Ingeteam RAPID 60 Installation And Operation Manual
  1. Manuals
  2. Brands
  3. Ingeteam Manuals
  4. Automobile Accessories
  5. INGEREV RAPID 60
  6. Installation and operation manual
Ingeteam RAPID 60 Installation And Operation Manual

Ingeteam RAPID 60 Installation And Operation Manual

Hide thumbs Also See for RAPID 60:
Table of Contents

Advertisement

Quick Links

Download this manual
INGETEAM RAPID 60
Installation and Operation Manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the RAPID 60 and is the answer not in the manual?

Questions and answers

Related Manuals for Ingeteam RAPID 60

Summary of Contents for Ingeteam RAPID 60

  • Page 1 INGETEAM RAPID 60 Installation and Operation Manual...
  • Page 2 Ingeteam Power Technology, S.A. - Energy 300000772_D 03/2024 Avda. Ciudad de la Innovación, 13 31621 SARRIGUREN (Navarra) - Spain Tel.: +34 948 28 80 00 Fax.: +34 948 28 80 01 e-mail: electricmobility.energy@ingeteam.com Service Call Center: +34 948 698 715...
  • Page 3 The copy, distribution or use of this document or of its content requires written authorisation. Any breach thereof will be reported for damages. All rights reserved including those of patent rights or design registration. The conformity of the document content with the hardware described has been checked. However, discrepancies may exist. Liability will not be assumed for total concordance.

  • Page 4: Important Safety Instructions

    Important safety instructions Important safety instructions This section describes the safety warnings and the personal protective equipment and symbols used in the unit. Safety conditions General warnings DANGER Opening the enclosure does not imply there is no voltage inside. The risk of electric shock exists even after disconnecting from the grid. Only qualified personnel may open it, following the instructions in this manual.
  • Page 5 Important safety instructions Potential hazards for people DANGER Electric shock. The equipment may remain charged after disconnecting the grid power. Carefully follow the mandatory steps in the manual for removing the voltage. Explosion. There is a very low risk of explosion in very specific cases of malfunction. The casing will protect people and property from the explosion only if it is correctly closed.

  • Page 6: Personal Protective Equipment (Ppe)

    Important safety instructions Personal Protective Equipment (PPE) When working on the unit, use the following safety equipment recommended by Ingeteam as a minimum. Name Description Safety footwear In compliance with standard UNE-EN-ISO 20345:2012 ANSI Z41.1-1991 In compliance with standard UNE-EN 397:1995, ANSI Z89.1-2014, provided Helmet with face shield there are elements with voltage directly accessible.

  • Page 7: Table Of Contents

    Contents Contents Important safety instructions ........................4 Safety conditions ........................... 4 Personal Protective Equipment (PPE) ...................... 6 Symbols ............................... 6 Contents ..............................7 1. About this manual ..........................9 1.1. Scope and nomenclature ........................ 9 1.2. Recipients ........................... 10 1.3. Symbols ............................10 2.
  • Page 8 Contents 9.1. Unit inspection ..........................53 9.1.1. Inspection ........................... 53 9.1.2. Hermetic sealing of the unit ....................53 10. Unit configuration ..........................54 10.1. Local connection ........................54 10.1.1. Local connection via Ethernet ..................... 54 10.2. Remote connection ........................55 11.

  • Page 9: About This Manual

    About this manual 1. About this manual The purpose of this manual is to describe the INGETEAM RAPID 60 units, providing appropriate information for their correct reception, installation, start-up, maintenance and operation. This manual contains important information that should be taken into account during the installation, operation and maintenance of the unit.

  • Page 10: Recipients

    About this manual 1.2. Recipients This document is intended for qualified personnel. The status of qualified personnel referred to in this manual will be, as a minimum, that which meets all the standards, regulations and laws regarding safety applicable to the tasks of installing and operating this unit. The responsibility for designating qualified personnel will always fall to the company to which the personnel belong.

  • Page 11: Unit Description

    100 km of range to be recovered in no more than 15 minutes. The different models of INGETEAM RAPID are compatible with mode 4 with standards CHAdeMO and CCS1/CCS2 in DC and with mode 3 with AC Type 2 in AC.

  • Page 12: Connectors

    Unit description 2.3. Connectors 2.3.1. Connectors for DC charging The following connectors are based on DC fast charging standards for electric vehicles. CCS1 PP: Proximity Pilot, pre-insertion signal CP: Control Pilot, post-insertion signal PE: Protective Earth CCS2 PP: Proximity Pilot, pre-insertion signal CP: Control Pilot, post-insertion signal PE: Protective Earth 300000772_D - Installation and Operation Manual...

  • Page 13: Connectors For Ac Charging

    Unit description CHAdeMO Charger side Vehicle side Power lines 12 V Control lines 12 V CAN BUS 2.3.2. Connectors for AC charging The following connector is based on AC charging standards for electric vehicles. IEC 62196-2 AC Type 2 socket PP: Proximity Pilot, pre-insertion signal CP: Control Pilot, post-insertion signal PE: Protective Earth...

  • Page 14: Protection

    Unit description 2.4. Protection This charging station has several protections, as described below: Arrangement of protection elements for TRIO units Arrangement of protection elements for ONE+ units Arrangement of protection elements for DUO units Arrangement of protection elements for ONE units 300000772_D - Installation and Operation Manual...
  • Page 15 Unit description Overvoltage protection Main DC charging switch. 125 A, 25 kA. Auxiliary services main protection. 10 A, 25 Power module protections. 63 A, 10 kA. Differential protection of auxiliary services. 25 DC charging differential protection. 63 A, 30 A, 30 mA, Type A. mA, Type A SI or Type B depending on the model.

  • Page 16: Accessories Equipped As Standard

    10.1” color touchscreen, multi-language. • Dual Ethernet port with switch mode. • OCPP, Autocharge, Plug&Charge. • DLM, static and dynamic power management with other Ingeteam DC and AC units. • Web Manager. 2.6. Additional options • Contactless bank card reader.

  • Page 17: Electrical Diagram Of The System

    Unit description 2.7. Electrical diagram of the system INGETEAM RAPID TRIO CCS1/CCS2/CHADEMO Supply DC wattmeters DC charging circuit breaker DC connectors type CCS1/CCS2/CHADEMO (right cable always CCS type) EMC Filter AC charging circuit breaker Protection differentials Residual current device Module power contactors...
  • Page 18 Unit description INGETEAM RAPID DUO CCS1/CCS2/CHADEMO Supply Power modules DC charging circuit breaker Parallelization contactors EMC filter Cable contactors Protection differentials DC wattmeters Module power contactors DC connectors type CCS1/CCS2/CHADEMO (right cable always CCS type) Module thermal magnetic protections 300000772_D - Installation and Operation Manual...
  • Page 19 Unit description INGETEAM RAPID ONE CCS Supply Power modules DC charging circuit breaker Parallelization contactors EMC filter Cable contactors Protection differentials DC wattmeters Module power contactors DC connectors type CCS1/CCS2 Module thermal magnetic protections 300000772_D- Installation and Operation Manual...
  • Page 20 Unit description INGETEAM RAPID ONE+ CCS Supply DC wattmeters DC charging circuit breaker DC connectors type CCS1/CCS2/CHADEMO (right cable always CCS type) EMC Filter AC charging circuit breaker Protection differentials Residual current device Module power contactors AC wattmeter Module thermal magnetic protections...

  • Page 21: Specification Table

    5 m (4.4 m usable length) with retractable system included Operating temperature -25°C to 55°C (derating from 40°C) | Low temperature kit at -35°C (optional) Humidity < 95% Maximum altitude 2,000 m (for higher altitudes, consult Ingeteam) Weight 140 kg 160 kg 165 kg Dimensions (h x w x d)

  • Page 22: Receipt Of The Unit And Storage

    Failure to follow the instructions in this section may lead to damage to the unit. Ingeteam accepts no liability for damage resulting from the failure to follow these instructions. If the unit is not installed immediately after reception, the following points should be taken into account in order to avoid damage: •...

  • Page 23: Transporting And Handling The Unit

    IP rating, etc. • Avoid, as far as possible, vibrations which may cause subsequent malfunction. If you observe any anomaly, please contact Ingeteam immediately. Separating the packaging You can deliver all the packaging to an authorized non-hazardous waste management company.

  • Page 24: Assembly Of The Charging Hoses

    Transporting and handling the unit 4.3. Assembly of the charging hoses Once the unit has been unpacked, mount the charging hoses following these steps: Cut the ties securing the hose. Mount the charging hose support. 300000772_D - Installation and Operation Manual...
  • Page 25 Transporting and handling the unit Attach the hose support using the 25 mm M8 screw. 300000772_D- Installation and Operation Manual...

  • Page 26: Handling The Unit

    Transporting and handling the unit 4.4. Handling the unit The charging stations from the RAPID 60 family have been designed for transport and installation using a forklift or pallet truck, as well as for handling from the top, allowing the unit to be lifted.
  • Page 27 Transporting and handling the unit Remove the screws that secure the unit to the pallet and the lower reinforcement boards from the pallet. 300000772_D- Installation and Operation Manual...
  • Page 28 Transporting and handling the unit Lift the unit centered to the forks of the pallet truck and remove the pallet. Move and position the unit with the pallet truck or forklift. Ensure that the forks are perfectly level to avoid overturning the unit. Do not transport the unit at an inclination greater than 18°.

  • Page 29: Lifting

    Transporting and handling the unit 4.4.2. Lifting The RAPID family of charging stations have been designed to be handled from the top. Carry out the following steps: Remove the top cover by loosening the 10 screws that secure it, exposing the two lifting hooks. Place the shackles on the lifting hooks and lift the unit.
  • Page 30 Transporting and handling the unit Remove the shackles from the top part and fit the cover, making sure that it is correctly tightened at all points. WARNING Take care when loading and transporting the unit. Before subjecting cables, ropes, slings, etc. to traction force, you must inspect them, as well as the fastening and attachment points.

  • Page 31: Preparation For Installing The Unit

    Preparation for installing the unit 5. Preparation for installing the unit When deciding the location of the unit and planning your installation, you must follow a set of guidelines based on the specifications of the unit. These guidelines are summarized in this chapter. 5.1.

  • Page 32: Environmental Conditions

    The operation of the unit at temperatures greater than 40ºC should only occur occasionally and not permanently. The unit can enter reduced performance mode (derating). Ingeteam is not responsible for the consequences to the unit resulting from operating it at temperatures higher than 40ºC. At altitudes higher than 2,000m, please contact Ingeteam.

  • Page 33: Type Of Grid

    Preparation for installing the unit 5.3. Type of grid These units must be connected to a three-phase grid with a star formation with grounded neutral. Therefore, admissible grounding systems are TT, TN-S and TN-C-S. They cannot be connected to IT, TN-C grids or delta grids with one of their lines grounded. The connections from the three-phase grid (L1, L2, L3 and N) and its ground (PE) must go to the unit.

  • Page 34: External Disconnection Device

    Preparation for installing the unit 5.4. External disconnection device The AC supply must be shut off for equipment inspection work. To do this, the installer must fit an external disconnection device. The switching component must be dimensioned for the DC input voltage and current of the charging terminal (see section „2.8.

  • Page 35: Installing The Unit

    Installing the unit 6. Installing the unit Before installing the unit, the packaging must be removed, taking special care not to damage the housing (see section „4.2. Unpacking“). Check that there is no condensation inside the packaging. If there are signs of condensation, the unit must not be installed until you are sure it is completely dry.
  • Page 36 Installing the unit To close the door, lift the piston and begin to close it, as indicated in the following image. This point only applies to equipments with mechanical locking as shown in the picture. No precautions are necessary for equipment with gas piston.
  • Page 37 Installing the unit The units must be attached to an even and solid surface, and must be placed in a perfectly vertical position. 300000772_D- Installation and Operation Manual...

  • Page 38: Fastening The Unit

    Installing the unit 6.2. Fastening the unit The fixing points are designed for the use of threaded rods or M12 screws. If using a threaded rod, its length above the ground must be 25 to 35 mm. Other similar anchoring systems can be used. The separation of the fastening system selected must be adjusted to the measurements shown below in a detail of the lower part of the charger.
  • Page 39 Installing the unit • If you use a different anchoring system, check that the solution provided complies with the conditions initially defined in this document. • Minimum thickness of the concrete pad: 300 mm. • The dimensions of the inspection chamber of the pad are shown in the following figure. •...
  • Page 40 Installing the unit • Minimum shear strength: 9.3 kN. Security coefficient 1.25. ≥75 300000772_D - Installation and Operation Manual...

  • Page 41: Connection Of Accessories

    Download the manual corresponding to each payment terminal from the INGETEAM EVC Training platform. https://www.ingeteamevctraining.com/ 7.3. External communication interconnection kit This kit contains an 8-port switch which permits the interconnection of up to 8 Ingeteam charging points in an installation. 7.3.1. Mechanical installation The Ethernet switch must be installed on the DIN rail located at the bottom of the door in the position shown in the figure.

  • Page 42: Electrical Connection

    Connection of accessories 7.3.2. Electrical connection Switch power supply: The Ethernet switch kit includes two blue cables which must be connected to the switch connector in the + and – positions, in accordance with the printing on the cables. Next, the cables must be routed through the ducts to the –XD2 distribution terminal block. Connect the other end of the cables in accordance with the printing on the cables to points 5+:1 and 1-:4.
  • Page 43 Connection of accessories Connect that end of the Ethernet cable to port number 1 on the switch. The remaining Ethernet cables from the other chargers of the installation should be inserted through the underground conduits and should go through the cable input system defined to this effect. To make the installation easier, the wall bushings may be released.

  • Page 44: Electric Vehicle Detector

    Connection of accessories 7.4. Electric vehicle detector CAUTION To install the kit it is necessary to access the unit, following the safety instructions given in this manual. The unit must not be powered. Mount the electric vehicle detector in the position shown in the figure. Connect the detector to the wiring kit included in this kit.
  • Page 45 Connection of accessories b. The electronic card is identified by the name –KZ1. The J26 connector is in the zone marked in the figure. 300000772_D- Installation and Operation Manual...

  • Page 46: Communications Kit

    Connection of accessories c. The detector must be tared with the standard parameters which are defined in the figure below. If the special features of the installation require a different taring, please refer to the appliance user manual. Detector configuration Follow the detector manufacturer’s instructions to connect the vehicle detection coils.
  • Page 47 Connection of accessories Then lower the other end of the card until it is locked in port J52. On the left side of the station, remove the material highlighted in gray in the figure below. Install the 4G antenna. 300000772_D- Installation and Operation Manual...
  • Page 48 Connection of accessories Pass the antenna cable through the cable conduit shown in the figure below. Subsequently, the 4G antenna cable must be connected to the card. The connection point is identified with the text “MAIN” or “M”. Finally, insert the MicroSim card into the housing defined for this purpose. 300000772_D - Installation and Operation Manual...

  • Page 49: Charger Power Supply Connection

    Charger power supply connection 8. Charger power supply connection This chapter explains the requirements and process for connecting the power supply cabling to the unit. The circuits for DC and AC (if available) charging and the auxiliary services power supply are derived internally from this connection.

  • Page 50: Cabling Requirements

    Charger power supply connection Image of the IP2X protection of the connection 8.2. Cabling requirements To guarantee the safety of persons, for the unit to function correctly and comply with the applicable standards, the unit must be connected to the ground of the installation. The AC connection must comply with section 8.3.

  • Page 51: Connection Process

    Charger power supply connection 8.3. Connection process Insert the cable grommets from the bottom upwards, making sure that they fit correctly into the equipment. Insert the wiring through the cable grommets by making a small tear in their membrane. Connect the three phases, neutral and ground to the terminal strip, respecting the polarities. The connection points are identified with various classifications, according to the systems of different countries.
  • Page 52 Charger power supply connection The tightening torque for the connection points of the phases and neutral is 14 Nm, and 6 Nm for the ground connection. 300000772_D - Installation and Operation Manual...

  • Page 53: First Connection To The Electric Grid

    First connection to the electric grid 9. First connection to the electric grid This chapter details the process for the charger's first connection to the grid. First review the unit. 9.1. Unit inspection You must check the correct condition of the installation before start-up. Each installation is different, depending on its characteristics, the country in which it is located or other special conditions which may apply.

  • Page 54: Unit Configuration

    A local connection is required to configure the unit for the first time. Once this first configuration has been carried out, a remote connection can also be established. The processes for both cases are described below. The configuration is done through the INGETEAM WEB Manager application. 10.1. Local connection To establish a local connection the charger and computer must be connected to the same communication network.

  • Page 55: Remote Connection

    Unit configuration 10.2. Remote connection The purpose of remote connection is to have access to the charger when the charger and the computer are connected to the Internet from different communication networks. The charger must be connected to the Internet via Wi-Fi, Ethernet or 4G.

  • Page 56: Operation

    Operation 11. Operation The main function of the charging station is to supply and measure electrical energy for users that have prior authorization with an RFID card reader system, except in stations configured without authentication. This section describes the operation of the charging station in detail. 11.1.

  • Page 57: Charging Process

    Operation 11.3. Charging process Depending on the client's requirements, the charging process will start with or without authentication. The process for both cases is described below. 11.3.1. Charging process with authentication Starting the charge process Check that the charging station is in awaiting vehicle status with the green light on. If you have an ID card, place the card next to the reader located on the area below the display.
  • Page 58 Operation The charging starts. The lighting remains blue, fixed if there is consumption and flashing if there is not. Ending the charge process To end the charging cycle, if you have an ID card, place it against the reader. If the charging is managed through the app, follow the instructions.

  • Page 59: Charging Process Without Authentication

    Operation 11.3.2. Charging process without authentication Starting the charge process Connect the vehicle to the recharging station. The charging starts. The lighting remains blue, fixed if there is consumption and flashing if there is not. Ending the charge process Disconnect the connector from the vehicle side. The charging process stops.

  • Page 60: Shutting Down The Unit

    Shutting down the unit 12. Shutting down the unit This section describes the procedure to shut down the unit. If you wish to work inside the unit, you must carry out these instructions in the order shown here to remove the power. If there is an active charge process, finalize the charge session.

  • Page 61: Maintenance

    13. Maintenance The maintenance described below lists a series of minimum measures necessary to maintain the charger in good working condition. Please consult Ingeteam preventive and predictive general maintenance if you wish to extend the service life of the charger.

  • Page 62: Cleaning Or Replacing Filters

    Maintenance 13.5. Cleaning or replacing filters Remove and clean the filters on the unit ventilation grilles. In the case of damage, replace with new filters. Air intakes There are filters in all of the air intakes (both inlets and outlets). These intakes are located on both sides of the charger.

  • Page 63: Waste Handling

    At the end of the unit's life, the waste must be correctly processed by an authorized hazardous waste management company. Ingeteam, in accordance with its policy of respect for the environment, will inform the authorized manager, via this section, of the location of components to be decontaminated.
  • Page 64 Notes - Notas - Remarques - Note - Anm.
  • Page 65 Thailand representative office e-mail: evc.energy@ingeteam.com e-mail: usa@ingeteam.com 100/67 Vongvanij B Building, 22nd floor, Ingeteam S.r.l. Ingeteam Power Technology México S de RL de CV Rama IX Road., HuayKwang, Via Emilia Ponente, 232 Av. Ejército Nacional Mexicano 351, 10320 Bangkok 48014 Castel Bolognese (RA) - Italy Chapultepec Morales, Granada, Te.: +66 22461798...
  • Page 66 300000772_D 03/2024 Ingeteam Power Technology, S.A. www.ingeteam.com...

This manual is also suitable for:

Rapid 60 trio ccs+ccs+t2sRapid 60 trio ccs+cha+t2sRapid 60 duo ccs+ccsRapid 60 duo ccs+chaRapid 60 one ccsRapid 60 one+ ccs+t2s

Table of Contents