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StarCharge Athena 60 Commissioning Manual

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Charging Infrastructure
Athena Commissioning Manual

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  • Page 1 Charging Infrastructure Athena Commissioning Manual...

  • Page 2: Legal Statement

    Legal Statement This document is part of technical file “Charging Infrastructure” and copyrighted. Without any prior written consent, it’s strictly not allowed to use it out of the permission of copyright, which is also applied to copied, translated, video taken and electronic media preserved version. Any party violating this statement is obligated to compensate for the losses!

  • Page 3: Table Of Contents

    Content General Principle ........................1 Purpose of this Document ....................... 1 Definition of Warning Sign ....................... 1 Preparation before Commissioning .................... 2 Safety Notice ........................... 2 Outside Appearance of EVSE ......................4 Datasheet ............................6 Specification of Power Module ......................7 LED Light Indication ........................

  • Page 4: General Principle

    General Principle 1.1 Purpose of this Document The purpose of this document is In In order to facilitate the normal successful use of Athena after installation. The information supports to discover and eliminate the failure or issues hidden dangers of the charger caused by factors such as installation quality, site conditions or and the environment (such as power voltage).

  • Page 5: Preparation Before Commissioning

    Preparation before Commissioning 2.1 Safety Notice Warning! Only manufacturer’s engineers or engineers trained by manufacturer are allowed to do commissioning to EVSE. Star Charge will not be responsible for any loss caused by the operation of any third-party engineers without Star Charge’s authorization. Each step of commissioning must be handled carefully.
  • Page 6 8) Without authorization and approval, any change of connection and structure inside of the EVSE is not allowed. 9) After operating, please put the components back to the original place, count the tools to prevent missing, and clean the operation site. 10) In case of any emergency, please launch the emergency response plan immediately, report the situation to the responsible person according to the plan, and carry out the on-site emergency treatment in the first time to control spreading, and rescue person and property.

  • Page 7: Outside Appearance Of Evse

    2.2 Outside Appearance of EVSE  Ground-mounted Figure 1 Outside Appearance of EVSE Commissioning Manual...
  • Page 8  [A] -- 7-inch touch screen  [B] -- Display mechanical buttons  [C] -- LED status indicator  [D] -- RFID card reader  [E] -- Charging connector  [F] -- Charging Cable Management systerm  [G] -- POS ...

  • Page 9: Datasheet

    2.3 Datasheet Athena CCS2 ChAdeMO Input Rating 400Vac±10%, 3-Phase, 50/60 Hz, L1+L2+L3+PE Power Factor 0.99 at nominal output power Power Input Current THD ≤5% at nominal output power Efficiency Rectifier ≥95% at nominal output power Output Interface 2 x CCS2 & CCS2+ChAdeMO Output Power 60kW max.

  • Page 10: Specification Of Power Module

    2.4 Specification of Power Module Athena uses Star Charge 30kW 1000V power module, which has a feature curve as follows: Figure 2 Feature curve Module High-voltage Low-voltage Parameter Value Value Range of output voltage 200～1000V 150～500V Rated output voltage 1000V 500V Rated output current Table 2 Datasheet of power module...

  • Page 11: Led Light Indication

    2.5 LED Light Indication LED Light State Definition Steady green Normal Flashing green RFID card identified Steady yellow There’s some fault which doesn’t affect charging. Steady blue Charging Steady red Fault Flashing red Fail to verify RFID Card Table 3 LED light indication Commissioning Manual...

  • Page 12: Commissioning Tools

    2.6 Commissioning Tools Please check and prepare the following tools before commissioning: Item Tools Usage Example Laptop Configure the settings and read logs Ethernet cable Web configuration J – LINK tool Programming 5/6 pin adaptor and flat cable Programming Micro SD Card and reader Programming Screwdriver set Assemble and disassemble the screws...
  • Page 13 Electrician protective gloves Safety protection Electrician protective Shoes Table 4 Tool list Commissioning Manual...

  • Page 14: Commissioning Process

    Commissioning Process 3.1 Commissioning Flowchart The commissioning flowchart of DC EVSE is as follow: Commissioning Flow Chart for DC EVSE Installation Technical Support Commissioning Engineer Engineer Engineer Installation recheck Whether the Corrective installation meets the maintenance requirements Check before power on Whether the appearance, internal wiring, insulation resistance and input...

  • Page 15: Installation Recheck

    Warning! During the commissioning process, the engineer cannot leave when the cabinet is opened and must remind any other people of staying far away. Make sure that all doors of the cabinet are closed when leaving the commissioning site. 3.2 Installation Recheck Commissioning must be operated by the engineers qualified by local special operation regulations.

  • Page 16: Insulation Resistance Check Of Input Power Cable

    Notice! It’s unnecessary to check again, if the checkpoint is accepted and listed in the construction acceptance report. The requirement listed above is the basic requirement. It is subject to the local laws and regulations. 3.2.2 Insulation Resistance Check of Input Power Cable Step 1: Turn off the switch in the power distribution cabinet corresponding to the EVSE;...
  • Page 17 Figure 5 Insulation resistance check of input power cable 2# Step 3: Get the megohmmeter ready. Step 4: Connect the megohmmeter to item to be tested. The black test lead E connects to the PE terminal of EVSE, connect red test lead L to the inlet cable L1, L2, L3 and N of EVSE. The insulation value should be ≥10MΩ.

  • Page 18: Check Before Power On

    3.3 Check before Power on 3.3.1 Using Condition Check 1) Working temperature：-30℃~50℃； 2) Working humidity：5%~95%, no condensation; 3) Working altitude：≤2000m 3.3.2 Internal Wiring Check 1) Short circuit: Check the input power cable connecting power distribution cabinet to the EVSE. Check whether there’s any short circuit between 3-phase live wire, neutral wire and grounding wire and whether the phase sequence is correct.
  • Page 19 Step 2: Take out all the power modules inside of the EVSE, detach it from the socket at the end of each power module, remove the grounding line of the surge protector, and remove the DC+ and DC- ports on the insulation testing board.

  • Page 20: Check After Power On

    3.4 Check after Power on Notice! The equipment must be powered on strictly in accordance with the following steps. Pay attention to the risk of electric shock, and wear protective gloves and shoes. 3.4.1 Power ON sequence Figure 10 Power ON sequence Step 1: Turn ON MCB which provides power to PCB.

  • Page 21: Web Configuration

    3.4.3 Web Configuration 3.4.2.1 Connection To connect to the network, insert the SIM (mini-SIM) according to the location of 4G communication module. Figure 11 SIM card Figure 12 Port to insert SIM card Connect the LAN port of router to the laptop by an Ethernet cable, and set the IP address as shown in the following picture (192.168.1.xxx, xxx can be any number but 136, 200, 201) Commissioning Manual...
  • Page 22 Figure 13 Set IP address Open the browser and input 192.168.1.136, log in with username (wbdh) and password (Wbdh26835941.) Commissioning Manual...
  • Page 23 Figure 14 Log in Web panel Figure 15 Web panel Change the language: Figure 16 Change the language Commissioning Manual...
  • Page 24 Update Notice! Program update is not the necessary step of commissioning. Contact with Star Charge engineer for specific program version information. Firmware Update: Click “Upload and download” – “Brows” – “firmware.zip” – “Submit”. Figure 17 Firmware update Update SECC via Micro SD Card: 1) Insert Micro SD card into laptop (specific card for programming, don’t use the Micro SD card put in the EVSE).
  • Page 25 3) Enter the driver of Micro SD card. For example, the driver of my Micro SD card is F. Figure 19 Update SECC via SD card 2# 4) If there’s warning shown as picture, enter y to confirm and wait for the file to be copied completely. Figure 20 Update SECC via SD card 3# Figure 20 Update SECC via SD card 4# 5) After that, press any key to exit and finish the programming Micro SD card.
  • Page 26 Figure 21 Update SECC via SD card 5# 6) Insert Micro SD card, switch both 2 switches marked red shown in the picture on. (Very important!) Figure 22 Update SECC via SD card 6# Commissioning Manual...
  • Page 27 7) Power on again, the LED light will be flashing all the time during the updating. When the LED light on the core board is steady lighting (flashing all the time before), wait for 30 seconds and then power offer, switch both 2 switches back to position 1 and 2 (very important!). Figure 23 Update SECC via SD card 7# 8) Insert the Micro SD card inserted in the module before, power on again and finish programming.
  • Page 28 Update A7 via Micro SD Card: 1) Insert Micro SD card into laptop (specific card for programming, don’t use the Micro SD card put in the EVSE). 2) Enter the folder (A6G2C-WB128LI-Flash), double click the file (m6g2c_burn_script.bat). Figure 25 Update A7 via SD card 1# 3) Enter the driver of Micro SD card.
  • Page 29 Figure 26 Update A7 via SD card 4# 5) After that, press any key to exit and finish the programming Micro SD card. Figure 27 Update A7 via SD card 5# 6) Insert Micro SD card, switch both 2 switches marked red shown in the picture on. (Very important!) Commissioning Manual...
  • Page 30 Figure 30 Update A7 via SD card 6# 7) Power on again, the LED light will be flashing all the time during the updating. When the LED light is steady lighting (flashing all the time before), wait for 30 seconds and then power offer, switch both 2 switches back to position 1 and 2 (very important! Figure 28 Update A7 via SD card 7# Commissioning Manual...
  • Page 31 8) Insert the Micro SD card inserted in the module before, power on again and finish programming. It will take a little longer for first reboot. Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink: 1) Connect Jlink with M4 board; Figure 29 Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink 1# M4 board Figure 30 Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink 2#...
  • Page 32 Figure 31 Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink 3# 4) Open file “.mot”; Figure 32 Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink 4# 5) Connect; Commissioning Manual...
  • Page 33 Figure 33 Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink 5# 6) Erase Chip; Figure 34 Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink 6# 7) Program & Verify (If fail, try one more time); Commissioning Manual...
  • Page 34 Figure 35 Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink 7# 8) Start Application; Figure 36 Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink 8# Commissioning Manual...

  • Page 35: Web-Quick Setup

    3.4.2.2 Web-Quick Setup In this page you will face some common configurations. Figure 37 Web-quick setup 1# ChargePoint ID: 1) Enter ChargerPoint ID; 2) Click “Submit”. Figure 38 Web-quick setup 2# Commissioning Manual...
  • Page 36 OCPP Setting: Take http://36.153.57.202:3400/steve/websocket/CentralSystemService as an example. The information needs to be filled in is shown as below: 1) “IP or Domain Name”: Enter IP address or domain name of the backend; 2) “SSL_Enable”: The value is “enable” when the backend uses TLS for access, otherwise the value is “disable”.

  • Page 37: Web-Software Setting

    Figure 40 Web-quick setup 4# 3.4.2.3 Web-Software Setting Figure 41 Web-software setting 1# Network Priority: 1) Find “Network priority”; 2) Set the priority, Ethernet>4G>WIFI for default; 3) Click “Submit”. Commissioning Manual...
  • Page 38 Figure 42 Web-software setting 2# 1) Find “4G configuration”; 2) Click “Enable modification”; 3) Set APN, User, Psw, Pin according to actual usage; 4) Click “Submit”. Figure 43 Web-software setting 3# Commissioning Manual...
  • Page 39 Ethernet: 1) Connect Ethernet cable; 2) Find “Ethernet configuration”; 3) Click “Dhcpc enable” to get IP address automatically or set IP address manually; 4) Click “Submit”. Figure 44 Web-software setting 4# Figure 45 Web-software setting 5# WIFI: 1) Find “Wifi configuration”; 2) Click “Enable modification”;...
  • Page 40 4) Fill in “SSID” (WIFI ID), “Psw” (WIFI password), “Encryption” (EncryMode, generally choose wpa2); 5) Click “Dhcpc enable”; 6) Click “Submit”. Figure 46 Web-software setting 6# Operation Backend: Take backend address: 36.153.57.202:3400/steve/websocket/CentralSystemService as an example. The information needs to be filled in is shown as below: 1) Find “CP Backend”;...
  • Page 41 Figure 50 Web-software setting 7# Maintenance Backend: Take backend address: 114.215.178.206:6668/ocppj, EVSE ID: 11111111 as an example. The information needs to be filled in is shown as below: 1) Find “Maintenance Setting”; 2) “URL”: Enter IP address or domain name of the backend; 3) “Path”: Enter the path after IP in “Path”;...
  • Page 42 Figure 47 Web-software setting 8# Card Type： 1) “Card Not Authentication”: Local start-stop card, the EVSE can work by swiping the card without connecting to the backend; 2) “Card Authentication”: Authentication card, the UID of RFID card must be entered into backend before using, and EVSE must connect to the backend;...

  • Page 43: Web-Cp Configuration

    3.4.2.4 Web-CP Configuration Figure 49 Web-CP configuration 1# Enter ChargerPoint ID, Group Number (if no, default is 12345678), EVSE ID: 1-1 (means could use both charging cables at the same time) #1 Gun Address: 1, #2 Gun Address: 2 Enter QR code for the two charging cables. Figure 50 Web-CP configuration 2# Output parameters for each charging cable: Gun Type: choose based on the actual situation;...
  • Page 44 Minimum Voltage (V): minimum output voltage for the charging cable, default and minimum value is 150V; Maximum Current (A): maximum output current for the charging cable, default and maximum value is 200A for CCS2 and 125A for ChAdeMO; Maximum Power (W): maximum output power for the charging cable, enter based on the quantity (X) of the power modules installed, default and maximum value is X*30kW;...

  • Page 45: Web-Power Unit Configuration

    3.4.2.5 Web-Power Unit Configuration Figure 53 Web-Power unit configuration 1# Select “180_relay” and click “Submit”. Figure 54 Web-Power unit configuration 2# Under-voltage Protection(V): minimum input voltage, default value is 173V; Over-voltage Protection(V): maximum input voltage, default value is 260V; Module Amount: Enter X (1 to 2) if there are X (1 to 2) power modules installed; Module Type: Select “Star Charge 30kW 1000V”;...
  • Page 46 Figure 55 Web-Power unit configuration 3# Commissioning Manual...

  • Page 47: Power Module Address Configuration

    3.4.2.6 Power Module Address Configuration Insert X power modules in the below X holes. Figure 60 Power module address configuration 1# Disable the door sensor. Figure 56 Power module address configuration 2# Commissioning Manual...
  • Page 48 Turn on the AC contactor. Figure 57 Power module address configuration 3# Set power module address (A&G) from 01 to 0X according the figure below. A01, G01 A02, G02 Figure 58 Power module address configuration 4# Commissioning Manual...
  • Page 49 1) Press ▲ or ▼, change the interface; 2) Press ▲ or ▼ for about the 2.5s, the value will be flashing; 3) Press ▲ or ▼ to change the value; 4) Press ▼ for about 2.5s to save the value. Turn off the AC contactor.

  • Page 50: Charging Function Check

    3.5 Charging Function Check 3.5.1 Charging Test The EVSE operation has two parts, connection and start charging. To use the product, the user must connect the EVSE to the vehicle first, and then carry out relevant charging operations through the touch screen interface.
  • Page 51 Figure 62 Charging Test 2# Step 4: During charging, the charging status interface is displayed on the display. Figure 63 Charging Test 3# Commissioning Manual...
  • Page 52 Figure 64 Charging Test 4# Step 5: Click "Stop" to enter the stop charging interface, and swiping card again or scanning QR code to stop charging. Figure 70 Charging Test 5# Commissioning Manual...
  • Page 53 Step 6: Charging results are displayed on the EVSE screen after charging is fully charged or stopped. Figure 65 Charging Test 6# Step 7: Unplug the charging connector from the vehicle, reposition it in the charging connector slot. Commissioning Manual...
  • Page 54 Hardware Function Test 1) Limit switch: Open the door of EVSE when charging, the EVSE should stop charging. 2) Emergency stop: Press the emergency stop button on the EVSE when charging, the EVSE should stop charging. 3) Fan: Check whether the fan inside of EVSE and fan of power module during charging. 4) Meter: Check whether the meter measures accurately during charging.

  • Page 55: Customer Training

    Customer Training After the commissioning work for the EVSE, the engineer should give a basic training relating to the main characteristics of the EVSE to guide the customer on using and some basic knowledge. The training form can be through either document or practical explanation on-site. The training content should cover safety knowledge, basic charging procedure and etc.

  • Page 56: Appendix 1 Customer Training Record Sheet

    Appendix 1 Customer Training Record Sheet Customer Training Record Sheet Customer： Product Trainer Training method Training Date Training Department Training Content Training Purpose 1.Basic charging operation procedure□ 2.Using scenario of emergency stop □ Outline of Training handout 3.Common sense of safety and emergency□ 4.Troubleshooting process□...

  • Page 57: Appendix 2 Commissioning Report

    Appendix 2 Commissioning Report Commissioning Report Date： Commissioning Engineer： Charging Station： Address： Commissioning Manual...
  • Page 58 Details of EVSE Power Charging Power Firmware Specification module Installation cable Backend module type version quantity length Commissioning Manual...
  • Page 59 Installation Recheck Object Content Conclusion Remark Foundation Check whether the foundation is fixed completely Check whether the cable specifications meet the power requirements of EVSE, no break, damage, or scratch, whether Power Cable the electrical connection and wiring are correct and complete, whether the connection is solid, and whether the grounding is reliable Insulation...
  • Page 60 3.2 Check the Internal Circuit (When using a multimeter to test the following items, ensure that the device is powered off.) Object Content Conclusion Remark Input L1 and L2 Open Circuit Input L1 and L3 Open Circuit Input L2 and L3 Open Circuit Input L1 and N Open Circuit...
  • Page 61 Object Content Conclusion Remark socket All screws are fastened without loosening or All grounding screws missing Screws on DC+ and DC- All screws are fastened without loosening or copper bar missing Each plug on the main control Each plug is firmly without loosening, and the board plug connection is firmly without loosening All screws are fastened without loosening or...
  • Page 62 Switch mode power The switch mode power supply can provide 12V/24V supply power supply voltage normally and stably 4.3 Parameter Configuration Content Object Conclusion Remark Configuration Configure according to the requirements Backend connection Connect successfully Charging Function 5.1 Charging Testing Object Content Conclusion...
  • Page 63 Conclusion Required voltage Required current Output voltage Output current EV type Remark Conclusion Remark □Qualified □Unqualified Commissioning Engineer: Customer: Date: Commissioning Manual...

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