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Sungrow IDC180E User Manual

Sungrow IDC180E User Manual

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User Manual
DC Charger
IDC180E
IDC180EDC
Ver14-202406
IDC180E-UEN-Ver14-202406

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  • Page 1 User Manual DC Charger IDC180E IDC180EDC ChargerUser ManualIDC180E-UEN- Ver14-202406 IDC180E-UEN-Ver14-202406...

  • Page 3: All Rights Reserved

    Software Licenses • It is prohibited to use data contained in firmware or software developed by SUNGROW, in part or in full, for commercial purposes by any means. • It is prohibited to perform reverse engineering, cracking, or any other operations that...

  • Page 4: About This Manual

    The content of this manual, including the pictures, marks, and symbols used herein, is all owned by SUNGROW. No part of this manual may be reproduced by any non-internal staff without the prior written authorization of SUNGROW.
  • Page 5 charging. The charger must only be installed by qualified technical persons. Qualified techni- cal persons must: • Have certain electrical wiring, electronic, and mechanical expertise, and be familiar with electrical and mechanical schematics; • Have received professional training in the installation and commissioning of electrical equipment;...
  • Page 6 Indicates supplementary information, emphasis on specific points, or tips related to the use of the product that might help to solve your problems or save your time.

  • Page 7: Table Of Contents

    Contents All Rights Reserved .....................I About This Manual......................II 1 Safety Instructions ....................1 1.1 Safety Signs on Charger .................1 1.2 Packaging, Transport, and Storage ..............2 1.3 Installation Safety ...................3 1.4 Electrical Safety .....................4 1.5 Operation Safety ....................5 1.6 Maintenance Safety ..................6 1.7 Disposal Safety ....................7 2 Product Description ..................1...
  • Page 8 3.6.4 AC Cable Connection ................21 3.6.5 Communication Interfaces ..............24 3.6.6 Communication Cable Connection ............25 4 Commissioning ....................27 4.1 Inspection Before Commissioning..............27 4.2 Commissioning Procedure ................28 5 LCD Touch Screen ..................31 5.1 Start Charging ....................31 5.1.1 Select an Authentication Method ............32 5.1.2 Select a Charging Connector ...............36 5.1.3 Plug Connector for Charging ..............38 5.1.4 End a Charging Process ..............40...
  • Page 9 8 Troubleshooting and Maintenance ..............56 8.1 Troubleshooting ...................56 8.2 Power Off Charger..................60 8.3 Replace Power Unit ..................61 9 Appendix ......................64 9.1 Technical Data .....................64 9.2 Quality Assurance ..................66 9.3 Contact Information ..................67...

  • Page 11: Safety Instructions

    • SUNGROW shall not be held liable for any damage caused by violation of gen- eral safe operation requirements, safety standards, and the safety instructions specified in this manual.

  • Page 12: Packaging, Transport, And Storage

    • Carry out an inspection upon receiving the delivery. In case of any damage to the goods during transport, contact your transport service provider and SUNGROW for negotiation. Storage • The packaged device should be stored indoors in places with a relative humidity of 5% to 95% and ambient temperature of -40℃...

  • Page 13: Installation Safety

    • You may proceed with the subsequent work only if the qualified personnel designated by SUNGROW confirm that the environment where the device is to be installed meets the requirements after an assessment. •...

  • Page 14: Electrical Safety

    1 Safety Instructions User Manual • No one is allowed to stay under the product when it is lifted up. • When rotating the crane for unloading, keep it rotating at a low speed. Keep the product steady and as close to the ground as possible. •...

  • Page 15: Operation Safety

    • It is strictly prohibited to use the charger when its charging connector or cable is defec- tive, frayed, cracked, or in case of exposed wires. Contact SUNGROW if you have found any of the above issues. •...

  • Page 16: Maintenance Safety

    1 Safety Instructions User Manual • During the charging process, do not touch any hot part of the charger (e.g., air outlet for heat dissipation); otherwise, it may cause burns. • After charging, insert the charging connector back into the holder on the charger, so as to avoid the ingress of water or sand into the connector.

  • Page 17: Disposal Safety

    • To minimize the risk of electric shocks, do not perform maintenance operations that are not specified in this manual. If needed, please contact SUNGROW for maintenance and repair services. Otherwise, damages caused therefrom will not be covered by the warranty.

  • Page 18: Product Description

    Product Description About the EV Charging System As electric vehicles (EVs) are gaining greater popularity, the EV charging demand is now witnessing constant growth. The EV charging system is constituted by the EV, charger, AC grid, and charging management system, as shown in the figure below. It is used to satisfy the demand for EV charging.

  • Page 19: Product Overview

    DC charger. Product Overview IDC180E is an integrated DC charger, with a rated power of 180kW, manufactured by SUN- GROW. It is mainly used in public charging stations for quick EV charging. The IDC180E charger is equipped with an LCD display. Except for charging their cars, users can also view the charging data, set the parameters, and perform fault diagnosis, etc.

  • Page 20: Application Scenarios

    2 Product Description User Manual Application Scenarios The IDC180E charger is mainly used in public charging stations for quick EV charging. For ease of charger operation and management, two charging scenarios are provided for users to choose: • Near-end charging: Operate the charger using an RFID card, a credit card, or its LCD display.

  • Page 21: Operating Principle

    Operating Principle IDC180E is an integrated charger equipped with two charging connectors. The two charging connectors can be used separately or together at the same time. The product is composed of six 30kW charging power units and one charging control system. The charging control system is constituted by one main control unit (TCU) and two sub-control units (one for each charging connector).

  • Page 22: Marks On The Product

    2 Product Description User Manual • Charging begins, where AC power from the grid flows through the charger into the EVs. Marks on the Product The nameplate is attached to the side of the charger and is used to present some important parameters of the charger.

  • Page 23: Product Exterior

    User Manual 2 Product Description Product Exterior table 2-3 Dimensions and Weight Weight Model Dimensions IDC180E 1930 mm x 930 mm x 615 mm 500 KG table 2-4 Product Exterior and Interfaces Description Mark Top indicators Lifting rings Energy Star-Ring (RFID card reader)

  • Page 24: Internal Structure

    2 Product Description User Manual Internal Structure table 2-5 Internal Structure Name Toll control unit Switch 4G router LCD screen assembly Switch mode power supply Smoke detector Charging control board DC contactor Meter Fuse Shunt Heater MCB (miniature circuit breaker) AC contactor MCCB (molded case circuit breaker)

  • Page 25: Indicators

    Indicators IDC180E is equipped with two types of indicators, the top indicators, and the Energy Star- Ring on the front. The left and right top indicators indicate the status of the left and right charging connectors separately, and the Energy Star-Ring indicates the overall status of the charger.

  • Page 26: Installation

    Installation • Installation is supplied from a dedicated power transformer or generator, and which is not connected to low voltage (LV) overhead power lines. • Installation is physically separated from residential environments by distance greater than 30 m or by a structure which acts as a barrier to radiated phenomena.

  • Page 27: Installation Tools

    User Manual 3 Installation • This device is not intended for use in residential environments and may not provide ad- equate protection to radio reception in such environments. Installation Space Requirements To ensure good heat dissipation and easy maintenance, the minimum space between the charger and the objects around it should not be smaller than that specified by the requirements.

  • Page 28: Packing List

    3 Installation User Manual table 3-1 Installation Tools Goggles Safety gloves Safety shoes Anti-static wrist strap Phillips screwdriver Slotted screwdriver Marker Safety helmet M6,M8,M10 Rubber mallet Socket wrench set Wire cutter Wire stripper (M6, M8, M10, M12) Hydraulic plier Heat gun RJ45 crimping tool Multimeter Allen wrench (T30)
  • Page 29 • Be careful not to damage the product while using tools for unpacking. Quantity Description No. Name Floor-standing IDC180E DC charger M12×100 Ex- Used to fix the charger to the foundation pansion bolt Door key Used to open the front door and the left and right side...

  • Page 30: Foundation Building

    Documents warranty card, test report, packing list In case of any damages or missing items, do not install the device. Contact your transport service provider or SUNGROW, and provide relevant photos for follow-up services. Foundation Building Background Information Considering its heavy weight, please fit the DC charger on a solid brick or concrete founda- tion to ensure its stable operation.
  • Page 31 User Manual 3 Installation Preparation • Expansion bolts: 4 pcs.
  • Page 32 3 Installation User Manual Step 1 Set up a foundation according to the charger's dimensions. Build the foundation by referring to the figure below. It is recommended to keep the foun- dation 200 mm higher than the horizontal ground, and 100 mm larger than the charger dimensions on the front, back, left, and right.

  • Page 33: Charger Moving And Handling

    User Manual 3 Installation Step 3 Insert the expansion sleeves into the holes reserved for expansion bolts. Step 4 Move the charger to the foundation. Remove the front and rear sealing plates from the bot- tom of the charger, and fix the charger base to the foundation with expansion bolts. It is rec- ommended to use a S10 (M12) socket wrench to tighten the bolts.

  • Page 34: Handle With Forklift

    3 Installation User Manual Step 1 Attach the steel wire ropes to the lifting rings on the top of the charger, as shown in the figure below. Step 2 Hoist the charger vertically and smoothly. Make sure it is always held steady and does not tilt. Step 3 Suspend hoisting when the charger is lifted 100 mm off the floor.

  • Page 35: Electrical Connection

    User Manual 3 Installation Step 2 Adjust the spacing between and height of the forklift's forks, and drive slowly forward until the forks are fully inserted under the bottom of the charger. Step 3 Pick up the charger slowly, and drive the forklift to the charger foundation at a constant speed.

  • Page 36: Crimp Ot/Dt/Sc Terminal

    3 Installation User Manual OT/DT/SC terminals (not included in the scope of delivery) are required for fixing the AC ca- ble to the terminal block. Please prepare OT/DT/SC terminals by following the requirements below. OT/DT/SC Terminals of AC Cable Specification of AC L1/L2/L3 Wires: M10 Specification of AC N/PE Wires: M8 figure 5-4 Terminal size requirements OT/DT/SC Terminals of external Protective Grounding Cable...

  • Page 37: Protective Grounding Cable Connection

    User Manual 3 Installation figure 5-5 Aluminum Cable Connection 1. Copper to Aluminum adapter terminal 2. Flange nut 3. Aluminum cable Ensure that the selected terminal can directly contact with the copper bar. If there are any problems, contact the terminal manufacturer. Ensure that the copper bar is not in direct contact with the aluminum wire.

  • Page 38: Ac Cable Connection

    The AC cable is used to connect the charger to the grid, so that the grid can supply power to the charger. Background Information The use of IDC180E is supported in grids adopting TN-S, TN-C-S, and TT earthing systems. Where the TT system is adopted, the ground electrode should be pre-buried at a depth of over 1 meter.
  • Page 39 User Manual 3 Installation figure 5-6 Earthing Systems • Do not connect the AC cable when the device is powered on; otherwise, it may lead to personal injury. • Do not power the charger before the AC cable connection and cable laying are all completed.
  • Page 40 3 Installation User Manual Step 5 Use wire strippers to strip the protective layer and insulating layer of the AC cable wires by an appropriate length, by referring to the figure below. Step 6 Crimp the OT/DT terminals onto the wires by referring to the instructions shown in the figure. Step 7 Lead the stripped AC cable through the cable hole on the foundation and into the AC cable inlet on the charger.

  • Page 41: Communication Interfaces

    OCPP (Open Charge Point Protocol) defines the protocol standard for network in- terconnection between the charger and the charging management platform. The IDC180E can communicate with the charging management platform over 4G and Ether- net networks. The parameters required for each type of network connection are detailed in the table below.

  • Page 42: Communication Cable Connection

    3 Installation User Manual 3.6.6 Communication Cable Connection The charger supports 4G and Ethernet communication, the former is a wireless communica- tion technology while the later requires wiring. A SIM card is required to enable the 4G func- tion on the charger; connecting the charger to a router through a communication cable is required to allow for Ethernet communication.
  • Page 43 User Manual 3 Installation Step 2 If you are about to adopt the wireless network connection, you can follow the steps below to install the SIM card into the card slot on the inside of the charger's cabinet door. Use the ejector pin to pop open the SIM card tray. Put the SIM card on the card tray and align it with the card slot on the charger, following the direction indicated in the figure below.

  • Page 44: Commissioning

    Commissioning Inspection Before Commissioning To ensure the safe use of the charger, please perform the following inspections on the charger before powering it on. Do not power the charger unless the inspections are completed. table 4-1 Inspection Items Methods/ Requirements Item Tools •...

  • Page 45: Commissioning Procedure

    User Manual 4 Commissioning Methods/ Requirements Item Tools • The three-phase power supply cable is securely at- tached to the MCCB. • The grounding cable is securely and properly con- nected to allow for effective grounding. Power Multimeter/ supply • The screws for the input cable are fastened.
  • Page 46 4 Commissioning User Manual Step 2 As per the instructions in the figure, switch on the circuit breakers. Step 3 Close the door of the charger. Check the indicators. If the top indicator is steady green, the charging connector is in standby mode; if the Energy Star-Ring is steady blue, the charger is working normally.
  • Page 47 User Manual 4 Commissioning Step 9 At this time, you will go to the interface for charging method selection, where you can select a charging method as needed. Step 10 Taking the RFID card as an example, if you choose "RFID", the Energy Star-Ring on the de- vice will blink blue, waiting for you to tap a card over the reader.

  • Page 48: Lcd Touch Screen

    LCD Touch Screen Start Charging The charger’s touch screen serves as an interface for human-machine interaction. You can perform various operations on the device via the touch screen, e. g., starting or stopping charging, viewing the charging data, and performing fault diagnosis. The flow chart of a charging session is shown as follows:...

  • Page 49: Select An Authentication Method

    User Manual 5 LCD Touch Screen 5.1.1 Select an Authentication Method When powered on for the first time, the system will run a self-check automatically, and then show the interface for authentication method selection if nothing abnormal. Three authentication methods are available for this device. You may choose based on your actual needs: •...
  • Page 50 5 LCD Touch Screen User Manual Step 1 Once the system check is completed, you will go to the home page. Different authentication methods lead to different charging processes. table 5-1 Home Page Introduction Description Charger ID, an unique identifier for the charger. Current date and time.
  • Page 51 User Manual 5 LCD Touch Screen Step 2 By tapping RFID, you will go into the process of charging the EV with an RFID card. In this process, the system will verify if you have tapped a card over the reader. Upon de- tecting the card, the system will verify its validity.
  • Page 52 5 LCD Touch Screen User Manual Step 3 By tapping Credit Card, you will go into the process of charging the EV with a credit card. In this process, the credit card terminal will be activated by the system. Then, a message will show up, reminding you to swipe your credit card for authentication by following the instructions.

  • Page 53: Select A Charging Connector

    User Manual 5 LCD Touch Screen Step 4 By tapping Mobile App, you will go into the process of charging by scanning a QR Code. In this process, you can use the App of the third-party operation platform on your phone to scan the QR code, or enter the charger ID, and then go to the interface for selecting a charg- ing connector.
  • Page 54 5 LCD Touch Screen User Manual Step 1 Tap an RFID card or swipe a credit card. If the card is verified to be valid by the system, you will go to the interface for selecting a charging connector. The interface is shown below. table 5-2 Interface for Selecting a Charging Connector Description A notice for users to select a connector within a certain period of time, with a count-...

  • Page 55: Plug Connector For Charging

    User Manual 5 LCD Touch Screen 5.1.3 Plug Connector for Charging Please note the following items when plugging in the charging connector: • Plug or unplug the charging connector neatly at one go. Do not shake it. • Do not bend or squeeze the charging connector, which may result in mechani- cal damage.
  • Page 56 5 LCD Touch Screen User Manual Step 3 Once prepared, the charging process will be started. You will then see the below interface. The charging information will be shown on this interface. You can tap to switch between the two views. See the table below for more details. table 5-3 Charging View Description Progress of charging (%).

  • Page 57: End A Charging Process

    User Manual 5 LCD Touch Screen - - End 5.1.4 End a Charging Process You can stop charging in the middle of a charging process manually, or wait for the system to stop charging automatically when the EV is fully charged. Pull out the charging connector after the charging session has ended;...

  • Page 58: Change System Language

    5 LCD Touch Screen User Manual Step 1 On the charging view, tap Home to go back to the home page, and start another charging session using the other connector. If you started charging with an RFID or credit card, you can swipe your card on the authentication method selection interface.

  • Page 59: Emergency Stop

    User Manual 5 LCD Touch Screen 5.2.3 Emergency Stop In case the charging process has to be stopped midway due to an emergency or a fault, press the emergency stop button on the side of the charger to stop charging immediately. The device will not work once the emergency stop button is pressed.
  • Page 60 5 LCD Touch Screen User Manual • No network connection, and the device cannot access to OCPP. When there is no network connection and the device cannot access to OCPP, the icon shows: When the network connection is normal but the device cannot access to OCPP, the icon shows:...

  • Page 61: Operation And Maintenance Mode

    Step 2 In the pop-up dialog box, enter the password and click. figure 7-2 Password input box • The password 202207 is for Read-only access. • To get configuration permission, in order to perform maintenance in factory mode, please contact SUNGROW for another password. - - End...

  • Page 62: Ccu_Info Page

    5 LCD Touch Screen User Manual 5.3.2 CCU_Info Page figure 7-3 CCU Info page Monitoring & System Data The left part is real-time monitoring. Select the corresponding CCU from the Monitoring drop-down box to switch to display the corresponding CCU monitoring data. Setting&Control The middle part is for CCU settings.

  • Page 63: Version Page

    User Manual 5 LCD Touch Screen 5.3.3 Version Page figure 7-4 Version page Firmware Version This part is specifical version information of the charger, which includes TCU, CCU & PCU, MDSP and SDSP. Firmware Update If the on-site network environment is well， we can perform remote upgrade through Sun- grow’s backend.

  • Page 64: Log Page

    5 LCD Touch Screen User Manual 5.3.4 Log Page figure 7-5 Log page Log Export The left part is about how to export the logs into USB or TF card. You can select all or specific logs and click the Export button below to get the logs you need . Charging Log The right part is charging log of the Connector.
  • Page 65 User Manual 5 LCD Touch Screen • If the SIM card is used for network connection, after finishing the OCPP config- uration, please complete the router configuration in "Config_2 page". • If Wifi or eth is used, after finishing the OCPP configuration, please disable Router connection in "Config_2 page".

  • Page 66: Config_2 Page

    5 LCD Touch Screen User Manual Click SSID List to select the Wi-Fi to be deleted. Click DeleteSSID to delete the settings. • Edit Wifi Click SSID List to select the Wi-Fi to be edited; Double-click the Wi-Fi information in Content. Edit Wi-Fi in the pop-up dialog box.

  • Page 67: Pm_Info_1 Page

    User Manual 5 LCD Touch Screen Enable: Checked Static IP: Checked eth configuration: eth0 gateway: 192.168.1.1 • Disable router Enable: Unchecked 5.3.7 Pm_Info_1 Page figure 7-8 Pm_Info_1 page Module id1/id2/id3 This part shows the detailed information about the power module. 5.3.8 Pm_Info_2 Page figure 7-9 Pm_Info_2 page Module id4/id5/id6...

  • Page 68: Dc_Meter Page

    5 LCD Touch Screen User Manual 5.3.9 DC_Meter Page figure 7-10 DC_Meter page The device is equipped with LEM meters. Here you can check the detailed information about the LEM meter and set the relevant parameters. 5.3.10 Logout Click hide to return to the initial page. figure 7-11 Operation &...

  • Page 69: Ienergycharge App

    iEnergyCharge App iEnergyCharge App is a tool that allows users to operate and manage their EV chargers. Users can complete account settings and charger configuration, manage charge cards, operate the charger, and reach customer service on the App. Depending on the version of iEnergyCharge you are using, the user interface might be slightly different.

  • Page 70: Add A Charger

    6 iEnergyCharge App User Manual - - End Add a Charger To add a charger to your account on the iEnergyCharge App for operation and management. Step 1 Tap Add device on the Home screen. You may scan the QR code on the side of the charger, or enter the charger S/N to add a charger to your account.

  • Page 71: Routine Inspection

    • Do not perform inspections on the product on rainy, humid, or windy days. SUNGROW shall not be held liable for any possible outcome resulted from inspections in such weath- er conditions.
  • Page 72 7 Routine Inspection User Manual Recommended In- Inspection Item Inspection Method spection Interval • Check if there is any deformation with the charger enclosure. • Check if there is paint peeling on the charger's exterior. Charger exterior Once every 6 months •...

  • Page 73: Troubleshooting And Maintenance

    Step 1. the vehicle 3. If the problem persists, please contact forcefully SUNGROW customer service. The PWM is inva- PWM_ Please contact SUNGROW customer lid on the CP-PE failure Failure service. interface 1. Pull out the charging connector, plug it...
  • Page 74 Step 1. process failed failure Failure 3. If the problem persists, please contact SUNGROW customer service. 1. Pull out the charging connector, plug it The charging back into the vehicle, and try to start the session hand- charging session again.
  • Page 75 Step 1. Incompati- change failed patibility bility 3. If the problem persists, please contact SUNGROW customer service. 1. Pull out the charging connector, plug it back into the vehicle, and try to start the The charging charging session again. Cable...
  • Page 76 If the voltage is greater than 1020V, the charging will not be successful. In this case, please contact SUNGROW custom- The DC output er service and do not proceed with the next DC out-...

  • Page 77: Power Off Charger

    If the current is larger than 82A, the charg- ing will not be successful. In this case, The DC output please contact SUNGROW customer serv- DC out- current exceeds ice and do not proceed with the next steps.

  • Page 78: Replace Power Unit

    • If the power unit needs to be replaced in time due to something abnormal, con- tact SUNGROW for support. • Inspect the new power unit for intactness before replacing the old one. Steps to replace the power unit are as follows: Step 1 Power off the charger.
  • Page 79 User Manual 8 Troubleshooting and Maintenance Step 2 Open the left cabinet door on the charger using the key included in the accessories. Find the power unit to be replaced, and remove the cover plate. Step 3 Remove the screws and wiring terminals connected to the power unit.
  • Page 80 8 Troubleshooting and Maintenance User Manual Step 4 Open the right cabinet door on the charger using the key included in the accessories. Re- move the gasket used to fix the power unit. Pull the power unit out of the cabinet by its handles.

  • Page 81: Appendix

    Appendix Technical Data table 9-1 Technical Data Specification IDC180E Charging Connector Outlet 1 : CCS2 Connector type Outlet 2 : CCS2 Number of EV served Cable length 7 m (optional) DIN SPEC 70121 EVSE-vehicle protocol ISO 15118 DC Output DC output power Max.
  • Page 82 9 Appendix User Manual Specification IDC180E Over/under voltage protection Over-current protection Short-circuit protection Leakage current protection Over-temperature protection Surge protection Emergency stop User Interface Display 10-inch color touch screen English (standard) Language Other languages available by firmware upgrade RFID-card / Plug & Play / Auto-charge (Standard) Authentication Plug &...

  • Page 83: Quality Assurance

    • The customer shall give SUNGROW a reasonable period to repair the faulty device. Exclusion of Liability In the following circumstances, SUNGROW has the right to refuse to honor the quality guarantee: • The free warranty period for the whole machine/components has expired.

  • Page 84: Contact Information

    9 Appendix User Manual • The fault or damage is caused by the use of non-standard or non-SUNGROW compo- nents or software. • The installation and use range are beyond stipulations of relevant international standards. • The damage is caused by unexpected natural factors.
  • Page 85 Sungrow Power Supply Co., Ltd. www.sungrowpower.com...

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