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InCharg ICE-44 V2X Installation And Operation Manual

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ICE-44 V2X Installation and Operation Manual
Version: 3
Last Edited: 04/15/2025
InCharge Energy Inc.
All Rights Reserves. This Manual May Be Subject to Change Without Notice
https://inchargeus.com/
Service Hotline: 818-697-GOEV
1 |
P a g e

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  • Page 1 ICE-44 V2X Installation and Operation Manual Version: 3 Last Edited: 04/15/2025 InCharge Energy Inc. All Rights Reserves. This Manual May Be Subject to Change Without Notice https://inchargeus.com/ Service Hotline: 818-697-GOEV P a g e...

  • Page 2: Table Of Contents

    4.2) Grounding Instructions ..................... 16 4.3) Unboxing and Visual Inspection ..................16 4.4) Assembly/Placing Instructions ..................16 4.4.1) ICE-44 V2X Wall Mounting ..................17 4.4.2) V2X Off Grid Box Wall Mounting ................21 4.4.3) Power Cable Connections ..................24 5.) Start Up ..........................30 5.1) Verification and Inspection ....................
  • Page 3 6.5.3) Charging/Discharging Steps ..................48 Appendix 1) Engineering and Technical Parameters ..............51 Appendix 2) ICE-44 V2X and Off Grid Box Schematic Diagram ............ 53 Appendix 3) V2X Off Grid Box Schematic Diagram ..............54 Appendix 4) Maintenance ......................55 1.) Maintenance Table ......................
  • Page 4 2.8) Alarm Information ......................63 3.) Maintenance Operation (V2X Off Grid Box) ............... 64 3.1) MCCB ........................... 64 3.2) Devices and Connection Points ..................65 3.3) AC SPD .......................... 66 3.4) Cooling Fan and Filter ....................66 Appendix 4) Error Codes and Possible Solutions ................. 68 P a g e...

  • Page 5: Important Safety Instructions

    1.) IMPORTANT SAFETY INSTRUCTIONS  Please read the operating instructions and notes carefully before starting operation to prevent accidents. The "Caution, Attention, Warning, and Danger" statements in the products and product manual do not represent all safety matters to be observed and are intended to supplement various operational safety precautions.

  • Page 6: Tools

    1.2) Tools Special tools must be used during various operations involving high DC and AC voltages. 1.3) Thunderstorm It is strictly forbidden to carry out live installation and maintenance work during thunderstorms.  A strong electromagnetic field will be produced in the atmosphere during a thunderstorm.

  • Page 7: Sharp Corners Of Objects

    1.6) Sharp Corners of Objects During the handling of equipment by hand, it is necessary to wear protective gloves to prevent injuries caused by sharp objects. 1.7) Power Cable Make sure that the cable label is correct before the connection of cables. 1.8) Signal Cables Signal cables should be kept away from power cables, with a minimum distance of 100mm.

  • Page 8: General Product Description

    2.) General Product Description The ICE-44 V2X is a 44kW “Vehicle-to-Everything” bidirectional DC Fast charger that supports Vehicle-to-Grid (V2G), Vehicle-to-Building, and other discharge use cases. Available as Buy America compliant, this charger may qualify for funding opportunities, including those with V2G-capability requirements.
  • Page 9 Note: The products marked in red are off grid distribution boxes, which can be ordered and installed when the off-grid function is required. Figure 2-1: Application Scenario P a g e...
  • Page 10 Component Description：  Optional Accessory V2X Box: Include main switch and load switch, an AC meter, and lead-acid batteries, used to achieve power distribution, protection, and hardware switching between parallel and off grid modes, supports three-phase loads.  QF1: Installed in V2X Box, Short circuit overload protection and disconnect switch of the system.
  • Page 11 Figure 2-2: Life Cycle of the backup battery (24V) 11 | P a g e...

  • Page 12: General Characteristics

    3.) General Characteristics 3.1) Technical Characteristics  V2X System technical characteristics are indicated in Table 3-1 and 3-2. This system is intended to have one DC output connection Table 3-1: ICE-44 V2X Technical Characteristics Technical Data Description Remarks Phases/Lines 3 phases + neutral + PE...
  • Page 13 Note 2: The protection level of the V2G charger is IP55. But for charging safety it should not be used during rain or snow if water can reach the charger connector. Table 3-2: Optional Accessory V2X Off Grid Box Technical Characteristics Technical Data Description Remarks...

  • Page 14: Name Plate Information

    3.2) Name Plate Information 3.3) Model Description Model Configuration Output Power ICE-44 V2X Charger I44-C1C1-R CCS-1 125A 44 kW ICE-44 V2X Off-grid BOX IAU125ATS-AW-2 250A MCCB x 1;125A MCCB x 2 44 kW 14 | P a g e...

  • Page 15: Standards

    3.4) Standards The System complies with the following standards: Table 3-3: Applicable Standards Technical Data Standards & Versions Remarks UL2202:2022 UL9741:2023 UL1741:2021 UL1741 SA/SB:2021 Applicable IEEE1547:2018 Standards IEEE1547.1:2020 Rule 21 HECO Rule 14 PRC-024-1 BELCO  UL2202: 2022: DC Charging Equipment for Electric Vehicles ...

  • Page 16: Installation

     Check if the exterior packaging has been damaged by mechanical impacts or any accidents during transportation.  If applicable, check that the exterior panels of the ICE-44 V2X are without fault.  Check if the interior of the Quick Charger Station is clean.

  • Page 17: 1) Ice-44 V2X Wall Mounting

    4.4.1) ICE-44 V2X Wall Mounting Figure 4-1: ICE-44 V2X Space Requirements View 17 | P a g e...
  • Page 18 Figure 4-2: ICE-44 V2X Back Hole Dimensions Figure 4-3: Holster Wall Mount Dimensions 18 | P a g e...
  • Page 19 19 | P a g e...
  • Page 20 Figure 4-4: Grid Input Wiring 20 | P a g e...

  • Page 21: 2) V2X Off Grid Box Wall Mounting

    4.4.2) V2X Off Grid Box Wall Mounting Figure 4-5: V2X Off Grid Box Space Requirements 21 | P a g e...
  • Page 22 Figure 4-6: V2X Off Grid Box Back Hole Dimensions 22 | P a g e...
  • Page 23 23 | P a g e...

  • Page 24: 3) Power Cable Connections

    4.4.3) Power Cable Connections End terminal for input wiring: 5(five) end terminals up to 3phases+neutral+protective ground Without V2X Off-Grid Box: Table 4-1: AC Cables choice for V2X charger The section for Amperage at Max. Power of Specification of terminal AC feed cables 480Vac charger screw...
  • Page 25 With V2X Off Grid Box: Table 4-2: AC input wiring cables chosen for V2X Off-grid Box The section for Amperage at Max. Power of Specification of terminal AC feed cables 480Vac charger screw 1/0 AWG 112A 88kW L1/L2/L3/N/PE is M8 Table 4-3: Backup output wiring cables choose for V2X Off-grid Box The section for Amperage at...
  • Page 26 Note 1: With out the Off Grid Box, Short connector XT3-7a to XT3-8a and XT3-7a to XT3-8a. Table 4-2: AC input wiring cables chosen for V2X Off-grid Box Notes:  The AC feed power cables to the charger are not included. ...
  • Page 27  QF1: AC Input MCB for Rectifier Module  QF2: AC Input for Auxiliary Power  L1 L2 L3 N: AC Input Connection  PE: Earth Bus Bar  XT3: Parallel Cabinet Terminals 27 | P a g e...
  • Page 28  Backup Battery Switch: Manually release the backup battery and start the system entering off grid mode.  Status Lamp: Indicate the device status as follows: STANDBY Solid green IN CHARGING Solid yellow INDISCHARGING Solid blue IN DISCHARGING Flashing blue 1S on 1S off 28 | P a g e...
  • Page 29  QF1: AC Input MCCB For V2G Charger & AC loads  QF2: AC Input MCCB For AC loads  QFP: AC Input for Auxiliary Power  QFS: Emergency manual switch, when V2G cannot function properly, set it to ON to continue maintaining load electricity usage ...

  • Page 30: Start Up

    5.) Start Up 5.1) Verification and Inspection  The installation location of charging device shall not be less than 20 feet away from commercial garage (repair facility) or outdoor vehicle fuel distribution device  Check if the bolts of the AC and protective ground cables of the V2G Charger & V2X off- grid Box are correctly tightened to the specified torque ...
  • Page 31 31 | P a g e...

  • Page 32: User Manual

    The Human Machine Interface (HMI) will give instructions and signal different stages. These sequences are shown in this chapter. 6.1) Output Connector The ICE-44 V2X is prepared to charge electric vehicles according to the charging systems mentioned. 6.1.1) CCS1 Connector...

  • Page 33: Operation Instructions

    6.2) Operation Instructions 6.2.1) Setting the Discharge Cutoff Conditions  Contact InCharge Energy to set proper discharge cutoff settings. The value of "V2X SOC Lower Limit" would be changed to a percentage, such as 30%. The V2X charger will stop discharging when the vehicle battery SOC reaches 30% in this example.

  • Page 34: 2) Off-Grid Standby Time Setting

    6.2.2) Off-Grid Standby Time Setting  When the power grid suddenly loses power, the V2X charger automatically enters the off- grid interface and starts the standby countdown. The default time is 3 minutes. If there are no dischargeable vehicles connected or the user does not start off grid discharge after 3 minutes, the control system will automatically power off...
  • Page 35 35 | P a g e...

  • Page 36: 3) Create Stand-Alone Inverter Supply Earthing System

    6.2.3) Create Stand-Alone Inverter Supply Earthing System  You can set "Is P-N off grid Pull in" to “Yes” according to local regulations. When the system is in off grid discharge mode, it will automatically short circuit the neutral wire to the PE wire to ensure electrical safety.

  • Page 37: Ethernet And Ocpp Setting

    6.3) Ethernet and OCPP Setting Here are basic descriptions of these parameters:  Time zone: this determines the local time display on LCD. Please change it according to local time zone (Note this parameter only takes effect via LCD, that means even if charger is connected to OCPP server, this parameter is not affected).

  • Page 38: 1) Connection Check

     Notes: The protocol upper controller supports OCPP-J 1.6 and 2.0.1. Please refer to the OCPP official documents if you have any questions about the above 2 parameters or the protocol itself. 6.3.1) Connection Check  If the above settings are done properly, you should see the ‘ ’...

  • Page 39: Network Setting

    6.4) Network Setting 6.4.1) Router Set Up  Look at the WIFI networks on your computer and locate the Cradlepoint Network. Connect to the Cradlepoint Wi-Fi network (Ex: IBR600C-1D7) and enter the password from the back of the device.  Once connected to the device via WIFI, Launch a browser in either Google Chrome or Firefox, and type in 192.168.0.1 ...
  • Page 40  Once logged in, click (Start NetCloud OS) and the Dashboard will launch.  On the left side of the dashboard, click (Connection Manager) 40 | P a g e...
  • Page 41  Click (Internal 150M-D (SIM2 – AT&T) from the list. Please note that the error (CPPM Failed: Carrier Reject) means the APN has not yet been provided.  Right click on the (Internal 150M-D (SIM2 – AT&T) and click (Edit) ...
  • Page 42  Click Save  The device will now be rebooted.  To check signal strength --> On the dashboard --> click Status --> Internet --> Connections --> and it will show the device information. 42 | P a g e...
  • Page 43  Verify the EVSE shows these icons in the upper right corner.  After verification, then the Device is now ready to use. 43 | P a g e...

  • Page 44: 2) Wireless Network Configuration

    6.4.2) Wireless Network Configuration  First, check if your system is equipped with an external wireless router.  This router is installed inside the Power Cabinet and is interconnected with the Network Switch with a RJ45 network cable. The router is usually pre-installed along with the charger before leaving the factory, therefore the only thing needed to ensure it is operating properly.

  • Page 45: Charger Software Update

    6.5 Charger Software Update  The charger can update the firmware through OCPP or OEM backend remotely, or local update through USB drive to update the firmware of the upper controller and pilot controller.  The following figure 6.2 software version is for reference only, the actual situation shall prevail.

  • Page 46: 1) Upper Controller Update

    6.5.1) Upper Controller Update  For upper controller’s update, firstly power on the controller, and then plug the USB drive into the controller’s USB inlet and then go into the setting in “Manual Ctrl” --> “Charger System” --> “Reboot System”, need to input “Soft Reset”, and waiting the automatic update finish, and then take off...

  • Page 47: 2) Pilot Controller Update

    Figure 6.3: Software Version 6.5.2) Pilot Controller Update  For pilot controller’s update, firstly power on the controller, and then plug the USB disk into the controller’s USB inlet. Then restart the system (disconnect the auxiliary switch, then close it again). Pay attention to the sound. After hearing three beeps, it means the upgrade is complete.

  • Page 48: 3) Charging/Discharging Steps

    6.5.3) Charging/Discharging Steps  When a user starts a session with an ICE-44 V2X, the HMI will display the following screen.  Plug the charging connector into the vehicle’s charging inlet.  Start charging/discharging on the screen 48 | P a g e...
  • Page 49  Waiting for charging/discharging  Starting up successfully, now “Charging”  After the vehicle is fully charged or reaches the SOC discharge cut off condition, stop the charging/discharging session and unplug the connector from the vehicle.  Charging interface, current display positive value. 49 | P a g e...
  • Page 50  Discharging interface, current display negative value  Stop Interface 50 | P a g e...

  • Page 51: Appendix 1) Engineering And Technical Parameters

    Appendix 1) Engineering and Technical Parameters ICE-44 V2X: Dimensional view 51 | P a g e...
  • Page 52 V2X Off Grid Box: Dimensional View 52 | P a g e...

  • Page 53: Appendix 2) Ice-44 V2X And Off Grid Box Schematic Diagram

    Appendix 2) ICE-44 V2X and Off Grid Box Schematic Diagram 53 | P a g e...

  • Page 54: Appendix 3) V2X Off Grid Box Schematic Diagram

    Appendix 3) V2X Off Grid Box Schematic Diagram 54 | P a g e...

  • Page 55: Appendix 4) Maintenance

    Appendix 4) Maintenance 1.) Maintenance Table 55 | P a g e...

  • Page 56: Maintenance Operation (Ice-44 V2X)

    2.) Maintenance Operation (ICE-44 V2X) Maintenance Position Method Tool cycle Visual Check AC input main breaker 2 months Devices and connection points Main circuit devices (circuit breaker, AC Visual Check contactor, DC contactor, DC fuse), Torque wrench 2 months copper bar, power module connector...

  • Page 57: Devices And Connection Points

    2.2) Devices and Connection Points  Check the following marked areas the connection points between the main circuit components (circuit breaker, AC contactor, DC contactor, fuse) and copper bar or cable, the connection points between copper bar and copper bar, and the connector of power module for burns or serious discoloration.

  • Page 58: Ac Spd

    2.3) AC SPD  Check the status window of SPD. If the window color changes from green to red, it indicates that SPD has been damaged. In this event, the manufacturer will need to be contacted for replacement. 2.4) Charging Plug ...

  • Page 59: Cooling Fan And Filter Cotton

    2.5) Cooling Fan and Filter Cotton  Open the side door through the side door striker and pull out the dust screen from both sides.  Check the dust screen on both sides for dust.  Use the fan to clean the dust on the dustproof net. ...
  • Page 60 60 | P a g e...

  • Page 61: Esd

    2.6) ESD  Check the emergency stop cover plate. If the cover plate is damaged, please contact the manufacturer for replacement. 2.7) Power Module Replacement  Step-1: Use a screwdriver to loosen the screws that secure the module:  Step-2: Pull out the yellow drawer in the direction shown in the diagram to separate the module from its socket.
  • Page 62 Connector Type Group A Group B CCS+CCS 62 | P a g e...

  • Page 63: Alarm Information

    2.8) Alarm Information  Click “?” In the upper right corner of the screen to view the alarm information.  If there is alarm information, it should be handled immediately. If it cannot be handled, contact the manufacturer to handle it. 63 | P a g e...

  • Page 64: Maintenance Operation (V2X Off Grid Box)

    3.) Maintenance Operation (V2X Off Grid Box) Position Method Tool Maintenance cycle MCCB 2 months Visual Check Devices and connection points Main circuit devices (circuit Torque wrench 2 months Visual Check breaker, AC contactor), copper AC SPD 3 months Visual Check Blower, Screwdriver Cooling Fan and Filter cotton...

  • Page 65: Devices And Connection Points

    3.2) Devices and Connection Points  Check the following marked areas the connection points between the main circuit components (circuit breaker, AC contactor, DC contactor, fuse) and copper bar or cable, the connection points between copper bar and copper bar, and the connector of power module for burns or serious discoloration.

  • Page 66: Ac Spd

    3.3) AC SPD  Check the status window of SPD. If the window color changes from green to red, it indicates that SPD has been damaged. Need to contact the manufacturer for replacement. 3.4) Cooling Fan and Filter  Open the cabinet door, check the dust screen on both sides for dust. ...
  • Page 67 67 | P a g e...

  • Page 68: Appendix 4) Error Codes And Possible Solutions

    Appendix 4) Error Codes and Possible Solutions  Reason for end of charging  In case of abnormal shutdown, the charging interface will display the reason code for the end of charging, such as (212) in the following figure. 68 | P a g e...
  • Page 69 Table: Charger Alarms Alarm ID Alarm Name Alarm Level Description Remark The system is out of service and charge is not System Not allowed. This usually Available comes after another critical alarm (e.g. EPO pressed). The system is out of service and charge is not System Disabled allowed.
  • Page 70 Rectifier group This means the specified Rectifiers Failure gun will not be available. 1/2 shall be specified Rectifier group Rectifiers Comm This means the specified Fail gun will not be available. 1/2 be specified Insulation Comm This means the specified Fail gun will not be available.
  • Page 71 Stop Reason Code Description Remark Classification Normal Stop Condition satisfied Normal Stop EV Request Stop EV Request Stop Parameter configuration failed Charging Enable timeout Abnormal volt of outside bus Unable lock charging gun Insulation inspection abnormal Insulation inspection timeout EV Relay Pull-In timeout Require Curr Timeout Remain time over stop Ring fail alarm (reserved)
  • Page 72 Ground Fault Detected CR Comm Fail kWhMeterComm Fail CCU Comm Fail Battery overvoltage Battery undervoltage Battery current deviation error High battery temperature Battery voltage deviation error Charger Connector Lock Fault Vehicle shift position EV Error Error Status Noticed by EV PLC Low Level Comm Fail PLC High Level Comm Fail PLC Authentication Timeout...

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