raption 150 Compact Service Manual 1- PC screen 2- Payment (N241.1) terminal (E243.1) 3- RCBO 1P+N 4- Service schuko 10A 30mA class A (E110.1) (Q110.1) 5- Supply 12-24V 6- RFID card reader door (E157.1/E157.2/ (E245.1) E157.3/E157.4) On the left door it is placed the CCS holder and beacon light. However, on the right door it is placed the CHA holder and beacon light.
  • Page 25 5 — B L O C K D I AG R A M...
  • Page 26 Raption 150 Compact Service Manual 7 — C O M M U N I C AT I O N S S C H E M E Find in the next scheme all the components communicating via TCP/IP Ethernet and its respectives IPs. As there are IPs already in use, when connecting a service terminal (laptop) to the charging station use DHCP or work with static IP 192.168.1.90.
  • Page 28 Raption 150 Compact Service Manual PC Screen (HMI) The PC screen (HMI) and the RFID reader are located at the right door. Normally, at the RJ45 port it is connected the Ethernet cable coming from the router when it is installed. However, it is also here where the Service PC should be connected when Charging Station has to be configured.

  • Page 29: Control Devices

    Control devices Electrical scheme Screen has two RS485 connectors. In one of them there is the RFID reader and the other there is a bus of communicactions with many devices. RS485 Connector 1: RS485 Connector 2: • Mode 4 • RFID Reader •...
  • Page 30 Raption 150 Compact Service Manual Update Screen can be updated from the Setup Webpage. Find the details of the procedure in the User Manual. Firmware file can be obtained from the Expert Area.

  • Page 31: B - Mode 4 Board

    Mode 4 Board Mode 4 board is controlling the communications of the Charging Station with the Electric vehicle. Also, most of the alarms like the emergency button, isolation protectors or clixon are managed by this board. Item Name Function Power supply connector, 12Vdc Inputs for Emergency, VCC;...
  • Page 32 Raption 150 Compact Service Manual Enable/disable power modules output Outputs doe Bender test, lock CCS, precharge, heater. Outputs for diode fan, modules. RS485-1-M communications with isolation detector device RS485-2-S Communications with the screen CAN 1 communications with CHAdeMO cable CAN 2 communications with Expansion board Input thermostats from CCS cable Relay output CHA cable and CCS contactor Relay output CHA contactor and CHA lock...
  • Page 33 Electrical scheme Update Mode 4 board is updated automatically by the Screen. So, when Screen is updated, both components are getting a new firmware version, each one its corresponding. Check in the previous point, the procedure to update the Screen and find the necessary files in the Expert Area.

  • Page 34: Cccs Board

    Raption 150 Compact Service Manual CCS Board This board is in charge of the communications of the CCS connector. It works as a bridge between the EV and the Mode 4, translating the communications from PLC to CAN protocol. Item Name Function Ethernet port for communications...
  • Page 35 Electrical scheme Update There is a specific guide explaining the procedure to update this board. It can be updated manually following the steps described in the guide "How to update CCS board IoTecha M2ievse" which can be found in the Expert Area. Additionally, remote upgrade via Screen firmware update, same as the Mode 4 board, is expected to be implemented soon.
  • Page 36 Raption 150 Compact Service Manual To know all the protection devices installed in the Charge Point, it is located a summary table in a visible place inside one of the doors. It would help to identify the main protection devices and the identificator label included in each component in case of configuration or maintenance.

  • Page 37: Protection Devices

    Protection devices MCCB/Disconnector Main disconnector, located in the bottom of the charger. These devices isolates the Charging Station from the grid. The disconnector not only is a circuit breaker, it also protects against overcurrents and short-circuits. It is installed a rotary handle which makes easier to control the different circuit operations by rotation.

  • Page 38: Brcd

    Raption 150 Compact Service Manual Composed by a compact system that includes a current transformer and differential relay that activates when current leakage is detected. CBS-400B model is installed in the DC circuit before the AC/DC converters, one of them in each connector. WGB-55 model is installed upstream and monitor the current.

  • Page 39: Cmcbs

    MCBs There are few MCBs in the Raption protecting components from overcurrents and overtemperatures in the cables. Overvoltage control part*: Power Modules: (*) Optional component...

  • Page 40: Drcbos

    Raption 150 Compact Service Manual RCBOs There are three RCBOs in the Raption protecting the Auxiliary branches. From the left to the right: • Service Schuko • Auxiliary Power supply distribution 230V AC • Ventilation / Heater Q110.1 Q109.1 Q109.2...

  • Page 41: E Transient Surge Protector

    Transient surge protector The charging station can be equipped with four pole transient surge protector as an opcional protection. It has four interchangeable cartridges based on varistor. Also, it is equipped with a visual indicator and a remote indicator. Remote indicator is not integrated, so make sure visually that the status of the cartridges is correct during maintenance tasks.

  • Page 42: F Isolation Protection Device

    Raption 150 Compact Service Manual Isolation protection device The ISOMETER monitors the insulation charging stations for electric vehicles for DC between 0 and 1100Vdc (CCS) or 0 and 500Vdc (CHA). This device protects both DC connectors in the output side. It is measuring constantly the resistance between positive wire to the ground and negative wire to the ground.
  • Page 43 Bender device can be configured manually using its buttons or via software. Check the Annexes to find the configuration steps in case service staff has to do the settings manually. When device is configured via software, ask support@circontrol.com to get the necessary files. Additional function Bender does not only work as an Isolation Protector.
  • Page 44 Raption 150 Compact Service Manual Electrical scheme CHAdeMo model scheme CCS model scheme...
  • Page 46 Raption 150 Compact Service Manual Raption Series is divided internally into 4 different circuits: Main branches: Auxiliar branches: • • Supply of internal components. • Heater/Ventilation • Service schuko...

  • Page 47: Other Components

    Other components Heater system The heater system is managed by the Mode 4 board. Depending on the temperature measured by the board, heater will be activated when necessary in orden to keep the temperature over the minimum values. The objective is to keep the unit over -15ºC. So heater will be activated previously in order to avoid reaching this value.
  • Page 48 Raption 150 Compact Service Manual The thermostat is configured at -15ºC. If temperature is lower than this value, contactor will open. When the contactor opens, it does two functions simltaneously: 1 — Disconnects the supply of the internal components. 2 — Activates the heater. So, as a result, when the Charging Station is powered and the environmental temperature is lower than -15ºC this system is activated.

  • Page 49: B Ventilation System

    Ventilation system Raption is equipped with some fans in order to keep a safe temperature thorugh different sections of it. There are 9 fans in the Charge Station: On the housing (M111.1 / M112.1 / M112.2 / M113.1) On the Backflow diode (M145.1 / M145.2) In the Power modules number 1, 2 and 3 (M114.1) In the Power modules number 1, 2 and 3 (M114.2) In the A8 screen (M241.1)

  • Page 50: Crfid Reader

    Raption 150 Compact Service Manual RFID reader The RFID reader is a device that can send and receive radio signals with RFID tags to identify the end-user without physical contact between the charger and the card. RS-485 Communications Operation LEDs RFID reader has a LED status indicator.

  • Page 51: Ddc Meter

    DC meter The three-phase electrical energy meter for indirect measurement for the DC side (one for each connector), measures current and voltage that supplies the DC sockets. The meter has RS485 communications with the Screen A1. This meter is a CEM C31. Electrical scheme...

  • Page 52: E Uninterruptible Power Supply (Ups)

    Raption 150 Compact Service Manual Uninterruptible power supply (UPS) The extra power supply provides enough supply to the Mode 4 control board to perform a controlled stop of an on-going charging session, in case there is a blackout or the RCBO of the main supply triggers. G150.3 It allows that the 12Vdc electronics remain supplied for few seconds when unit is powered OFF.

  • Page 53: F Power Supplies

    Power supplies There is a power supply of 12Vdc and another one of 24Vdc supplying most of the internal components: fans, boards, screen, router, etc. Power supply 24Vdc Power supply 12Vdc...

  • Page 54: G Contactors

    Raption 150 Compact Service Manual Contactors There are included two of them before the power modules, one for operate power modules from 1 to 3, and other for power modules from 4 to 6. It closes when Charging Station is powered ON for power modules detection procedure.

  • Page 55: H Teltonika Rut 240

    Teltonika RUT 240 Raption includes a router in order to allow the Charging Station to communicate and remote access. This device is used normally to establish communications with a CSMS so Raption can be remotely managed. It also allows remote access, which is very useful for maintenance, remote diagnosis and eventually, to adjust the settings of the Charging Station, such as tariffs or language.
  • Page 56 Raption 150 Compact Service Manual RFID Reader - Legic Alternative RFID reader Legic Advant / Legic Prime. This model is compliant with a large number of ISO certifications. • LEGIC Advant • LEGIC Prime • ISO14443 A+B compatible to part 4: MIFARE DESFireEV13), MIFARE Plus S, X3), MIFARE Pro X3), MIFARE SmartMX3), SLE66Rxx (my-d move)3), SLE44R351), PayPass1), NTAG2xx4), •...

  • Page 57: Other Optional Components

    Other optional components Electrical scheme This RFID reader has two particular points. • It is supplied with 5Vdc, so it is necessary a power supply device converting from 24Vdc to 5Vdc. • It communicates via RS232 protocol. It is necessary to convert this signal to a RS485, so there is installed a converter in between.

  • Page 58: B Omnidirectional Tilt Switch

    Raption 150 Compact Service Manual Omnidirectional Tilt Switch The Tilt switch is connected directly to Mode 4 Board. Mode 4 filters the signal, if the signal remains for more than 500 ms, then it is decided that there is a problem and the board must give the tilt power stop command which is sent to the A8 board via relay K204.1.
  • Page 60 Raption 150 Compact Service Manual Troubleshooting introduction The Charging Station can report about different sort of errors, coming from different parts or devices. When the ‘Error screen’ appears, the ‘Information’ button has to be pressed in order to see the error message, as the one seen below, which needs to be decoded to understand what is happening to the Charging Station:...

  • Page 61: Troubleshooting & Errors

    Troubleshooting & Errors This section provides the necessary information to decode, indentify and understand the errors. However, eventually, Circontrol staff help may be needed support@circontrol.com to solve the issues. In that case, please, contact to get help. When contacting Circontrol, it is important to provide some background information regarding the issue.
  • Page 62 Stopping process. • Permanent error. 3 — Does the error appear with a specific car model? Circontrol performs interoperability tests periodically with the new brand cars of the market in order to ensure a correct compatibility between charging stations and EVs.
  • Page 63 Service staff can perform some basic checks on those situations where they don’t have the tools to decode the error or access to the EVSE. These checks can provide helpful information and eventually fix the issue. BASIC CHECKS • Verify that no MCBs have been trigered. •...

  • Page 64: B Log Files

    Raption 150 Compact Service Manual Log files Log files provide useful information about the Charging Station. All the steps it goes trough, the current status, detail about the charging session, error code, etc. All this information will be helpful when trying to locate and identify an error. However, there is a very important point to take into account: •...
  • Page 65 http://”IP ADDRESS”/services/cpi/record.xml: Then, to access to a specific register, for example nº2: http://”IP ADDRESS”/services/cpi/record.xml?id=2...

  • Page 66: C Decoding The Error

    Raption 150 Compact Service Manual Decoding the error There is a specific order which has to be followed to decode the error. First step is to identify the parts of the error. Engine errors DC errors As indicated in the picture above there are ‘Engine errors’ and also ‘DC errors’. Errors from AC side are normally easier to identify.
  • Page 67 ENGINE ERRORS This part is divided in three different levels. Every level has its own code and a table for consulting the meaning of the code. The correct order to check these levels is: Socket: One plug may have more than one socket. Error can affect one socket and the plug still being available.
  • Page 68 Raption 150 Compact Service Manual C H A R G E P O I N T L E V E L Error Hexadecimal Decimal Description No error Invalid Configuration READER Reader Error. DISPLAY Display Error. TAMPER Tamper Error. TILT 0x10 Charge point is tilted.
  • Page 69 P L U G L E V E L Error Hexadecimal Decimal Description No error. Invalid Configuration. Charge Point error. Plug is inoperative. MASTER Check Charge point error affected. USER_INTERFACE User Interface error. LOCK Lock error. SUPPLY 0x10 Power supply dropped. 0X20 RCD tripped CONTACTOR...
  • Page 70 Raption 150 Compact Service Manual S O C K E T L E V E L Error Hexadecimal Decimal Description No error. Invalid Configuration. Plug error. Socket is inoperative. Check MASTER plug error affected. USER_INTERFACE User Interface error. LOCK Lock error. SUPPLY 0x10 Power supply dropped.
  • Page 71 DC ERRORS This part has to be checked only after reviewing the Engine section. In some cases, Engine section does not provide enough information, describes a general error or is not conclusive. These situations require to continue investigating using the DC error. DC error section is also divided in subparts.
  • Page 72 Raption 150 Compact Service Manual D E C O D I N G T O O L To understand this DC error section, it is required a decoding tool. Circontrol support team, support@circontrol.com can provide an user profile if necessary.
  • Page 73 On the left part, it is displayed a menu in which you can choose according the topology of the error (if the error was displayed in the touch screen or through OCPP protocol).: TO U C H S C R E E N Value Description Charger Model...
  • Page 74 Raption 150 Compact Service Manual At the time ‘Error subsystem’ is selected, it appears some extra gaps below to include more information of the error. Depending on the option chosen, the extra gaps to appear could be different. When an error is introduced, it appears a short description of the error. In case of the extra gaps mentioned above, in addition to the description of the error, if a click is pressed on it, extra boxes appear with possible causes of the error introduced and some advice to solve them.
  • Page 75 O C P P Value Description Error origin Type and responsible of error Module Part or component that causes the failure Error type Concrete description of failure Example of an error appeared.

  • Page 76: D Error Code In Remote

    Raption 150 Compact Service Manual Error code in remote As it has been shown at the beginning of this chapter, error can be consulted directly from the screen, by pressing the connector in fault status and the ‘Information’ button. However, in most cases, service staff wants to know this code in advance in order to prepare the on-site assistance.
  • Page 77 With a few line breaks it can be turned into a more familiar look: Nov 8 09:39:18 raption user.info pss[306]: ------------------- VECTOR OF ERROR FLAGS OBJECTS ------------------- Error Flags Object -> Module Type: 31, Name: CCS2 Error flags: 0000 0000 0000 0000 0000 0000 0000 0020 Historical error flags: 0000 0000 0000 0000 0000 0000 0000 0120 Predecessor errors: 0 - 0 Status message flags: 0000 0000 0000 0000 0000 0001 0000 0001...

  • Page 78: E - Communications Errors

    Raption 150 Compact Service Manual Communication errors When an internal device cannot reach the main controller of the Charging Station, the Screen, a communication error will be generated. These types of errors can be generated by many reasons:: • Device improperly powered •...

  • Page 79: Focpp Errors

    Can not get charge device name The internal application of charge point is corrupted/lost or is not installed. It requires to upload a file provided by Circontrol support team within Configuration Update section on web page of the charge point.
  • Page 80 Raption 150 Compact Service Manual Notifying Boot - -1 There is some kind of filter on the network related with the size of the messages sent from the charger, maybe in the simcard provider side or in the CS. This filter cause that the message, or part of the message is not sent to the CS, so information is not completely delivered.
  • Page 81 No Data, get host by name failed in tcp_connect() Hostname cannot be resolved in charge point side:http://ip_address:8080/html/ setup.html • Check ‘Enable DNS protection’ parameter in Teltonika router. • Check if DHCP=ON whithin Network section on web page from CP. Reboot required.
  • Page 82 Raption 150 Compact Service Manual OCPP 1.6 CS Connection FAILED. Fail reason: Underlying Transport Error Hostname cannot be resolved in charge point side:http://ip_address:8080/html/ setup.html Host URL introduced is not correct. Check it on OCPP configuration. • Check 'Enable DNS protection' parameter in Teltonika router. •...

  • Page 83: G - Power Modules Errors

    Raption Series Service Manual Power modules errors Power modules of 25kW. LED lights placed in rectifier: LED named “OK” Green/Yellow bi-colour LED named “RFA” Meaning of colours in relation with service: Colour System Status Green Everything ok No diagnostic or user interaction required Yellow Check following table for further diagnosis Replace rectifier...
  • Page 84 Raption 150 Compact Service Manual The unit needs regular maintenance and part inspection during its life. Before starting with the maintenance or with the spare parts replacement procedure, it is very important to disconnect the Charging station from any power source.

  • Page 85: Maintenance

    Maintenance The maintenance plan is based in years from start-up, hours of charging or standby, and cycles of charging. Depending on the group of components, it is necessary to apply a specific maintenance period. Check periods in the next table: Years from start-up* 6 months / 1 year /...
  • Page 86 Raption 150 Compact Service Manual Another important point to check is the torque of the components. Here a list indicating the specific torque for those components: Component Description Torque MCBs 3.5 Nm RCBOs 2.5 Nm Backflow diode 6.5 Nm...
  • Page 87 DC input 8 Nm contactor DC output 6.5 Nm contactors Clamp for CHAdeMO 7 Nm connector Clamp for CCS 3 Nm connector...

  • Page 88: Accs Holder Adjustment

    The adjustable retainer system is located inside the Charge Point. A technical procedure manual is available to download in Circontrol Expert Area explaining step by step how to adjust the pressure in each CCS holder.
  • Page 90 Raption 150 Compact Service Manual In order to update easily the content of the Annexes from this manual, it has been created the next list. All this material is available in Circontrol’s Expert Area where can be downloaded by being registered.

  • Page 91: Annexes

    Annexes Find all the documents from the List of Annexes in the Expert Area. If you have any trouble, ask support@circontrol.com for the requested file or document. https://expertarea.circontrol.com/...
  • Page 92 Raption 150 Compact Service Manual GENERAL SPECIFICATIONS AC Power Supply 3P + N + PE AC Voltage 400V AC +/- 10% Maximum AC input current 260A Required power supply capacity 160kVA Power Factor 0.98 Efficiency 95 % at nominal output power Frequency 50 / 60 Hz Electrical input protection...

  • Page 93: Technical Data

    Technical Data Dimensions (D x W x H) 550x1140x1910 mm (without cable engaged) Weight 450 kg Cooling system Air cooling fans < 55 dBA Operational noise level AC Meter Compliant with the EN 50470-1 and EN 50470-3 (MID European standards) or IEC 62052-11 Wireless Comunication EU 4G LTE/WiFi Hotspot/GPRS/GSM OPTIONAL DEVICES...
  • Page 94 Raption 150 Compact Service Manual...

  • Page 95: Need Help

    Need help? In case of any query or need further information, please contact our Support Department support@circontrol.com circontrol.com (+34) 937 362 940 (+34) 937 362 941...
  • Page 96 CIRCONTROL Raption 150 Compact Service MANUAL A comprehensive guide on how to use and configure your Raption Charging Station. V1.0, June edition 2022 R513 CIRCONTROL S.A. - ALL RIGHTS RESERVED...

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