EXP EXP180K2-FD User Manual

Fast dc charger

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EXP180K2-FD Fast DC Charger

User Manual

Ver: V1.1

Released time: 2020-12-10

BOM:

201040154

Shenzhen Infypower Co.,Ltd

www.infypower.com

Service hotline:：(+86) 0755 8657 4800

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Page 1 EXP180K2-FD Fast DC Charger User Manual Ver: V1.1 Released time: 2020-12-10 BOM: 201040154 Shenzhen Infypower Co.,Ltd All rights reserved. This Manual may be subject to change without notice. www.infypower.com Service hotline:：(+86) 0755 8657 4800...
Page 2 Important safety instructions ➢ Please read the operating instructions and notes carefully before starting operation. In order to prevent accidents. The "Caution, Attention, Warning and Danger" statements in the products and product manual do not represent all safety matters to be observed and are intended to supplement various operational safety precautions.
Page 3 A strong electromagnetic field will be produced in the atmosphere under the thunderstorm. Therefore, the equipment should be well grounded to avoid damage to the equipment due to lightning strikes. Static Electricity Static electricity generated by the human body may damage electrostatic sensitive components on the circuit boards, such as the large-scale integrated circuit (IC), etc.
Page 4: Table Of Contents
TABLE OF CONTENTS 1 GENERAL PRODUCT DESCRIPTION ......................... 2 2 GENERAL CHARACTERISTIC ............................. 3 2.1Technical characteristics ................................3 2.2 Model description ..................................3 2.3 Standards ....................................4 3 PRODUCT PARTS PRESENTATION ........................... 5 INSTALLATION ................................6 4.1 Safety and compliance ................................6 4.2 Grounding instructions ................................6 4.3 Unpacking and visual inspection ..............................6 4.4 Assembly/placing instructions ..............................6 4.4.1 Preparation of concrete foundation ..........................7...
Page 5: General Product Description
1 GENERAL PRODUCT DESCRIPTION ➢ The EXP180K2-FD is able to fast charge all electric vehicles compliant with combined charging system (CCS) standard. ➢ IP55 for severe environment using，-30℃~45℃ ambient temperature full power charging. ➢ Depending on the battery capacity, EXP180K2-HD can charge properly equipped electric vehicles from 0% to 80% in roughly 30 minutes, output power up to 180kW，output voltage...
Page 6: General Characteristic
Note 2: The protection level of the DC Charger is IP55. But for charging safety it should not be used during rain or snow if water can reach the charger connector. Specifications are subject to change, without prior notice. 2.2 Model description Model Configuration Remarks 180KW EXP180K2-FD-EU CCS-2 + CCS-2...
Page 7: Standards
2.3 Standards The EXP180K2 DC Charger complies with the following standards: Table 2 –EXP180K2 Applicable Standards Technical Data Remarks IEC 61851-1 IEC 61851-23 Applicable IEC 61851-24 EN 61851-1 Standards EN 61851-23 EN 61851-24 1 IEC 61851-1 2017: Electric vehicle conductive charging system. Part 1: General Requirements 2 IEC 61851-23 2014: Electric vehicle conductive charging system - Part 23: DC electric vehicle charging station 3 IEC 61851-24 2014: Electric vehicle conductive charging system - Part 24: Digital communication...
Page 8: Product Parts Presentation
3 PRODUCT PARTS PRESENTATION The charging system is composed of DC charging cabinet and DC charging connector. The System can be installed outdoors (But for safety reasons, it should not be used during rain or snow if water can reach the charger DC connector). The EXP180K2 series fast DC Charger has various possible output combinations as showed below:...
Page 9: Installation
4 INSTALLATION 4.1 Safety and compliance Since the working voltage inside the charging system is very high and the current is very large, the following rules should always be observed to ensure personal safety: Only personnel who have received the training of the charging system and fully mastered the ➢...
Page 10: Preparation Of Concrete Foundation
4.4.1 Preparation of concrete foundation EXP180K2 concrete foundation view...
Page 11: Cabinet Installation
4.4.2 Cabinet Installation ➢ As shown in the figure below, the protective covers on both sides of the steel base of the cabinet can be removed, and the cabinet can be transported to the concrete foundation by forklift. ➢ Align the installation hole of the cabinet base and fix the cabinet on the concrete foundation with expansion bolts.
Page 12: Power Cables Connections
4.4.3 Power cables connections End terminals for input wiring: 5(five) end terminals up to 3phases+neutral+protective ground. UPPER AC INPUT EXP180K2 Table4-AC input wiring cables choose The section for Amperage Max. Power Specification of Reserved length AC feed cables at 380Vac of charger terminal screw inside cabinet...
Page 13 ※ PE: Earth Bus Bar ※ Copper bar: Power main input: L1 L2 L3 N ※ Q1: AC Input MCB For Rectifier Module ※ Q2: AC Input RCD For Auxiliary Power ※ Q3: AC GUN output- power main input MCB ※...
Page 14: Power Module Installation
4.4.4 Power Module Installation Step-1: Open the front door. Plug the power module(s) into the module slot(s) inside the cabinet, before plug the power module(s) must be noticed the install position，and locknut tightly. ※ Step-2: If pull the module out, It is very heavy, it is best to hold it by hand ※...
Page 15: Start-Up
5 START-UP 5.1 Verification and inspection ➢ Check if the bolts of the AC and protective ground cables of the EXP180K2 are correctly tightened to the specified torque ➢ Check the resistance between the EXP180K2 protective ground and the low voltage switchboard ground connection;...
Page 16: User Manual
6 USER MANUAL The EXP180K2 operation depends on its output connections: CCS. During the charging process, the Human Machine Interface (HMI), will give instructions and will signal different stages. These sequences are shown in this chapter. 6.1 Output connector The EXP180K2 is prepared to charge electric vehicles according to the mentioned charging systems Combo TYPE2 CCS2 Connector Handing 6.2 Operation instructions...
Page 17 Then swipe the RFID or scan QR Code or use OTP by input the password to start the charging process. OTP password display interface:...
Page 18 The user can choose BMS/TIME/ENERGY/SOC charging termination methods in the next display interface: Then input or select the value int the next display interface, the middle icon is auto, that means it will according the actual EV full charging requirement to finish the charging process. After enter a relevant value, then push <...
Page 19 The user need waiting for automatic charge termination before the setting value has been reached, or terminated <CANCEL> by swiping the RFID card again. Or click the button to stop the charging process, if it is OTP mod, need to input the password again. After finish, the next display interface will show the charging summary information, energy, used amount, used <BACK>...
Page 20 6.2.2 Information LCD interface Touch the icon <en>on the menu of the main display interface, we can go to Language selection. Also we can click <?> to go into the information display interface, we can get the system information, current system alarm information and charging records.
Page 22 In this Param Set interface, with: Param Set/Charger system/Local Authorize Enabled, if we disabled it, then we can realize one key start charging function with no any authority. In this Param Set interface, with: Param Set/CCU Group/Charger/CCU Specific Settings/Power Merging Mode, we can choose the different type of the charging power sharing: 1.
Page 23: Ethernet And Occp Setting
6.2.3 Ethernet and OCCP setting Enter into the /Param Set/Charger System/Charger ID, Network Setting, OCPP Server End URL, we can do the Ethernet access and OCPP setting. 6.2.3.1 Network configuration The ‘Network Setting’ includes a network configuration parameter list that can do check/adjustment after network is physically ready.
Page 24 (Note: ‘Auto Set by DHCP’ is preferred to be set to ‘ON’ if controller is connected to LAN that where a DHCP server is available) Wireless Network Configuration Before setup the wired network, you shall check the LTE modem is properly installed. - Antenna is well mounted - A valid(supported by the modem) SIM card is installed Figure 10.
Page 25 Figure 11. Wireless network configuration example 6.2.3.2 OCPP Configuration There are 2 standard parameters for back-end setting. Please get them from the back-end supplier. -Charger ID -OCPP Server End Url Figure 12. Example from OCPP-J 1.6 spec (Note: The protocol upper controller supports is OCPP-J 1.6, please refer to the OCPP official documents if you have any question about the above 2 parameters or the protocol itself) Connection Check If the above settings are done properly, you should see the ‘...
Page 26: Charger Software Update
6.2.3.3 Charger software update The charger can update the firmware by OCPP, and also support the local update by Micro SD card to update the upper controller’s firmware and by USB disk to update the pilot controller’s firmware. For upper controller’s update, firstly power on the controller, and then plug the Micro SD card into the controller’s SD inlet, and then go into the setting in“Manual Ctrl”->“Charger System”->“Reboot System”, need to input “...
Page 27 Chapter 4 Maintenance 4.1、Maintenance table Position Method Tool Maintenance cycle Eyes check AC input main breaker 2 months Devices and connection points Main circuit devices (circuit breaker, Eyes check Torque wrench 2 months AC contactor, DC contactor, DC fuse), copper bar, power module connector Eyes check 3 months Eyes check...
Page 28 4.2.2 Devices and connection points 1) Check the connection points between the main circuit components (circuit breaker, AC contactor, DC contactor, fuse) and copper bar or cable, the connection points between copper bar and copper bar, and the connector of power module for burns or serious discoloration. If yes, please check the torque and connection according to point 2) and replace the damaged cable;...
Page 29 4.2.4 Charging plug Check whether the charging plug is cracked or damaged. If so, please contact the manufacturer； Check whether the DC + and DC - terminals of the charging plug have obvious burning marks. If so, please contact the manufacturer for treatment； Use a brush to remove the dust on the surface of DC + and DC - terminals；...
Page 30 4.2.7 Alarm information 1) Click “?” In the upper right corner of the screen To view the alarm information; 2) If there is alarm information, it should be handled immediately. If it cannot be handled, it should contact the manufacturer for handling. Click here to view alarm information...
Page 31: Appendix 1 Engineering And Technical Parameters
Appendix 1 Engineering and Technical Parameters ※ The DC Charger has front and back doors. Aminimum 1000mm clearance should be provided on both sides to provide space for maintenance. ※ Hot ventilation air exits to the right and left. A minimum 1000mm clearance should be provided to prevent hot air from recirculating back to the air intake.
Page 32: Appendix 2 Schematic Diagram
Appendix 2 Schematic Diagram...
Page 33: Appendix 3 Error Codes And Possible Solutions
Appendix 3 Error codes and possible solutions...
Page 34 Table: Charger_Alarms Alarm_ID Alarm_Name Alarm_Level Description Remark System is out of service and charge is not allowed. System Not This usually comes after Availabe other critical alarm(e,g EPO pressed) System is out of service and charge is not allowed. System Diabled This happens after system is set to 'In-operative' by service guy or backend.
Page 35 This is from IMSU-D after Insulation Alarm detected the insulation abnormal This is from IMSU-D when PLC ComFail Alarm the PLC communication is lost This is from IMSU-D after Ground Fault detected ground fault This is from IMSU-D after AC Fail Alarm(for detected AC gun input AC only) fails(DI)
Page 36 Stop Reason Code Description Remark Classification Normal Stop Condition satisfied Normal Stop EV Requst Stop EV Reqest Stop Parameter configuration failed Charging Enable timeout Abnormal volt of outside bus Unable lock charging gun Insulation inspection abnomaly Insulation inspection timeout EV Relay pull-In timeout Require Curr Timeout Remain time over stop Ring fail alarm (reserved)
Page 37 Battery overvoltage Battery undervoltage Battery current deviation error High battery temperature Battery voltage deviation error Charger Connector Lock Fault EV Error Vehicle shift position Error Status Noticed by EV PLC Low Level Comm Fail PLC High Level Comm Fail PLC Authentication Timeout PLC ParamDiscovery Timeout Local Stop Server Stop...