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InCharg ICE-60 DCWB Installation And Operation Manual

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ICE-60 DCWB (AC-DC) Installation and Operation Manual
Version: 1
Last Edited: 05/15/2025
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-60 DCWB (AC-DC) Installation and Operation Manual Version: 1 Last Edited: 05/15/2025 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 ..................... 10 4.3) Unboxing and Visual Inspection ..................10 4.4) Assembly/Placing Instructions ..................10 4.4.1) ICE-60 DCWB Wall Mounting ..................11 4.4.2) Power Cable Connections ..................15 5.) Start Up ..........................16 5.1) Verification and Inspection ....................16 5.2) Switch On .........................
  • Page 3 6.5.1) Upper Controller Update ................... 27 6.5.2) Pilot Controller Update ..................... 29 Appendix 1) Engineering and Technical Parameters ..............30 Appendix 2) ICE-60 DCWB Schematic Diagram ................31 Appendix 4) Maintenance ......................32 1.) Hardware Torque Values ....................32 2.) Maintenance Operation (ICE-60 DCWB) ................33 2.1) AC Input RCD For Auxiliary Power ................

  • Page 4: Important Safety Instructions

    1.) IMPORTANT SAFETY INSTRUCTIONS  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 5: 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 6: 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 7: General Product Description

    2.) General Product Description 2.1) Main Features  The ICE-60 DCWB can fast charge all electric vehicles compliant with combined charging  system (CCS1) charging system standards.  IP55 for severe environment using -30℃ to 50℃ ambient temperature full power charging.

  • Page 8: General Characteristics

    3.) General Characteristics 3.1) Technical Characteristics  ICE-60 DCWB technical characteristics are indicated in Table 1.  This system is intended to have at least one DC output connection (CCS1 / NACS). Table 3-1: ICE-60 DCWB Technical Characteristics Technical Data...

  • Page 9: Model Description

    3.2) Model Description Table 3-2: Model Overview Model Configuration Output Power ICE-60 DCWB I60W-C1C1-R CCS1 + CCS1 60 kW 3.3) Standards The System complies with the following standards: Table 3-3: Applicable Standards Technical Data Remarks UL 2202:2022 R2.18 Applicable UL 2231-2 R08.16 UL 2231-1 R08.16...

  • Page 10: 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-60 DCWB are without fault.  Check if the interior of the Quick Charger Station is clean.

  • Page 11: 1) Ice-60 Dcwb Wall Mounting

    4.4.1) ICE-60 DCWB Wall Mounting Figure 4-1: ICE-60 DCWB Space Requirements View 11 | P a g e...
  • Page 12 Figure 4-2: ICE-60 DCWB Back Hole Dimensions Figure 4-3: Holster Wall Mount Dimensions 12 | P a g e...
  • Page 13 13 | P a g e...
  • Page 14 Figure 4-4: Grid Input Wiring 14 | P a g e...

  • Page 15: 2) Power Cable Connections

    4.4.2) Power Cable Connections End terminal for input wiring: 5(five) end terminals up to 3phases+neutral+protective ground Table 4-1: AC Cables choice for ICE-60 DCWB The section for AC Amperage at Max. Power Specification of Tightening feed cables 480Vac of charger...

  • Page 16: Start Up

     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 ICE-60 DCWB are correctly tightened to the specified torque ...
  • Page 17  Finally, the display will present the following screen.  CCS1 + CCS1 Units: 17 | P a g e...

  • Page 18: User Manual

    6.2.1) Setting the Discharge Cutoff Conditions  When a user starts an operation on the ICE-60 DCWB, the HMI display will show one of the following screens if All output connections are idle or, the unit allows the charging of DC power simultaneously.

  • Page 19: Ethernet And Ocpp Setting

    o Plug the charging gun into the vehicle interface o Start charging on the screen o Waiting for charging o After the vehicle is fully charged, stop charging first, then unplug the charging gun 6.3) Ethernet and OCPP Setting Here are basic descriptions of these parameters: 19 | P a g e...

  • Page 20: 1) Connection Check

     Time zone: this determines the local time display on LCD. Adjust 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 21: 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 22  Once logged in, click (Start NetCloud OS) and the Dashboard will launch.  On the left side of the dashboard, click (Connection Manager) 22 | P a g e...
  • Page 23  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 24  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. 24 | P a g e...

  • Page 25: 2) Wireless Network Configuration

     Verify the EVSE shows these icons in the upper right corner.  After verification, then the Device is now ready to use. 6.4.2) Wireless Network Configuration  First, check if your system is equipped with an external wireless router. ...

  • Page 26: 3) Wired Network Configuration

    6.4.3) Wired Network Configuration  First, check if your system is equipped with an external wireless router.  Connect the customer ethernet cable from their router LAN port to the WAN port of the Cradlepoint. 26 | P a g e...

  • Page 27: 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 28 Figure 6.3: Software Version 28 | P a g e...

  • Page 29: 2) Pilot Controller Update

    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 short beeps and one long beep, it means the upgrade is complete.

  • Page 30: Appendix 1) Engineering And Technical Parameters

    Appendix 1) Engineering and Technical Parameters ICE-60 DCWB: Dimensional view 30 | P a g e...

  • Page 31: Appendix 2) Ice-60 Dcwb Schematic Diagram

    Appendix 2) ICE-60 DCWB Schematic Diagram 31 | P a g e...

  • Page 32: Appendix 4) Maintenance

    Appendix 4) Maintenance 1.) Hardware Torque Values 32 | P a g e...

  • Page 33: Maintenance Operation (Ice-60 Dcwb)

    2.) Maintenance Operation (ICE-60 DCWB) Maintenance Position Method Tool cycle AC Input RCD For Auxiliary Power Visual inspection 2 months Devices and connection points Main circuit devices (circuit breaker, AC contactor, Visual inspection Torque DC contactor, DC fuse), copper bar, power module...

  • Page 34: 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 35: Charging Plug

    2.4) Charging Plug  Check whether the charging plug is cracked or damaged. If so, please contact the manufacturer.  Check whether the DC + and - terminals of the charging plug have obvious burning marks. If so, please contact the manufacturer for treatment. ...
  • Page 36  Remove the dust screen with a screwdriver, and use a soft brush, blower and vacuum cleaner to remove the dust effectively.  Use vacuum cleaner and soft brush cloth to effectively remove any dust/debris in the cabinet. 36 | P a g e...

  • Page 37: 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 38: 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. 38 | P a g e...

  • Page 39: Appendix 3) Error Codes And Possible Solutions

    Appendix 3) 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. 39 | P a g e...
  • Page 40 Table: Charger Alarms Alarm ID Alarm Name Alarm Level Description Remark System is out of service and charge is not allowed. System Not This usually comes after Available other critical alarm(e,g EPO pressed) System is out of service and charge is not allowed. System Disabled This happens after system is set to 'In-operative' by...
  • Page 41 Rectifier group 1/2 be Rectifiers Comm This means the specified Fail gun will not be available specified Insulation Comm This means the specified Fail gun will not be available This is from Rectifiers after Output Shorted detected the internal circuit shorted This is from IMSU-D after Insulation Alarm...

  • Page 42: Stop Codes

    Stop Codes Code Description Remark 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 abnormally Insulation inspection timeout EV Relay pull-In timeout Require Curr Timeout Remain time over stop Ring fail alarm (reserved)
  • Page 43 GunOverTemp OutputShortCircuit PWM Failure 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 EV Error Vehicle shift position Error Status Noticed by EV PLC Low Level Comm Fail PLC High Level Comm Fail PLC Authentication Timeout...

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I60w-c1c1-r

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