CAR-connect LDC.22-500 User manual

Operating manual
Mobile high-voltage DC charger LDC.22-500
41.CC.2210.3042_BA_V00_EN

Legal notice
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Legal notice
Legal notice
Manufacturer CAR-connect GmbH
Am Egelingsberg 8
38542 Leiferde, Germany
Phone: [phone]
Fax: [phone]
[e-mail]
www.car-connect.cc
Reproduction Reproduction or reprinting, whether in whole or in part, always requires the written
permission of the manufacturer.
Copyright TRANSLATION OF THE ORIGINAL OPERATING MANUAL
All rights reserved.
All text, images and graphics are subject to copyright and other intellectual property laws.
Copyright 2020 CAR-connect GmbH.
Image sources Symbols for warnings, prohibitions, mandatory actions and standards are taken from publicly
accessible sources, such as the Internet. CAD product images and product photos are
provided by the manufacturer. Images showing the product in use are provided with a
reference to the source.
Revision Date Reason
V00 19.07.2021 First edition

Contents
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Contents
Contents .............................................................................................................................3
1Introduction ...............................................................................................................6
1.1 Preliminary information.............................................................................................................. 6
1.2 Validity of the declaration of conformity .................................................................................. 6
1.3 Manufacturer specifications ...................................................................................................... 6
2Safety..........................................................................................................................7
2.1 Warning levels ............................................................................................................................. 7
2.2 Important safety instructions..................................................................................................... 8
2.3 Safety functions .......................................................................................................................... 9
2.3.1 Emergency stop button ..................................................................................................... 9
2.4 Intended use .............................................................................................................................. 11
2.5 Requirements for the target group.......................................................................................... 11
2.6 Duties of the operator............................................................................................................... 11
2.7 Note to the grid operator .......................................................................................................... 12
3Transport and storage ............................................................................................13
3.1 Transport on receipt of goods................................................................................................. 13
3.2 Unpacking the product ............................................................................................................. 14
3.3 Transporting the product at the place of use......................................................................... 16
3.3.1 Engaging the parking brake............................................................................................ 16
3.3.2 Adjusting the parking brake ............................................................................................ 17
3.4 Ambient conditions at the place of use .................................................................................. 18
4Product description ................................................................................................19
4.1 Scope of delivery ...................................................................................................................... 19
4.2 Design ........................................................................................................................................ 20
4.3 Symbols and connections........................................................................................................ 21
4.4 Displays and controls............................................................................................................... 23
4.5 Technical data ........................................................................................................................... 24

Contents
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Contents
5Operation .................................................................................................................25
5.1 Preparing the power supply connection ................................................................................ 25
5.2 Startup........................................................................................................................................ 26
5.3 Initial startup.............................................................................................................................. 27
5.3.1 Cold start......................................................................................................................... 27
5.3.2 Warm start ...................................................................................................................... 28
5.3.3 Setting the contrast ......................................................................................................... 28
5.3.4 Startup after long downtimes .......................................................................................... 29
5.3.5 Self-test........................................................................................................................... 29
5.4 Starting charging ...................................................................................................................... 30
5.4.1 Setting the charging time ................................................................................................ 30
5.4.2 Setting the auto-off function............................................................................................ 31
5.4.3 Charging the vehicle ....................................................................................................... 31
5.5 Finishing charging .................................................................................................................... 32
5.5.1 Waiting for charging to finish .......................................................................................... 32
5.5.2 Canceling the charging process ..................................................................................... 33
5.6 Using the LC display................................................................................................................. 35
5.6.1 Function keys.................................................................................................................. 35
5.6.2 Menu structure ................................................................................................................ 36
5.6.3 Main menu ...................................................................................................................... 37
5.6.4 Operating parameters ..................................................................................................... 37
5.6.5 Configuration parameters ............................................................................................... 38
5.6.6 Information parameters................................................................................................... 39
5.6.7 Restoring the factory settings ......................................................................................... 41
5.7 Troubleshooting........................................................................................................................ 42
5.7.1 Warning messages ......................................................................................................... 42
5.8 Cleaning ..................................................................................................................................... 45
5.9 Storage ....................................................................................................................................... 45
5.10 Disposal ..................................................................................................................................... 45

Contents
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Contents
5.11 Maintenance............................................................................................................................... 46
5.11.1 Inspection and maintenance intervals ............................................................................ 46
5.11.2 Authorized inspection and maintenance personnel........................................................ 47
5.11.3 Inspection and maintenance areas on the product......................................................... 47
5.11.4 Inspection and maintenance table .................................................................................. 48
5.11.5 Tightening torques .......................................................................................................... 50
5.11.6 Replacing wearing parts ................................................................................................. 50
6Help ..........................................................................................................................54
6.1 Warranty..................................................................................................................................... 54
6.2 Customer service ...................................................................................................................... 54

Introduction
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1 Introduction
1.1 Preliminary information
Read through this operating manual carefully before using the product.
The product is delivered with a USB stick containing the operating manual in various
languages. You can find the current version and additional languages on our homepage.
There is a QR code on the product. You can scan this QR code with a device that is
connected to the internet to go directly to the download area for your product.
The operating manual is an essential part of the product and must be kept together with
the product. If you sell or transfer ownership of the product, the operating manual must be
handed over to the new operator.
In addition to this operating manual, all the relevant regulations for charging traction
batteries in electric vehicles are binding. They include but are not limited to: instructions
from the vehicle manufacturer and the operator, company-specific safety requirements and
the latest engineering standards for working with electric vehicles.
1.2 Validity of the declaration of conformity
The declaration of conformity applies to the product described in the operating manual. Any
changes, modifications or extensions shall void the declaration of conformity and the risk
assessment.
1.3 Manufacturer specifications
CAR-connect GmbH
Since its founding, our company has focused on groundbreaking solutions for
electromobility. CAR
-
connect develops and produces custom solutions for the automotive
industry, repair shops and special vehicle fleets.
Our core
business is developing and producing innovative high-
voltage charging
technology for electric vehicles. Our portfolio also includes measurement and diagnostic
technology for the entire vehicle and battery analysis equipment.
With extensive experience in so
ftware and hardware development, CAR-
connect is your
dependable partner at every production stage, from prototyping to series production.
CAR-connect GmbH – Experience, Expertise and Innovation – MADE IN GERMANY

Safety
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2 Safety
This safety chapter provides information about the following:
•The warning levels contained in this operating manual
•Important safety instructions for the product
•Intended use of the product
•Requirements for the target group
This operating manual is only valid for the following product:
Item number
2210
3042
Designation
Mobile high
-voltage DC charger LDC.22-500
2.1 Warning levels
This chapter provides information about the warning levels used in this operating manual.
DANGER
Failure to observe the safety instructions WILL result in death or serious injury!
WARNING
Failure to observe with the safety instructions CAN result in death or serious injury!
CAUTION
Failure to observe the safety instructions CAN result in minor physical injury!
CAUTION
Failure to observe the safety instructions can lead to damage to the product!

Safety
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2.2 Important safety instructions
This chapter contains the safety instructions that must be observed when handling the
product.
DANGER
Danger of fatal electric shock!
The electrical voltage in the product is lethal and will cause death by electric shock!
Liquids and moisture may cause short circuits!
•Do not let the product come into contact with liquids!
•Do not use the product outdoors or in damp environments!
•Protect the product against the effects of all kinds of weather!
•Do not attempt to open or damage the product!
WARNING
Risk of explosion!
Product components may produce sparks and electric arcs.
•Never disconnect high-voltage plug connections while under load!
•Do not use the product in potentially explosive atmospheres!
•Ensure that the product is at least 50 cm above the ground during operation!
WARNING
Danger of electric shock!
The electrical voltage in the product is dangerous and can cause serious injury from
electric shock!
•Never attempt to power other devices with the product!
WARNING
Danger of fatal electric shock!
Defective and damaged products can no longer guarantee protection against electrical
voltage!
•Do not let the product come into contact with chemicals!
•Replace a defective or damaged product immediately!
•Never attempt to repair or tamper with the product!

Safety
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CAUTION
Risk of damaging individual wires!
When bending or coiling the DC charging cable, you can damage individual wires if the
bending radius is too small.
•When coiling or laying the DC charging cable, maintain a bending radius of at least
22 cm!
•When coiling or laying the DC charging cable, maintain sufficient distance from the
corners of buildings or other objects.
2.3 Safety functions
The product is equipped with various safety functions that interrupt all dangerous current
in the product in the event of certain hazards.
2.3.1 Emergency stop button
WARNING
Danger due to impaired safety function!
Damage to the emergency stop button can impair the product’s safety function!
•Check the function of the emergency stop button at regular intervals (see the
“Pressing the emergency stop button” and “Maintenance” sections)!
•Make sure that the emergency stop button is always readily accessible!
WARNING
Danger of fatal electric shock!
The electrical voltage in the product is dangerous and can cause serious injury or
death from electric shock!
The product is live even after the emergency stop button is pressed!
•Completely disconnect the product from all power sources before opening the
product or removing cables.
•Do not use the emergency stop button to perform maintenance on the product.

Safety
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The product is equipped with an emergency stop button. Pressing the emergency stop
button causes the following to happen:
1. The contactors in the DC charger are opened, immediately interrupting the electrical
connections to the power supply from the AC/DC converters and to the vehicle.
2. A signal is sent to the controller, which makes it impossible to resume charging by
resetting the emergency stop button.
3. The message “Emergency stop pressed” appears on the LC display.
Position Description
1
Emergency stop button
2
LC display
Pressing the emergency stop button
Push in the emergency stop button until it clicks into place.
The message “Emergency stop pressed” appears on the LC display.
Resetting the emergency stop button
1. Turn the emergency stop button clockwise and pull out until it clicks into place.
2. Press the “On” button.
The message “Emergency stop pressed” disappears from the LC display.
You cannot resume a previous charging process by resetting the emergency
stop button. You have to restart the product.

Safety
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2.4 Intended use
The high-voltage DC charger is a mobile workshop cart for rapidly charging traction
batteries in electric vehicles in the workshop. The high-voltage DC charger is used to
charge traction batteries with direct current in charging mode 4.
The high-voltage DC charger has a GB/T charging plug, dynamic power adjustment and
control and protection functions that make it suitable for all the conventional electric
vehicles available on the market.
Use the high-voltage DC charger only on the DC charging socket of your electric vehicle!
Connect the high-voltage DC charger only to fused power sockets with protective and
neutral conductors!
Extension cords or adapters are strictly prohibited!
Any use beyond what is listed here is prohibited!
2.5 Requirements for the target group
DANGER
Danger of fatal electric shock!
The electrical voltage in the product is lethal and will cause death by electric shock!
•Keep the product away from children and adolescents!
Only qualified personnel may work with this product!
In this operating manual, qualified personnel is defined as personnel meeting the following
requirements:
•Personnel have received comprehensive training on working with electric vehicles.
•Personnel have received training on working with all charging modes, in particular
mode 4.
•Personnel must not be under the influence of medication or drugs while using the
equipment!
2.6 Duties of the operator
The operator is responsible for ensuring that all staff working with the high-voltage charger
fulfills the requirements for the target group.
Furthermore, the operator is responsible for ensuring the following:
•The high-voltage charger is always in perfect working order.
•The regular inspection intervals for the high-voltage charger are observed and
recorded.
•Replacement of components is logged when the maximum number of mating cycles is
reached.

Safety
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2.7 Note to the grid operator
In some countries, you may require a permit from the energy utility to operate electric
vehicle charging stations.
•Contact your grid operator before starting up the product.
•Have the grid operator or an electrician check your home’s connection to see if it is
suitable for operating an electric vehicle charging station.

Transport and storage
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3 Transport and storage
3.1 Transport on receipt of goods
The product has been packed securely and ready for use in a multi-piece heavy duty
cardboard box on a disposable pallet.
Immediately check the condition of the product and the completeness of the package.
Document any damage or signs of a customs inspection and contact the carrier or
manufacturer immediately.
Observe the following warnings when transporting the product.
CAUTION
Improper transportation
Transporting the product using unsuitable means can lead to property damage and
personal injury!
•Always use a suitable industrial truck or hoist to transport the packaged product!
CAUTION
Risk of damage!
Slings suspended from indoor cranes can damage the packaging!
•Do not transport the packaged product using slings and indoor cranes.

Transport and storage
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3.2 Unpacking the product
The packaging consists of a two-part cardboard box. The lower half is firmly attached to a
disposable pallet. Inner packaging within the cardboard box protects the product.
CAUTION
Risk of injury due to heavy product!
Lifting the product can lead to back injuries.
Body parts can become trapped or crushed when the product is lowered.
•Always use two people to lift the product!
•Always wear protective footwear when transporting the product!
CAUTION
Risk of damage!
There is a risk of damaging the insulation on the cables.
•When cutting the packaging straps, take care not to cut through the cardboard!
•Carefully remove the protective foil from the cables!
1. Carefully cut the packaging straps.
2. Remove the top half of the heavy duty cardboard box.

Transport and storage
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3. Remove the inner packaging.
4. Unfold the front opening of the heavy duty cardboard box.
5. Grasp the product by the handle and pull it out of the heavy duty cardboard box in the
horizontal position.
6. Stand the product upright.
When in the vertical position, the product’s own weight engages the parking
brakes.
7. Remove the protective foil from the wiring harnesses.
The product is now unpacked. Keep the inner packaging and the heavy duty
cardboard box for future transportation.
You can now check the scope of delivery (see the “Scope of delivery” section).

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3.3 Transporting the product at the place of use
The product is mounted on wheels that allow it to be easily transported to the place of use
or storage. Observe the following warnings when transporting the product to the place of
use:
CAUTION
Risk of crushing and bruising!
If not secured, the product can roll away unintentionally on uneven ground!
Body parts can become crushed or bruised!
•Always secure the product by engaging the parking brakes!
•Always wear personal protective equipment and footwear when working on the
product!
3.3.1 Engaging the parking brake
The parking brake on the wheels automatically engages as soon as the product is upright.
When the product is set down on its front feet, the product’s own weight causes the brake
to be pressed against the wheels.
(1) Parking brake
(2) Wheel
(3) Front feet

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3.3.2 Adjusting the parking brake
This adjustment ensures that the parking brake securely locks the wheels as soon as the
product is upright.
Requirement:
•The product must be disconnected from the power supply and from the vehicle.
•The product must be resting on a level surface.
Use a spirit level to check that the product is vertical.
Loosen the upper lock nut.
Secure the lower lock nut so that it cannot rotate.
Turn the set screw to adjust the pressure on the wheel so that it fixes it securely in
place.
Tighten the upper lock nut.
Check the adjustment and repeat if necessary.
The parking brake is now adjusted.

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3.4 Ambient conditions at the place of use
CAUTION
Overheating!
If excessive heat is produced, the DC charger automatically switches off!
•Do not expose the product to direct sunlight!
•Ensure that the ventilation grilles are always clear while the product is in operation!
•Always unwind the cables completely!
•Never operate the product in a closed container!
•Never operate the product on carpet or other textile floor coverings!
•Observe the permitted ambient temperatures (see the “Technical data” section)!
To ensure optimum ventilation, always maintain at least one meter of clearance from other
bodies and the wall.

Product description
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4 Product description
4.1 Scope of delivery
Immediately check the condition of the product and the completeness of the delivery. If
anything is missing or defective, please contact the manufacturer immediately.
(1) High-voltage DC charger
(2) USB stick with operating manual

Product description
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4.2 Design
Product design:
(1) Emergency stop button
(2) Service port
(3) LC display with membrane keypad
(4) GB/T charging plug
(5) Power supply plug
(6) Handle
(7) Rubber cushion
(8) Wheels