Atlas Copco ZCharger 160 CE Instruction Manual
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Atlas Copco ZCharger 160 CE Instruction Manual

Atlas Copco ZCharger 160 CE Instruction Manual

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ZCharger 160 CE
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  • Page 1 Instruction Manual Instruction Manual for ZCharger English ZCharger 160 CE ZCharger 240 CE...
  • Page 3 Instruction Manual for fast charger ZCharger 160 CE ZCharger 240 CE Original instructions Printed matter No. 2960 8280 03 ATLAS COPCO - POWER AND FLOW DIVISION www.atlascopco.com 02/2024...
  • Page 4 Neglecting maintenance or making changes to the setup of the machine can result in major hazards, including fire risk. While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors.

  • Page 5: Table Of Contents

    Table of contents Preface Installation steps of charging equipment 32 Tools required..........32 Please read the following instructions carefully before Introduction..........7 starting to use your fast charger, Unpacking the outer package of the cabinet 34 About the safety and operating instructions 7 6.2.1 Placing charger ...........

  • Page 6: Table Of Contents

    Replacement of common devices ....52 9.7.1 Replacing the dust screen ......61 9.7.2 Guidance for replacement of dust filter ..63 Troubleshooting ........66 10.1 ZCharger 160 CE........66 10.2 ZCharger 240 CE........69 Emergency unlock ........72 11.1 Introduction..........

  • Page 7: Introduction

    Introduction Thank you for choosing a product from Atlas Copco. Since 1873, we have been committed to finding new and better ways of fulfilling our customers' needs. Through the years, we have developed innovative and ergonomic product designs that have helped customers improve and rationalize their daily work.

  • Page 8: Safety Precautions

    Atlas Coco after-service center or death. directly. If unauthorized found third party to maintenance under warranty, Atlas Copco will not be liable. - 8 -...

  • Page 9: Safety Instructions For Operation

    Therefore, the product unauthorized modifications to the product or will not cause property damage or endanger removal of the product. Atlas Copco will not be human health under normal circumstances if the liable for any consequence caused by the violation...

  • Page 10: Storage Precautions

    Do not connect or disconnect avoid personal electric shock and equipment power cables with power on. damage. Atlas Copco shall not be liable for any consequence caused by any of the following events: • After maintenance, close and lock the door properly so that the insulation of the equipment •...
  • Page 11 Special symbols Caution Danger Warning • Please read the maintenance • Because some of the parts of the power • Special tools must be used in all kinds instructions carefully before system are at a high voltage during of operations at high DC and AC maintenance.

  • Page 12: Overview

    Overview To reduce the risk of serious injury or death to • The intelligent standby mode can effectively yourself or others, read the Safety precautions reduce the operation cost of customers in the section found on the previous pages of this manual whole project life cycle, and improve the return before operating the machine.

  • Page 13: Product Views

    Product views Reference Descriptions Outside view of the Atlas Copco DC fast charger Status LED Human machine interface Emergency button Door Handle/ Lock Charging connector Digital input receiver Eye bolts for lifting Pay card reader Air outlet - 13 -...
  • Page 14 Inside view of the Atlas Copco DC fast charger Reference Descriptions Main circuit breaker AC incoming copper bar Inlet hole Reserved signal line hole - 14 -...

  • Page 15: Installation

    Installation Equipment installation requirements 1. The charger is opened in front, left and right, and the connectors are used from both sides. Space should be reserved around. See Figure 3.2-A for the reserved size. 4. Install 4 stainless steel M12* 80 mm expansion bolts between the base and the 2.

  • Page 16: Construction Of Distribution Cables

    Construction of distribution cables Process requirements of distribution cables Layout requirements of distribution cables 1. Cable laying shall be free from external force, distortion and damage of insulation layer. 1. The input cable of the system is introduced from the inlet hole at the bottom of the charger, and the cable shall be laid through the cable trench.

  • Page 17: Cable Specifications For Ac Input

    Cable specifications for AC input Capacity Cable specification (YMvKas mb) Capacity of superior Screw specification Cable material distribution switch (A) (diameter: mm) 160kW 4*150 mm + 150 mm L1/L2/L3/N/PE: M12 L1/L2/L3/N/PE: DT150-12 240kW 4*300 mm + 1*120 mm L1/L2/L3/N: M16 L1/L2/L3/N: DT240-16 PE: M12 PE: DT120-12...

  • Page 18: Dimensional Drawing

    Dimensional drawing ZCharger 160 with frame (9829372790-01-01) Frame ZCharger Lifting Eye HMI Screen Emergency Stop Charging Connectors 190(2x) 1300 ForkLift slot 1408 1340 - 18 -...
  • Page 19 ZCharger 160 (9829372790-01-02) Cable Inlet Lifting Eye HMI Screen Emergency Stop Charging Connector 1000 - 19 -...
  • Page 20 ZCharger 240 with frame (9829372960-01-01) Z charger Lifting eye Frame Screen Emergency Stop Charging Connector 190(2x) 1300 Forklift Slot 1340 1408 - 20 -...
  • Page 21 ZCharger 240 (9829372960-01-02) Cable inlet Lifting Eye HMI Screen Emergency Stop Charging Connector - 21 -...

  • Page 22: Circuit Diagram

    Circuit diagram ZCharger 160 (9829370152-01-02) To Fan To PLC Door switch Emergency stop RS232 PLC1 RS485 DC1- DC1+ KM K KM11 AC inlet To electric car KM12 SPD1 screen card reader RS232 RS232 SPD0 to CJ5 SPD2 KM22 To electric car KM21 RS485 DC2- DC2+...
  • Page 23 ZCharger 160 (9829370152-01-03) LEFT BEHIND OF DOOR RIGHT Cubicle Top antenna NCM-4G system power DC surge protection device RSP-200-12 system power SPD1 SPD2 SPD1-PE SPD2-PE WY3-L;WY2-L;Wh1-L;Wh2-L LRS-35-24 WY3-N;WY2-N;Wh1-N;Wh2-N WY1-L T1-J30-3; CJ5-J2-2 PLC1 WY1-N 1C1-J4-3; 2C1-J4-3 PLC communication module PLC1-CON8-2;PLC2-CON8-2 T1-J30-1; CJ5-J2-1 PLC1-CON8-1;PLC2-CON8-1 1C1-J4-1;...
  • Page 24 ZCharger 160 (9829370152-01-04) LEFT DOOR MODULE TOP OF DOOR FAN1 DC FAN INLET T SENSOR 1C1-J20-1 NOTE:AT INLET OF MODULE 1C1-J20-2 OUTLET T SENSOR 1C1-J20-2 NOTE:AT OUTLET OF MODULE 1C1-J20-3 WY3- +V CCS-PE CCS-PE CJ5-J10-1;FAN2-BLUE WY3- -V Magnet Ring *3pc， φ37mm。...
  • Page 25 ZCharger 160 (9829370152-01-05) M8（G0 A8） M7（G0 A6） M6（G0 A4） M5（G0 A2） M4（G0 A7） M3（G0 A5） M2（G0 A3） M1（G0 A1） Note:Front view，M*- label No. G*-Grouping setting No.，A*-Module setting No. - 25 -...
  • Page 26 ZCharger 240 (9829372961-01-01) Display Card reader RS232 RS232 To Fan Emergency Entrance To PLC Guard Button RS232 PLC1 L1 L2 L3 DC1- DC1+ Temp.sensor Humidity sensor KM11 AC INPUT To electric car KM12 1CCS To CJ5 Board KM22 To electric car KM21 2CCS PE RS232...
  • Page 27 ZCharger 240 (9829372961-01-02) TOP SIDE OF DOOR Cubicle Top antenna LEFT ENTRANCE GUARD FRONT ENTRANCE GUARD RIGHT ENTRANCE GUARD MAINTENANCE LAMP SWITCH NCM-4G NC(2) NC(2) LED1-J1-1 NC(2) NC(2) NO(3) COM(1) NO(3) COM(1) NO(3) COM(1) SQ3-NO(3) SQ2-COM(1) 1C1-J6-3 1C1-J6-4 SQ1-COM(1) SQ1-NO(3) NO(3) COM(1) 2C1-J4-4...
  • Page 28 ZCharger 240 (9829372961-01-03) THE LEFT SIDE THE TOP OF THE FRONT THE RIGHT SIDE LED1 LED2 LED3 Tilt Sensors Smoke transducer UP1- +V UP1- +V UP1- -V CJ5-J10-3 1C1-J7-2 1C1-J7-1 CJ5-J10-4 UP1- -V OPTIONAL THE UPPER FRONT DOOR 1CJ1 2CJ1 1CCS-PE 2CCS-PE Positive and negative poles of charging connector need to cover the magnetic ring,inner diameter 37mm...
  • Page 29 ZCharger 240 (9829372961-01-04) LEFT DOOR OF THE CABINET MODULE PLUG IN BACK FRONT BACK IN CABINET INLET T SENSOR 1C1-J20-1 4G Router NOTE:AT INLET OF MODULE 1C1-J20-2 SOCKET TYPE 5.5*2.1 UP1- +V/-V Light line 4G antenna WAN LAN1 LAN2 LAN3 LAN4 SEV-D8-A00 FAN2 FAN1...
  • Page 30 ZCharger 240 (9829372961-01-05) M12 (GO A12) M11 (GO A10) M10 (GO A8) M9 (GO A6) M8 (GO A4) M7 (GO A2) M6 (GO A11) M5 (GO A9) M4 (GO A7) M3 (GO A5) M2 (GO A3) M1 (GO A1) NOTE: 1.In the front door view,M* as the tag number, G* indicates the group number, and A* indicates module number - 30 -...

  • Page 31: Internal Wiring Diagram Of Equipment

    Internal wiring diagram of equipment The internal AC input cables are N,L1,L2,L3 and PE from left to right. The cabinet grounding is divided into two parts, one is the grounding bar inside the cabinet, and the other is the grounding of cabinet shell, as shown in figure - 31 -...

  • Page 32: Installation Steps Of Charging Equipment

    Installation steps of charging equipment Tools required Tools Photograph Insulation shoes Tools Photograph Claw hammer Adjustable wrench Herringbone ladder Art Knife Cross Screwdriver 1 Insulating gloves - 32 -...
  • Page 33 Tools Photograph Electric drill equipped with 16 mm drill bit Cable clipper Hydraulic clamp Anti-theft wrench - 33 -...

  • Page 34: Unpacking The Outer Package Of The Cabinet

    Unpacking the outer package of the Foundation drilling cabinet Tools required: electric drill, Dia 16 mm drill bit, protective gloves • Tools required: Herringbone ladder. claw • Lay the control paper on the cement installation hammer, art knife, protective gloves top of the base, and the cable hole of the mouldboard packing material with a claw hammer, and remove corresponds to the cable hole of the base.

  • Page 35: Placing Charger

    Placing charger 2. The inlet cable sealing plate of the cabinet can be removed, but the protection coil shall be avoided from damage during the removal process. . • Use forklift to transport the cabinet to the installation base, and use the crane to lift the cabinet.
  • Page 36 Installation steps of inlet cable 4. First install the front and rear sealing plates in the direction of the arrow, and then install the M16*15 • Use the cable clipper to cut the cable to the screws from the left and right side of the fastening. appropriate wiring length, press the lug with hydraulic clamp and put on the heat shrinkable •...

  • Page 37: Wiring Of Router And Card Reader

    Wiring of router and card reader Host card reader module (CM20) wiring TCU (T1) wiring diagram diagram Since the router, host card reader, and subordinate card reader are installed on site, cable connections Note need to be wired according to the following 1.
  • Page 38 Overall wiring diagram - 38 -...

  • Page 39: Inspection After Installation

    Inspection after installation • Check the installation of the equipment according to the foundation installation drawing. Stability • After the pile is installed, shake the cabinet from different directions, and there should be no obvious loosening and shaking. Clean up •...

  • Page 40: Operation Interface

    Operation interface Charging process Waiting for connector insertion Connecting interface interface When the charger is in standby mode, the screen is in the energy-saving mode. Before operation, touch the screen with your finger to light up the screen. Standby interface Click next to enter the interface of charging mode selection.

  • Page 41: Charging Modes Interface

    Charging modes interface Click the payment method you want to enter the next charging operation. - 41 -...

  • Page 42: Qr-Based Charging Process

    QR-based charging process Scan the QR to enter the start charging interface . Charging interface Click "end" to end charging and enter the settlement interface . - 42 -...

  • Page 43: Card-Based Charging Process

    Card-based charging process Select or enter the precharge amount to enter the card swiping interface. Pay by card according to the interface prompt to enter the charging start interface Charging interface. Click "End" to end charging and enter card interface. Enter the settlement interface after paying by card...

  • Page 44: Password-Based Charging Process

    Password-based charging process Enter the password to enter the start charging interface . Charging interface. Click "end" to end charging and enter the pay interface. - 44 -...

  • Page 45: Power Limitation Settings

    Power limitation settings The following instructions are based on MCU version higher than 111.01.104.42. Single connector To change the power limitation for a single connector, change the value for ‘Maximum Power’ with following steps: Settings > CCU > Protection > Maximum Power This setting only applies to an individual connector’s power output.
  • Page 46 2. Set the maximum power limits for both the connectors as the desired total power limit. Administrator mode (password 080808) > Setting > CCU > Protection > Connector No: A > Maximum power: The value to be limited in total Connector No: B >...

  • Page 47: Technical Specifications

    Technical specifications Category Parameter Value/Description ZCharger 160 CE ZCharger 240 CE Input Input 3P+N+PE 3P+N+PE Characteristic Input Voltage AC 380 ± 15% AC 400 ± 10% Frequency 50/60 Hz 50/60HZ Power Factor 0.99 0.99 THDi < 5% <5% Output Output Voltage...
  • Page 48 Category Parameter Value/Description ZCharger 160 CE ZCharger 240 CE Environmental Operating temperature -25 ~ 65 degree C (Above 45 degree C derating -20 ~ 50 degree C (Full power) conditions operation) Humidity 5% ~ 95% 5% ~ 95% Altitude < 2000 m <...

  • Page 49: Maintenance

    It guarantees that all necessary parts are replaced at the same time keeping down time to a minimum. Scan the QR code to access into the Atlas Copco The order number of the Service Packs are listed in Power Connect site. Enter the machine serial number the Atlas Copco Parts List (ASL).

  • Page 50: Charger Maintenance Items And Checking Cycle

    Charger maintenance items and checking cycle Checking item Checking Checking content Treatment method cycle Front-end Three months Each item is checked in accordance with the maintenance manual of the distribution box. Maintenance and repairing distribution box (Note: The maintenance manual of the distribution box is provided by the supplier of distribution box) Appearance of One year...
  • Page 51 Checking item Checking Checking content Treatment method cycle Equipment Half a year Check whether the ground wire of the equipment housing is loose or detached. Maintenance and repairing grounding System grounding Half a year Check whether the grounding cable inside the cabinet is loose and fall off, whether the Maintenance and repairing grounding sign is complete and obvious, and whether there is any loss or damage.

  • Page 52: Replacement Of Common Devices

    And then the electric meter can be removed. 3. Replace with a new electric meter in the opposite way to disassemble it. ZCharger 160 CE - 52 -...
  • Page 53 Main circuit breaker ZCharger 160 CE ZCharger 240 CE Tools required: allen wrench, screwdriver and socket wrench Tools required: screwdriver and socket wrench Replacement steps: Replacement steps: 1. Remove the screws in the fixed bus bar of the circuit breaker by using an Allen 1.
  • Page 54 2. Use a screwdriver to remove the four fixing screws of the fan. And then the fan can be removed. 3. Replace with a new cooling fan in the opposite way to assemble it. ZCharger 160 CE - 54 -...
  • Page 55 AC Contactor ZCharger 160 CE ZCharger 240 CE Tools required: screwdriver Tools required: socket wrench Replacement steps: Replacement steps: 1. Use a screwdriver to unscrew six screws fixing the bus bar in the AC contactor. 1. Use a socket wrench to unscrew six screws fixing the bus bar in the AC Note that these screws cannot be taken out and can only be unscrewed.
  • Page 56 Transformer ZCharger 160 CE Tools required: screwdriver Replacement steps: 1. Use a screwdriver to remove the protective cover on the transformer and remove the connecting cable. 2. Use the screwdriver to remove the four screws of the fixed plate at the bottom of the transformer.
  • Page 57 3. Use the screwdriver to remove the fixing screw in the upper right corner and lower left corner of the DC contactor. And then the DC contactor can be removed. 4. Replace with a new DC contactor in the opposite way to assemble it. ZCharger 160 CE - 57 -...
  • Page 58 Fuse System operating power supply ZCharger 240 CE ZCharger 240 CE Tools required: socket wrench Tools required: screwdriver Replacement steps: Replacement steps: 1. Remove the fuse connection cable. 1. Remove the connection cable from the system power supply. 2. Remove the screw from the fuse. 2.
  • Page 59 Display screen ZCharger 240 CE Tools required: screwdriver Replacement steps: 1. Remove the connection cable from the display screen. 2. Hold the display screen from the front and remove the twelve screws and the clips from the back. 3. Remove the display from the front. 4.
  • Page 60 Connector line ZCharger 240 CE Tools required: spanner, screwdriver Replacement steps: 1. Remove the connecting cable of the connector line. 2. Remove the screws from the connector line terminals and the U-clips holding the connector line in place. 3. After loosening the PG head with a spanner and taking the connector line out, remove the PG head from the connector line.

  • Page 61: Replacing The Dust Screen

    Replacing the dust screen ZCharger 160 CE Tools required: screwdriver Replacement steps: 1. Turn off the power supply and open the left and right doors of the cabinet. 3. Use the drawing pipe of dust screen to draw out the old dust screen and scrap it.
  • Page 62 4. Insert the new dust screen with the same specification into the left and right Install the side cover plate and lock the screw (M14*16). The reference torque side door respectively. of screw tightening: 16kgf. cm. The top of the cover plate shall be hung first for installation of the One end of the pull ring is kept outside for the next change.

  • Page 63: Guidance For Replacement Of Dust Filter

    Guidance for replacement of dust filter ZCharger 240 CE Tools required: screwdriver Replacement steps: 1. Turn of the power supply and open the left and right doors of the cabinet. 3. Use the drawing pipe of dust filter to draw out the old dust filter and scrap it. 2.
  • Page 64 4. Insert the new dust filter with the same specification into the left and right side Install the side cover plate and lock the screw (M14*16). The reference torque door respectively. of screw tightening: 16kgf. cm. The top of the cover plate shall be hung first for installation of the One end of the pull ring is kept outside for the next change.
  • Page 65 6. The dust filter has been replaced. - 65 -...

  • Page 66: Troubleshooting

    Troubleshooting ZCharger 160 CE Content of Failure Cause of failure Method of treatment • • Abnormal The connection of CAN bus between TCU and Use a multimeter to check whether the CAN communication line Communication of controller of charging pile is loose.
  • Page 67 Content of Failure Cause of failure Method of treatment Access control failure • The door is not closed. • Close and lock the door again. • The line of the micro-motion travel switch is not • Check whether the line of the micro-motion trip switch is inserted inseted or damaged.
  • Page 68 Content of Failure Cause of failure Method of treatment Input undervoltage • The grid voltage fluctuates and the input voltage • Use a multimeter to measure whether the input three-phase voltage is failure is lower than the input voltage protection lower than the protection threshold of input voltage of the charging threshold of the charging pile.

  • Page 69: Zcharger 240 Ce

    ZCharger 240 CE Error Content of Failure Cause of failure Method of treatment code 1000 Abnormal • The connection of CAN bus between MCU and • Use a multimeter to check whether the CAN communication line Communication of controller of charger is loose. between MCU and the charging controller is connected abnormally, control panel whether the matching resistance is connected reliably, and whether...
  • Page 70 Error Content of Failure Cause of failure Method of treatment code • • Off-line Check whether the router has a network or the Check whether there is a network with a router directly connected to signal of the station is weak the laptop.
  • Page 71 Error Content of Failure Cause of failure Method of treatment code Input undervoltage • The grid voltage fluctuates and the input voltage • Use a multimeter to measure whether the input three-phase voltage is failure is lower than the input voltage protection lower than the protection threshold of input voltage of the charger.

  • Page 72: Emergency Unlock

    Emergency unlock Introduction Procedure Mechanism This section shows how to detach the connector when 1. Insert the urgent detaching tool in the hole for The connector is locked and cannot be removed when it cannot be removed under some abnormal situation. urgent detaching at the side of the connector grip.

  • Page 73: Disposal

    (for example sand, sawdust) and recyclable materials. dispose it according the applicable local disposal Your Atlas Copco ZCharger consists for the most part regulations. Do not drain into the sewage system or For more information check with your local waste of metallic materials, that can be remelted in surface water.
  • Page 75 Scan the QR code to access into the Atlas Copco Power Connect site. Enter the machine serial number to get the Atlas Copco Spare Parts List (ASL).

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