Circontrol Wallbox eVolve Rapid Series Service Manual
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Circontrol Wallbox eVolve Rapid Series Service Manual

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Wallbox & Post eVolve
Rapid Series
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  • Page 1 Wallbox & Post eVolve Rapid Series 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 4: Table Of Contents

    1 — So, Hello! A - Important safety instructions B - Work in a safe environment C - Personal Protective Equipment (PPE) D - Recommended tools 2 — Features A - Wallbox main features B - Post main features C - Wallbox dimensions D - Post dimensions E - Components overview 3 —...
  • Page 5 How to service your Wallbox and Post eVolve Rapid F - Power supplies G - Contactors H - Teltonika RUT 240 I - Isolation protection device 5 — Other optional components A - RFID Reader - Legic 6 — Troubleshooting & Errors A - Troubleshooting introduction B - Log files C - Decoding the error...
  • Page 6 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 7: 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 8: B - Work In A Safe Environment

    Wallbox & Post eVolve Rapid 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 9 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 10: C Personal Protective Equipment (Ppe)

    Wallbox & Post eVolve Rapid 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...

  • Page 11: D Recommended Tools

    Recommended tools LAPTOP SWITCH MULTIMETER ALLEN TOOLS MULTI-TOOL TORX-TOOLS USB-RS485 SCREW DRIVERS ETHERNET CABLE RATCHET WRENCH...

  • Page 12: Features

    Wallbox & Post eVolve Rapid Service Manual Wallbox main features Satellite Serie Basic Serie 1 — Hat 5 — Wall support 9 — Stop button 2 — Key lock access 6 — Base 10 — Power input 3 — Ventilation 7 —...

  • Page 13: B - Post Main Features

    Features Post main features Satellite Serie Basic Serie Master Serie 1 — Hat 6 — Ventilation 11 — Cable gland 2 — LED beacon light 7 — Base 12 — Screen 3 — Holder 8 — Start button 13 — RFID reader 4 —...

  • Page 14: C Wallbox Dimensions

    Wallbox & Post eVolve Rapid Service Manual Wallbox dimensions Measures in mm...

  • Page 15: D Post Dimensions

    Post dimensions Measures in mm...

  • Page 16: E Components Overview

    Wallbox & Post eVolve Rapid Service Manual Components overview — WA L L B O X 1 — 25kW Power Module (G1) 2 — Electronic boards, electrical protections, electrical actuators 3 — Door 4 — Tamper 5 — Power supply (F1, F2, F3, N) 6 —...
  • Page 17 — P O S T 1 — 25kW Power Module (G1) 2 — Electronic boards, electrical protections, electrical actuators 3 — Door 4 — Tamper 5 — Power supply (F1, F2, F3, N) 6 — Residual current relay 4 poles 63A class B (F1) 7 —...
  • Page 18 Wallbox & Post eVolve Rapid Service Manual — 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 WA L L B O X 1- Mode 4 Control Board (A1) 2- RCBO 1P+N 10A 30mA...
  • Page 19 — 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 P O S T 1- Mode 4 Control Board (A1) 2- RCBO 1P+N 10A 30mA 3- Feed-through terminal...
  • Page 20 Wallbox & Post eVolve Rapid Service Manual 2 — P O W E R M O D U L E In both models is assembled a unique power module of 25kW, but is located in different place. While in wallbox we have to look behind the mode 4 control board, in post is completely visible and easy to access.
  • Page 21 3 — D O O R Depending on the model chosen and specifications, are some relevant differences between them. WA L L B O X B A S I C WA L L B O X S AT E L L I T E P O S T B A S I C P O S T S AT E L L I T E P O S T M A S T E R...
  • Page 22 Wallbox & Post eVolve Rapid Service Manual 4 A — B L O C K D I AG R A M F O R P O S T M A S T E R...
  • Page 23 4 B — B L O C K D I AG R A M F O R P O S T S AT E L L I T E...
  • Page 24 Wallbox & Post eVolve Rapid Service Manual 4 C — B L O C K D I AG R A M F O R P O S T B A S I C...
  • Page 25 4 D — B L O C K D I AG R A M F O R WA L L B O X S AT E L L I T E...
  • Page 26 Wallbox & Post eVolve Rapid Service Manual 4 E — B L O C K D I AG R A M F O R WA L L B O X B A S I C...
  • Page 27 5 — 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: Control Devices

    Wallbox & Post eVolve Rapid Service Manual PC Screen (HMI) The PC screen (HMI) and the RFID reader are located at the door. Normally, at the RJ45 port it is connected the Ethernet cable coming from the router when it is installed.
  • Page 29 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 Wallbox & Post eVolve Rapid 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 Inputs for Clixon, tamper and Isolation Detection Inputs for Tacometer, Precharge state CCS...
  • Page 32 Wallbox & Post eVolve Rapid Service Manual Enable/disable power modules output Outputs for Bender test, heater. Outputs for diode fan, modules. RS485-1-M communications with isolation detector device RS485-2-S Communications with the screen Input thermostats from CCS cable Relay output CCS cable and CCS contactor CCS LEDs...
  • Page 33 Electrical scheme Update Mode 4 board is updated automatically by the Screen in case of Post evolve Rapid Master. Check in the previous point, the procedure to update the Screen and find the necessary files in the Expert Area. In the other models of the eVolve Rapid Series, mode 4 board should be updated with a RS-485 cable.

  • Page 34: C - Ccs Board

    Wallbox & Post eVolve Rapid 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...
  • 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: Other Components

    Wallbox & Post eVolve Rapid Service Manual 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.

  • Page 37: B - Ventilation System

    Other components Ventilation system The Charge Point is equipped with some fans in order to keep a safe temperature thorugh different sections of it. There are 3 fans: 1 — 2 in the upper part of the Charge Point. 2 — In the A8 screen. Screen's fan is working always.

  • Page 38: C - Rfid Reader

    Wallbox & Post eVolve Rapid 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 Charge Point and the card. RS-485 Communications Operation LEDs RFID reader has a LED status indicator.

  • Page 39: D - Ac Meter

    AC meter The three-phase electrical energy meter measures current and voltage that is supplied to the socket. The meter has RS485 communications with the Screen This meter is a CEM C21. Electrical scheme...

  • Page 40: E - Uninterruptible Power Supply (Ups)

    Wallbox & Post eVolve Rapid Service Manual Uninterruptible power supply (UPS) The uninterruptible 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. It is only available for Post eVolve Rapid Master, which allow that the 12Vdc electronics remain supplied for few seconds when unit is powered OFF.
  • Page 41 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 42 Wallbox & Post eVolve Rapid Service Manual Contactors Contactor closes when Charging Station is charging. Model for Wallbox Model for Post...
  • Page 43 Teltonika RUT 240 The Charge Point 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 the Cahrge Point 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 44 Wallbox & Post eVolve Rapid Service Manual Isolation protection device The ISOMETER monitors the insulation charging stations for electric vehicles for DC between 0 and 1100Vdc. 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 45 RS485 communications. 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. It has a secondary function.
  • Page 46 Wallbox & Post eVolve Rapid 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 47 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 48 Wallbox & Post eVolve Rapid Service Manual Troubleshooting introduction The Charge Point 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 49 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 50 Stopping process. • Permanent error. 2 — 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 51 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 52 Wallbox & Post eVolve Rapid 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 53 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 54 Wallbox & Post eVolve Rapid 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’. Regardless of the error type, the check order always must be: Engine errors DC errors.
  • Page 55 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 56 Wallbox & Post eVolve Rapid 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 57 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 58 Wallbox & Post eVolve Rapid 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.
  • Page 59 Charging Station, second line about the historic. Current situation Historic To understand this DC error section, it is required a decoding tool. This tool is available in the Expert Area. Circontrol Support Department, support@circontrol. also can provide it if necessary.
  • Page 60 Wallbox & Post eVolve Rapid Service Manual Introduce the lines from the error code in the Connector faulted and Converter section. Example about how to fill the decoder tool.
  • Page 61 Once error code has been introduced, the right side of the decoder tool will show indications regarding the issue, the faulty component or the possible causes.. It is shown the curernt error (or alarm) and the historical. In some cases, historical is helpful in order to understand how the charger went into the error state.
  • Page 62 Wallbox & Post eVolve Rapid 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 63 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 64 Wallbox & Post eVolve Rapid 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: •...
  • Page 65 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 department within Configuration Update section on web page of the charge point.
  • Page 66 Wallbox & Post eVolve Rapid 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 67 Getting valid public ID timeout • The password of the modem (f.e. Admin001 in Teltonika Rut240) has been changed. It cannot be changed. • Check the list of Blocked IPs of the modem. If IP of the charger is included there, remove it from the list No Data, get host by name failed in tcp_connect() Hostname cannot be resolved in charge point side:http://ip_address:8080/html/...
  • Page 68 Wallbox & Post eVolve Rapid 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 69 Power modules errors LED lights placed in rectifier: LED named “OK” Green/Yellow bi-colour LED named “RFA” Meaning of colours in relation with service: Green Everything ok No diagnostic or user interaction required Yellow Check following table for further diagnosis Replace rectifier Meaning of colours in relation with LED status: Colour LED Status...
  • Page 70 Wallbox & Post eVolve Rapid 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 71 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 72 Wallbox & Post eVolve Rapid 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 73 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 74 Wallbox & Post eVolve Rapid Service Manual Wallbox eVolve Rapid Models General Specifications AC Power Supply 3P + N + PE AC Input Voltage 400V +/- 10% three-phase Power Factor > 0.98 Efficiency 94% at nominal output power Frequency 50 / 60Hz Required power supply capacity 27 kVA Maximum AC input current...
  • Page 75 Technical Data Satellite Master Ethernet UTP Communication Model Specifications Models Wallbox Satellite Wallbox Basic Safety Protections RCD type B 30mA (Optional) MCB curve C RCD type B 30mA MCB curve C Operating Temperature -5ºC to +45ºC -5ºC to +45ºC Environment Indoor Indoor Dimensions (W x H x D)
  • Page 76 Wallbox & Post eVolve Rapid Service Manual Post eVolve Rapid Models General Specifications AC Power Supply 3P + N + PE Master AC Input Voltage 400V +/- 10% Network 10/100TX (TCP-IP) three-phase connection Power Factor > 0.98 Interface protocol OCPP 1.5 / 1.6J / 2.0 HW Ready Efficiency 94% at nominal output...
  • Page 77 Optional devices Wireless communication LATAM/APAC - 4G LTE/GPRS/GSM (only available in Master) Switch TCP ethernet 16 ports Network hub RFID Extension (only available in Master) RFID Extension Legic Advant / Legic Prime ISO 15693 / ISO 18092, Sony FeliCa Contactless payment Integrated credit card payment terminal (only available in Master) Model Specifications...
  • Page 78 Wallbox & Post eVolve Rapid Service Manual...
  • Page 79 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 80 CIRCONTROL WB & Post eVolve Rapid Service MANUAL A comprehensive guide on how to serice your Charging Station. V1.0, May edition 2022 R511 CIRCONTROL S.A. - ALL RIGHTS RESERVED...

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