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StarCharge Venus 30 Commissioning Manual

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Charging Infrastructure
Venus 30 Commissioning Manual
Wanbang Digital Energy Co. Ltd.

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Summary of Contents for StarCharge Venus 30

  • Page 1 Charging Infrastructure Venus 30 Commissioning Manual Wanbang Digital Energy Co. Ltd.

  • Page 2: Legal Statement

    Legal Statement Wanbang Digital Energy Co., Ltd. No. 39 Longhui Road, Wujin High-tech Zone, Changzhou, Jiangsu, Chinawww.starcharge.com All rights are reserved by Wanbang Digital Energy Co., Ltd. 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,...

  • Page 3: Table Of Contents

    Content General Principle ............................1 Purpose of this Document ........................1 Application Scope ..........................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 Customer Training ............................. 41 Appendix 1 Customer Training Record Sheet ....................42 Appendix 2 Commissioning Report ........................43...

  • Page 5: General Principle

    EVSE can work stably, efficiently and safely. 1.2 Application Scope This document is applied for the commissioning work of Venus 30 before delivering to customer. 1.3 Definition of Warning Sign Item...

  • Page 6: 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 7 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 8: Outside Appearance Of Evse

    2.2 Outside Appearance of EVSE  Wall-mounted  [A]——Touch screen  [B]——LED status indicating light and RFID identification area  [C]——Meter  [D]——Air-cooling outlet  [E]——Lock  [F]——Emergency stop button  [G]——Charging cable and cable holder Commissioning Manual Wanbang Digital Energy Co., Ltd.
  • Page 9  Column-mounted  [A]——Touch screen  [B]——LED status indicating light and RFID identification area  [C]——Antenna  [D]——Meter  [E]——Lock  [F]——Air-cooling outlet  [G]——Emergency stop button  [G]——Column  [I]——Charging cable and cable holder Commissioning Manual Wanbang Digital Energy Co., Ltd.

  • Page 10: Datasheet

    2.3 Datasheet Venus 30 Input Rating 400Vac±10%, 3-Phase, 50/60 Hz, L1+L2+L3+N+PE Power Factor 0.98 at nominal output power Power Input Current THD ≤5% at nominal output power Efficiency Rectifier ≥95% at nominal output power Output Interface 1 x CCS2 Output Power 30kW max.

  • Page 11: Specification Of Power Module

    2.4 Specification of Power Module Venus 30 uses Star Charge 30kW 1000V power module, which has a feature curve as follows: Module High-voltage Low-voltage Parameter Value Value Range of output voltage 200～1000V 150～500V Rated output voltage 1000V 500V Rated output current Commissioning Manual Wanbang Digital Energy Co., Ltd.

  • Page 12: 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 Commissioning Manual Wanbang Digital Energy Co., Ltd.

  • Page 13: Commissioning Tools

    2.6 Commissioning Tools Please check and prepare the following tools before commissioning: Item Tools Usage Example Configure the settings, Laptop And read the log Ethernet cable Web configuration J – LINK tool Programming Read the log, RS232 tool and adaptor Programming TF Card and reader Programming...
  • Page 14 Electrician protective Gloves Safety protection Electrician protective Shoes Commissioning Manual Wanbang Digital Energy Co., Ltd.

  • Page 15: 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 16: 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 17: Grounding Resistance Check

    7) Others: Whether the fireproof material inside of the EVSE is in place to prevent insects or dirt from entering the cabinet. 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.
  • Page 18 Step 2: Take out all the power modules inside of the EVSE, detach it from the socket at the end of each module, remove the grounding line of the surge protector, and remove the DC+ and DC- ports on the insulation testing board.
  • Page 19 Step 5: Recover the situation inside of the EVSE to the original state after the test. Commissioning Manual Wanbang Digital Energy Co., Ltd.

  • Page 20: 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 21 Step 2: Take out all the power modules inside of the EVSE, detach it from the socket at the end of each module, remove the grounding line of the surge protector, and remove the DC+ and DC- ports on the insulation testing board.

  • Page 22: 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 Basic Check 1） Voltage check after power on: Check whether the output voltage of the main breaker inside of the EVSE is correct, and make sure there’s no fault such phase loss, overvoltage, undervoltage and wrong phase sequence.

  • Page 23: Web Configuration

    3.4.2 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. Commissioning Manual Wanbang Digital Energy Co., Ltd.
  • Page 24 Connect the main board to the laptop by an Ethernet cable, and set the IP address as shown in the following picture (192.168.88.xxx, xxx can be any number but 206) Commissioning Manual Wanbang Digital Energy Co., Ltd.
  • Page 25 Commissioning Manual Wanbang Digital Energy Co., Ltd.
  • Page 26 Open the browser and input 192.168.88.206, log in with username (xxcd) and password (28912891) Commissioning Manual Wanbang Digital Energy Co., Ltd.
  • Page 27 Change the language: Commissioning Manual Wanbang Digital Energy Co., Ltd.

  • Page 28: Software Update

    3.4.2.2 Software 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” PLC Update: 1) Connect to RS232 tool Commissioning Manual Wanbang Digital Energy Co., Ltd.
  • Page 29 2) Shown as below, connect RS 232 tool to port on PLC board. T/R- to TX，RXD+ to RX，GND to GND 3) Open programing software “ ” 4) Follow the steps shown below to update Update via TF Card： 1) Insert TF card into laptop adaptor (specific card for programming, don’t use the TF card put in the Commissioning Manual Wanbang Digital Energy Co., Ltd.
  • Page 30 EVSE). 2) Enter the folder (A6G2C-WB128LI-Flash), double click the file (m6g2c_burn_script.bat)，enter the driver of TF card. For example, the driver of my TF card is G. If there’s warning shown as picture, enter y to confirm and wait for the file to be copied completely. After that, press any key to exit and finish the programming TF card.
  • Page 31 4) Power on again, the LED light on the core board will be flashing all the time or steady lighting during the updating. 5) When the LED light on the core board is off (flashing all the time or steady lighting before), wait for 30 seconds and then power offer, switch both 2 switches back to position 1 and 2 (very important!).

  • Page 32: Web-Hardware Setting

    3.4.2.3 Web-Hardware Setting 1） Enter ChargerPoint ID (if no, default is 1234), Group Number (if no, default is 1234), EVSE ID: 1 2） Click “Submit”. The default settings are shown as below: Commissioning Manual Wanbang Digital Energy Co., Ltd.
  • Page 33 Commissioning Manual Wanbang Digital Energy Co., Ltd.

  • Page 34: Web-Software Setting

    3.4.2.4 Web-Software Setting Network Priority: 1) Find “Network priority selection” 2) Click “Enable modification” 3) Set the priority, Ethernet>4G>WIFI for default 4) Click “Submit”. 1) Find “4G configuration” Commissioning Manual Wanbang Digital Energy Co., Ltd.
  • Page 35 2) Click “Enable modification” 3) Set APN, User, Psw, Pin according to actual usage 4) Click “Submit”. Ethernet: 1) Connect Ethernet cable 2) Find “Ethernet configuration” 3) Click “Dhcpc enable” 4) Click “Submit”. Commissioning Manual Wanbang Digital Energy Co., Ltd.
  • Page 36 WIFI: 1) Find “Wifi configuration”。 2) “Mode selection” choose “STA” 3) Fill in “SSID”(WIFI ID) “Psw”(WIFI pasword) “Encryption”(EncryMode, generally choose wpa2) 4) Click “Dhcpc enable” 5) Click “Submit”. OCPP: Take http://36.153.57.202:3400/steve/websocket/CentralSystemService as an example. The information need to be filled in is shown as below: 1) Find “OCPP Part”...
  • Page 37 Card Type： 1) “Start stop card”: Local start-stop card, the EVSE can work by swiping the card without connecting to the backend. 2) “Billing card”: Authentication card, the UID of RFID card must be entered into backend before using, and EVSE must connect to the backend 3) “Local PnC”: plug in and charge Click “Submit”...

  • Page 38: Charging Function Check

    3.5 Charging Function Check 3.5.1 Charging Test  Swipe Card for Charging Operation steps are shown as below: Step 1: Click anywhere to turn on the touch screen. Step 2: The screen will automatically jump to next step after plugging the charging cable. Commissioning Manual Wanbang Digital Energy Co., Ltd.
  • Page 39 Step 3: Swipe the card for charging: swipe the RFID card in the specific swiping area to start the EVSE charging. Step 4: The screen shows the charging status when charging, click “Details” for more specific information. Step 5: Swipe the card for stopping charging: Click “Stop” to enter stop charging interface and select mode of “swipe the card”...
  • Page 40 Step 6: The charging result is displayed on the screen after charging and stopping. Step 7: Pull out of the charging cable charging on the vehicle. Put it back on the holder. Commissioning Manual Wanbang Digital Energy Co., Ltd.
  • Page 41  Scan QR Code for Charging Operation steps are shown as below: Step 1: Click anywhere to turn on the touch screen. Step 2: The screen will automatically jump to next step after plugging the charging cable. Step 3: Open the App and scan the QR code displayed on the screen. Step 4: The screen shows the charging status when charging, click “Details”...
  • Page 42 The details will also be shown on APP. Step 5: To stop charging during charging process, click “Stop” in APP to stop charging. Commissioning Manual Wanbang Digital Energy Co., Ltd.
  • Page 43 Step 6: The charging result is displayed on the screen after charging and stopping. Step 7: Pull out of the charging cable charging on the vehicle. Put it back on the holder. Commissioning Manual Wanbang Digital Energy Co., Ltd.

  • Page 44: Hardware Function Test

    3.5.2 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 45 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 46 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 3.Common sense of safety and emergency□ handout 4.Troubleshooting process□...

  • Page 47: Commissioning Report

    Appendix 2 Commissioning Report Commissioning Report Date： Commissioning Engineer： Charging Station： Address： Commissioning Manual Wanbang Digital Energy Co., Ltd.
  • Page 48 Details of EVSE Power Charging Power Firmware Specification module Installation cable Backend module type version quantity length Commissioning Manual Wanbang Digital Energy Co., Ltd.
  • Page 49 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 Grounding...
  • Page 50 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 51 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 52 The switching power supply can provide 12V/24V Switching power supply power supply voltage normally and stably 4.3 Parameter Configuration Object Content Conclusion Remark Configuration Configure according to the requirements Backend connection Connect successfully Charging Function 5.1 Charging Testing Object Content Conclusion Remark Charging via APP...
  • Page 53 Conclusion Required voltage Required current Output voltage Output current EV model Remark Conclusion Remark □Pass □Fail Commissioning Engineer: Customer: Date: Commissioning Manual Wanbang Digital Energy Co., Ltd.

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