Autel MAXICHARGER DCFC 60kW Manual
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Autel MAXICHARGER DCFC 60kW Manual

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MAXICHARGER
DC FAST 60KW-240KW
SPECIFICATIONS
•
FLEXIBLE POWER MODULE DESIGN
•
MULTIPLE CABLE & CHARGING
CONNECTOR OPTIONS
• 27-INCH TOUCHSCREEN DISPLAY
1.844.765.0150
I
WWW.AUTELENERGY.COM
™
•
SMART CLOUD PORTAL WITH
REMOTE DIAGNOSTICS
• DYNAMIC LOAD BALANCING
• ISO 15118 PLUG & CHARGE
I
AUTELENERGY@AUTEL.COM
WITH 20KW
INCREMENTS

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Summary of Contents for Autel MAXICHARGER DCFC 60kW

  • Page 1 MAXICHARGER ™ DC FAST 60KW-240KW WITH 20KW INCREMENTS SPECIFICATIONS • FLEXIBLE POWER MODULE DESIGN • SMART CLOUD PORTAL WITH REMOTE DIAGNOSTICS • MULTIPLE CABLE & CHARGING CONNECTOR OPTIONS • DYNAMIC LOAD BALANCING • 27-INCH TOUCHSCREEN DISPLAY • ISO 15118 PLUG & CHARGE 1.844.765.0150 WWW.AUTELENERGY.COM AUTELENERGY@AUTEL.COM...
  • Page 2 UL 2202, UL 2231-1, UL 2231-2, NEC Article 625, CSA C22.2 No. 107.1-16 COMPLIANCE & SAFETY FCC Part 15 Class A, Class B (Optional) EMC COMPLIANCE 24 Months with Warranty Extensions Available WARRANTY * CCS1 Max 200A, CCS1 Boost 300A (Max 400A) ** RCD: Residual Current Detector For Ground Fault Protection 1.844.765.0150 WWW.AUTELENERGY.COM AUTELENERGY@AUTEL.COM...
  • Page 3 Installation and Operation Manual MaxiCharger DC Fast (UL)
  • Page 4 Autel will not be liable for any direct damages or for any special, incidental, or indirect damages or for any economic consequential damages (including the loss of profits).

  • Page 5: Table Of Contents

    CONTENTS USING THIS MANUAL .......................... 1 1.1 C ..............................1 ONVENTIONS 1.1.1 Bold Text ............................... 1 1.1.2 Illustrations ............................1 1.1.3 Hyperlink ............................... 1 1.1.4 Notes and Important Messages ......................1 1.1.5 Procedures ............................1 1.1.6 Revision History ............................ 1 1.2 T ..............................
  • Page 6 5.5.2 Connecting the PE Wire ........................32 5.5.3 Grounding the Enclosure ........................33 5.5.4 Connecting the AC Input Wires ......................33 5.5.5 Connecting to the Internet ......................... 35 5.6 I ......................... 37 NSTALLING THE HARGING ODULE 5.7 P ........................40 REPARING FOR OMMISSIONING OPERATION ............................
  • Page 7 9.5 P ........................60 OWER ATING PECIFICATIONS 9.6 AC I DC O ....................... 61 NPUT AND UTPUT PECIFICATIONS 9.7 P ......................63 OWER ONSUMPTION PECIFICATIONS 9.8 I ....................63 NPUT HORT IRCUIT URRENT PECIFICATIONS...

  • Page 8: Using This Manual

    Using This Manual This manual describes the installation and use of the MaxiCharger DC Fast 120kW (DF120) and MaxiCharger DC Fast 240kW (DF240). Prior to installation, read through this manual to become familiar with the instructions of this MaxiCharger to ensure a successful installation and smooth operations. 1.1 Conventions The following conventions are used.

  • Page 9: Terminology

    1.2 Terminology Term Definition Alternating current Combined Charging System, a standard charging method for electric vehicles Charging Control Unit: a control unit used to communicate with the BMS (Battery Management System) and control the power delivery to the EV Abbreviation of CHArge de MOve, a standard charging method for electric CHAdeMO vehicles Direct current...

  • Page 10: Safety

    Safety The safety messages herein cover situations of which Autel is aware. Autel cannot know, evaluate or advise you as to all of the possible hazards. You must be certain that any condition or service procedure encountered does not jeopardize your personal safety.

  • Page 11: Owner Responsibilities

    ü Ensure there is no damage to the gasket that may cause water intrusion. ü Protect the MaxiCharger with safety devices and measures that the local rules specify. ü Installation personnel must have the correct protective equipment such as protective clothing, safety gloves, safety shoes, and safety glasses.

  • Page 12: Igns On The Axi Harger

    These measures may include firewall building, authentication methods, data encryption, and anti-virus programs installation, etc. Autel is not liable for damages and/or losses pertaining to the security breaches described above.

  • Page 13: General Introduction

    DANGER ü The equipment must be operated as described in this manual or other related documents released by Autel. Failure to comply may result in human injury and/or damage to the property. ü Use the equipment only as intended. NOTE...

  • Page 14: Product Descriptions

    Product Descriptions...
  • Page 15 Emergency Stop Button Vent Handle Lock Holster Base NOTE Autel can deliver the MaxiCharger with different payment terminals. The available options vary depending on the region of the installation. Consult Autel9s customer service to obtain more information about the different payment options.
  • Page 16 Table 3-2 Indicator Descriptions Charging Status Color Description Solid Green A connector is available. Standby Mode Solid White An EV is connected to the MaxiCharger. EV Connected Illuminating Green in Turn Indicates the charging progress. Charging An EV is fully charged or has stopped Flashing Green Charging Completed charging.

  • Page 18: Working Principle

    Working Principle Local Service Portal The Local Service Portal is a service tool provided by Autel that provides information pertaining to the equipment. This service tool configures key parameters for commissioning, enables on-site diagnostics. For the operation procedures, refer to Local Service Portal Operations.

  • Page 19: Cloud Service Portal

    Device Model Maxi US ************ Rated Power 120kW Rated Voltage 950V Maximum current 200A Set Current 200A Max Power 120kW Cloud Service Portal Different cloud-based tools are provided to commission, monitor, and troubleshoot the MaxiCharger. For more information, contact Autel support.

  • Page 20: Preparation

    Preparation General installation procedure: 1. Ensure the installation site is ready and you have all the parts and tools described in the sections below. 2. Install the MaxiCharger as described in Chapter 3. Energize the MaxiCharger and verify it is fully operational as described in Chapter 6.
  • Page 21 Front side of the MaxiCharger Rear side of the MaxiCharger Left side of the MaxiCharger Right side of the MaxiCharger Cabinet Table 4-1 Space Requirements for DF120 Specification Parameter 32.3 31.5 31.5 23.6 19.7 33.5 Table 4-2 Space Requirements for DF240 Specification Parameter 32.3...
  • Page 22 EV9s. NOTE While Autel tests the MaxiCharger with a majority of upcoming vehicles, we cannot guarantee the port locations of future vehicles and cannot warrant the configurations proposed will work for all vehicles.

  • Page 23: Electrical Design

    4.1.2 Electrical Design The MaxiCharger requires underground wiring. The conduit and wire size are based on the length of runs from the electrical panel to the installation site. The wiring must be run through the conduit or ducting, or armored cable must be used to comply with local electrical codes. Consult the national and local codes or a service engineer for the quality, grade, and size of the conduit or cable.

  • Page 24: Preparing The Foundation

    4.1.3 Preparing the Foundation General Procedures: 1. Select a suitable base to install the cabinet on. 2. Embed the cables in the ground with a cable conduit. 3. Prepare the foundation. 4.1.3.1 Preparing the Foundation 1. Dig a hole according to the foundation dimensions. The recommended dimensions of the hole are: ü...
  • Page 25 3. Run the conduit to the designated location. 4. Pour the concrete into the hole and wait until the concrete has hardened. Verify that the foundation should be 5.9 inches (150 mm) higher than the surface. The concrete should be at a rated minimum of 2500 PSI.
  • Page 26 6. Place the drilling template on the concrete surface, aligning with the marked area (C). Mark the four mounting holes (D) and remove the drilling template. Drill into the holes with depth over 4.3 inches (110 mm) and 4/5 inch (20 mm) in diameter. Clean any debris. Figure 4-3 Foundation Diagram Table 4-4 Foundation Specifications 2 Specifications...

  • Page 27: Unpacking

    30° of tilt or total overturn, refuse the delivery. ü If the Shockwatch displays red, contact Autel customer service and the delivery personnel, and then inspect the product for any damage. Do not accept the delivery until the inspection is complete and no damage is found.

  • Page 28: Packing List

    Packing List 4.3.1 Packing List for DF120 Expansion Bolt MaxiCharger (M16 x 150) 1 PC 4 PCS Bolt (M10 x 30) Flat Gasket (Size 10) 7 PCS 10 PCS Hex Nut (M10) Screw (M4 x 10) 7 PCS 24 PCS Bolt (M8 x 25) Eye Bolt (M16) 2 PCS...

  • Page 29: Packing List For Df240

    4.3.2 Packing List for DF240 Expansion Bolt MaxiCharger (M16 x 150) 1 PC 4 PCS Bolt (M10 x 35) Flat Gasket (Size 10) 7 PCS 14 PCS Spring Washer Hex Nut (M10) (Size 10) 7 PCS 7 PCS Bolt (M8 x 25) Screw (M4 x 10) 2 PCS 48 PCS...
  • Page 30 Recommended Tools The following tools are recommended when installing the MaxiCharger. Ensure you have these tools readily available prior to installation. þ Multimeter þ Spirit Level þ Tape Measure þ Brush þ Cellular Signal Detection Device þ Wire Stripper þ Cable Lug þ...

  • Page 31: Recommended Tools Installation

    Installation Before Installing Prior to installation, check the following: ü The installation site is prepared. ü The appropriate service wiring, circuit protection, and metering is in place at the installation site. ü A grounding conductor that complies with local codes is properly grounded to earth. ü...

  • Page 32: Center Of Gravity

    Center of Gravity Please see the figure below for the center of gravity when installing the MaxiCharger. Figure 5-1 Center of Gravity Specifications Parameter DF120 DF240 15.8 15.8 13.0 11.8 33.1 33.1...

  • Page 33: Moving The Cabinet To The Site

    Moving the Cabinet to the Site There are two ways to move the cabinet to the construction site: ü Hoist ü Forklift WARNING Risk of pinching or crushing. Heavy Equipment. ü Ensure that the hoisting equipment or forklift truck can lift the cabinet safely. ü...

  • Page 34: Forklifting The Cabinet

    5.3.2 Forklifting the Cabinet ø To forklift the cabinet 1. Ensure the forks (A) of the forklift truck in the gaps go through the gaps in the side of the pallet. 2. Move the cabinet to the construction site. Figure 5-3 Transporting the Cabinet by Forklift...

  • Page 35: Installing The Cabinet

    Installing the Cabinet 1. Remove the front and rear base covers (A) using a screwdriver. Reinstall them after all the installation work is completed. Figure 5-4 Removing the Base Covers 2. Open the front door of the MaxiCharger. DANGER Hazardous voltage Ensure that only qualified personnel have access to the door key.
  • Page 36 Figure 5-5 Removing the Galvanic Isolation Board 4. Loosen the four fasteners (A) on the cable gland plate, remove the plate, and close the door. Figure 5-6 Loosening the Fasteners 5. Remove the cabinet from the pallet by removing the four hex nuts (D), spring washers (E), flat gaskets (F1), expansion bolts (G), and flat gaskets (F2).
  • Page 37 Figure 5-7 Removing the Cabinet from the Pallet 6. Hoist the cabinet. If the cabinet has not been hoisted before, refer to for hoisting instructions. 5.3.1 7. Carefully move the cabinet at 20 inches (500 mm) above the foundation. Put the service wiring through the AC inlet hole.

  • Page 38: Electrical Wiring

    Electrical Wiring 5.5.1 Preparing for the Electrical Wiring 1. Reinstall the cable gland plate. 2. Guide the service wiring (A) and the Ethernet cable (C) through the cable gland plate as per the diagram below. Reinstall and tighten the four fasteners to secure the cable gland plate. Figure 5-9 Guiding the Cables through the Cable Gland Plate NOTE Install a spare Ethernet cable through cable gland (B) only as needed.

  • Page 39: Connecting The Pe Wire

    5.5.2 Connecting the PE Wire 1. Cut the PE wire (C) of the power cable to the correct length to reach the PE busbar (A). 2. Use the wire stripper to remove 0.8 in (20 mm) of the insulation from the end of the PE wire. Ensure the stripped length is compatible with the cable lug (B).

  • Page 40: Grounding The Enclosure

    5.5.3 Grounding the Enclosure Connect the earth conductor to the pin of the enclosure. Connect the earth conductor to the earth electrode. Figure 5-12 Grounding the Enclosure 5.5.4 Connecting the AC Input Wires 1. Cut the wires L1, L2, and L3 to the correct length to reach the connectors on the AC fuse. 2.
  • Page 41 Figure 5-13 Connecting the AC Input Wires (1) 6. Use duct seal to seal the conduit opening as needed. IMPORTANT The conduit opening must be sealed to protect the wiring from the environment. If needed, connect two AC input wires of the same type to each connector as shown below: Figure 5-14 Connecting the AC Input Wires (2)

  • Page 42: Connecting To The Internet

    5.5.5 Connecting to the Internet The MaxiCharger can be connected to the Internet via the Ethernet cable, cellular network or Wi-Fi. 5.5.5.1 Connecting the Ethernet Cable Plug the Ethernet cable into the RJ45 port. Figure 5-15 Connecting the Ethernet Cable...
  • Page 43 5.5.5.2 Installing the SIM Card 1. Press the button (A) to release the SIM card tray. 2. Insert the SIM card into the tray. Ensure the card is placed correctly. 3. Push the card tray into the slot. Figure 5-16 Installing the SIM Card...

  • Page 44: Installing The Charging Module

    Installing the Charging Module 1. Slowly push the module into the slot. Figure 5-17 Installing the Charging Module (for DF120) Table 5-1 Charging Module Installation Specifications Model Rated Power Number of Modules Location DF120 60 kW 3 PCS 1, 2, 4 (UF60A3001) DF120 80 kW...
  • Page 45 Figure 5-18 Installing the Charging Module (for DF240) Table 5-2 Charging Module Installation Specifications Model Rated Power Number of Modules Location DF240 140 kW 7 PCS 1, 2, 3, 4, 7, 8, 9 (UF140A4001/UF140A3001) DF240 160 kW 8 PCS 1, 2, 3, 4, 7, 8, 9, 10 (UF160A4001/UF160A3001) DF240 180 kW...
  • Page 46 2. Install and torque the M4 x 10 screws to 10.6 lb·in (1.2 N·m) to secure the module. Figure 5-19 Tightening the Screws 3. After the installation is completed, set the hardware address. For details, contact manufacturer certified installation engineer. 4.

  • Page 47: Preparing For Commissioning

    Preparing for Commissioning DANGER Hazardous voltage Only a service engineer from the manufacturer is qualified to commission the MaxiCharger. Ensure that the site complies with these requirements: ü The MaxiCharger is installed as instructed in this manual. ü The grid can support the AC input power. ü...

  • Page 48: Operation

    7. Set the RCCB to the ON position and check the indicators on CCU, ECU, TCU, and the screen display. ü If any indicator of CCU, ECU or TCU is off or the screen display is abnormal, please contact Autel technical support.

  • Page 49: Emergency Situations

    Emergency Situations If there is an emergency, push the emergency stop button. Then the MaxiCharger will stop all charge sessions and the touchscreen will display the following message: Figure 6-1 Fault Message Screen Reset the MaxiCharger after an emergency (making sure that the situation is safe again first): Turn the emergency button clockwise to release it.

  • Page 50: Standby Screen

    ü Observe the screen for any abnormality, such as an error message, before starting a charge session. Check the surroundings and the MaxiCharger for any abnormality or damage as well. ü DO NOT operate the MaxiCharger if the screen displays an error message. Contact Autel personnel for support.

  • Page 51: Start Charging

    When the Authorization Screen appears, you can use any of the following methods to start a charge session: ü Scan the QR code on the screen ü RFID card ü Plug & charge (supports the ISO 15118 PnC function) ü Credit card (optional) Figure 6-3 Authorization Screen 6.4.3 Start Charging...

  • Page 52: Charging

    Use the same authentication method to begin the charge again. ü QR Code/Credit Card: Tap the Stop button on the Charging Screen of the Autel Charge app. ü RFID Card: Tap the RFID card on the card reader again to finish charging.

  • Page 53: Finish Charging

    Charging Errors This section depicts several common problems that may arise during a charge session along with possible causes/solutions to resolve them. If the problem persists, contact Autel technical support. 6.5.1 Connector Connection Error If the connector is not connected to the EV, then the Connector Not Connected screen will appear.

  • Page 54: Powering Down The Maxicharger

    Powering Down the MaxiCharger General Procedure: 1. Set the upstream breaker which provides the power to this MaxiCharger to OFF and lock it. Ensure that this breaker stays in the OFF position during the procedure. 2. Open the front door. 3.

  • Page 55: Measuring The Dc Voltage

    6.6.2 Measuring the DC Voltage Use a voltage tester to measure the DC voltage between the output terminals: ü Power module group output 1- (B) to power module group output 1+ (A) ü Power module group output 2- (D) to power module group output 2+ (C) ü...

  • Page 56: Local Service Portal Operations

    To set the OCPP parameters 1. Tap the upper-left corner of the screen. 2. Tap Device Maintenance. Enter the default password (contact Autel customer service to obtain the password). 3. Tap Set Parameters. Wait for the system to load the data. This can take a few seconds.

  • Page 57: Maintenance

    Maintenance 7.1 Routine Maintenance Routine maintenance can keep the MaxiCharger in a safe and stable state. ü Clean the cabinet every quarter, tighten the screws and bolts of key parts, and check whether the wire connection of the connector is burned out. If any abnormality is found, replace the parts in time. ü...

  • Page 58: Cleaning And Replacing The Air Filters

    ü Fail: There is no response when pressing the Test button. Please disconnect the AC power of the MaxiCharger and close the cabinet door, then contact Autel technical support. Do not use the MaxiCharger until the repair is completed. 4. Close the front door of the MaxiCharger after the test is finished.
  • Page 59 ø To clean or replace the air outlet filter 1. Ensure there is no active session and perform lockout-tagout to secure the MaxiCharger. 2. Open the left-side door of the MaxiCharger. When the cabinet door is open, the internal components of the MaxiCharger should not be exposed to rain, snow or harsh environments. 3.

  • Page 60: Inspection And Maintenance

    Stop the charge session and do not connect the power to the MaxiCharger until all the inspections are completed. 7.3 Remote Maintenance The MaxiCharger can connect to the Autel cloud platform to monitor parameters in real time. Autel9s cloud platform provides remote upgrades, diagnosis, and services, and identifies any issue during operation. ü Daily system self-check.

  • Page 61: Troubleshooting And Service

    Troubleshooting and Service Troubleshooting The table below describes the most common faults when operating the MaxiCharger. Contact Autel technical support if the fault encountered is not in this table. Error Error Code Possible Cause Solution Perform remote restart It may be caused by signal or reset.
  • Page 62 Autel technical support. may be damaged or there are foreign objects in the busbar. Communication error between Check the network Charger offline 0x9001 gateway and the Autel Charge connection and OCPP Cloud configurations.

  • Page 63: Technical Specifications

    Technical Specifications General Specifications Table 9-1 Product Specifications Parameter Description ü UL 2202 ü UL 2231-1, UL 2231-2, Compliance and Safety ü CSA C22.2 No. 107.1-16; ü NEC Article 625 ü FCC Part 15 Class A IP Rating NEMA 3R IK Rating IK10 Short Circuit Current Rating...

  • Page 64: Packaging Specifications

    Table 9-2 Operating Conditions Parameter Specification ü Indoor General Environment ü Outdoor Storage Temperature -40 to 158 ° F (-40 to +70 ° C) ü -31 to + 131 ° F (-35 to + 55 ° C) Operation Temperature Range ü...

  • Page 65: Installation Specifications

    Installation Specifications Table 9-5 Operable Element Specifications Specification Parameter Description Highest user operable element of MaxiCharger 53.2 1350 Lowest user operable element of the POS 30.2 Foundation height of MaxiCharger Figure 9-1 Operable Element Specifications...

  • Page 66: Communication Interface Specifications

    Communication Interface Specifications Table 9-6 Communication Interface Specifications Parameter Specification RFID Standard ISO 14443 A + B to part 4 ISO/IEC 15693 ü Mifare ü NFC ü Calypso RFID-supported Applications ü Ultralight, Pay-Pass ü HID For information about the options, contact the manufacturer. ü...
  • Page 67 Power Rating Specifications Table 9-8 Rating During Normal Duty Operation Model Specification DF120 (UF60A3001) 60 kW DF120 (UF80A3001) 80 kW DF120 (UF100A3001) 100 kW DF120 (UF120A3001) 120 kW DF240 (UF140A4001/ UF140A3001) 140 kW DF240 (UF160A4001/ UF160A3001) 160 kW DF240 (UF180A4001/ UF180A3001) 180 kW DF240 (UF200A4001/ UF200A3001) 200 kW...
  • Page 68 AC Input and DC Output Specifications Table 9-10 Rating During Heavy Duty Operation Parameter Specification If the local regulations require shielded wires, connect Wire Shielding (optional) the wire shielding to the PE bus at both ends of the wire. Diameter of the Phase Conductors Refer to the local regulations.
  • Page 69 Table 9-12 General DC Output Specifications Parameter Specification ü CCS: 150 to 950 V DC DC Output Voltage Range ü CHAdeMO: 150 to 500 V DC Minimum DC Output Current ü CCS: IEC 62196-1:2014 and IEC 62196-3:2014, UL2251:2013, 3rd Ed. and SAE J1772 :2017 Connection Standard ü...
  • Page 70 Power Consumption Specifications Table 9-14 Power Consumption during Stand-by Parameter Specification Stand-by Power (Heater Off) 0.08 kVA Stand-by Power (Heater On) 1.00 kVA NOTE The heater will operate daily when the outside air reaches the dew point, to avoid condensation inside the cabinet.

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