CTEK CGC100 User manual

CGC MANUAL
Document time: Pd_IM_0006, Issue A.1
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CGC100
Installation manual

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Warranty
The CTEK E-Mobility warranty for load balancers in the CGC range is valid
for 12 months starting from the date of delivery. Products that become
defective during the warranty period will be repaired or replaced. The
warranty is only valid if the product has been used in accordance with the
manufacturer’s instructions.
Manual
This manual is as accurate and up-to-date as possible at the time of issue.
However, some information may have been updated since then. CTEK E-
Mobility reserves the right to change the content of this manual without
prior notice.
An exclamation mark in a triangle means there is important information that you must read.
A lightning symbol in a triangle means there could be a risk of electric shock while installing the
product.

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TABLE OF CONTENTS
1General information ....................................................................................................................... 4
1.1 Purpose ................................................................................................................................... 4
1.2 References .............................................................................................................................. 4
2Before installation.......................................................................................................................... 4
2.1 Tools........................................................................................................................................ 4
2.2 Material/ equipment................................................................................................................. 4
2.3 Details...................................................................................................................................... 4
2.4 Dimensions.............................................................................................................................. 4
2.5 Installation site......................................................................................................................... 4
2.6 Installation................................................................................................................................ 5
2.7 Cable installation ..................................................................................................................... 5
2.7.1 General information............................................................................................................. 5
2.7.2 Cable installation –Ethernet................................................................................................ 5
2.7.3 Current transformers ........................................................................................................... 5
2.7.4 Cable installation –power ................................................................................................... 6
3Installation ...................................................................................................................................... 6
3.1 Step by step............................................................................................................................. 6
3.2 Options .................................................................................................................................... 6
3.2.1 Internet connection Charge Portal....................................................................................... 6
4Functionality................................................................................................................................... 8
4.1 Vehicle charging...................................................................................................................... 8
4.2 Maintenance............................................................................................................................ 8
4.3 Resetting of personal protective device .................................................................................. 8
5Testing............................................................................................................................................. 8
5.1 Testing of electric vehicle connector ....................................................................................... 8
5.2 Earth fault testing..................................................................................................................... 8
5.3 Testing the load monitor.......................................................................................................... 8

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1 General information
The CHARGESTORM® Connected Grid
Central (CGC100) is a load monitor for electric
vehicle charging stations. It can also monitor
other loads at the property during load
balancing. The CGC100 can act as an internet
gateway to Charge Portal, CHARGESTORM®
Connected cloud-based charging portal.
The CGC100 can manage up to 100 loading
outlets.
The CGC100 communicates with charging
stations using an Ethernet connection.
1.1 Purpose
This document explains how to perform
installation and commissioning and how the
product works.
1.2 References
ID Document
1) Configuration manual CCU, PD_CM_003
2) CHARGESTORM® Connected User
Manual, Pd_UM_00050.5
3) CCU NanoGrid Configuration Manual,
Pd_CM_004
2 Before installation
2.1 Tools
Recommended tools for installation.
•Screwdriver
•Stripping pliers
•Spirit level
•Drill
•Mini USB cable
2.2 Material/ equipment
The following materials are also needed to
install the CGC100.
•CHARGESTORM® Connected or the
CSR100 to be load balanced by the
CGC100 load monitor
•Ethernet switch
•Ethernet cables
•Screw joints for cable feeds
•Screw for wall mounting
2.3 Details
CGC100 contains the following components:
•Energy meter Carlo Gavazzi, model
EM21, with current transformers
•Control board, CCU
•Power supply CCU
•Fuse 10A
•Terminal block for 230VAC
•Triangular key for door.
All the components are mounted on your DIN
rail.
2.4 Dimensions
The CGC100 has the following external
dimensions in mm.
Model
Height
Width
Depth
CGC100
280
mm
600 mm
450 mm
Note: it is important to check that the enclosure
door can be opened at the installation site.
2.5 Installation site
Note the following:
•Run the incoming cables (electrical,
Ethernet, transformer cables) through

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the sub-unit enclosure (at top or
bottom).
•If Internet access is via 3G, check
whether there is adequate coverage at
the relevant location. Do not install an
antenna in the sub-unit as this may
impair reception.
•The enclosure can be locked with a
standard electrical enclosure key
(triangular key).
2.6 Installation
Screw the enclosure to the wall through the
back of the enclosure.
2.7 Cable installation
2.7.1 General information
The CGC100 communicates with the
CHARGESTORM® Connected and/or
CSR100 charging stations over Ethernet via a
switch.
Note that the Ethernet switch is not part of the
load monitor and must be purchased
separately. One port is needed per charging
box plus one for the load monitor. You will also
need an additional port for Internet access, if
required.
It is advisable to run the Ethernet and electrical
cables simultaneously.
A personal protective device for each charging
outlet is located in the charging station.
2.7.2 Cable installation –Ethernet
The following Ethernet cables need to be
connected (the Ethernet cables should be Cat5
or Cat6 cables with an RJ45 connector at each
end).
•You will need one cable between
each charging box and switch. For
instance, if there are eight charging
boxes in the installation, you will need
eight cables.
•Install one cable between the load
monitor and the switch.
•If Internet access is required, please
install an appropriate cable.
Note that the Ethernet cables may not be
longer than approx. 90 m. If longer cables are
needed, repeaters must be used to strengthen
the signal.
2.7.3 Current transformers
When other loads in the premises need to be
monitored by the load monitor, current
transformer cables must be installed from the
energy meter in the CGC100 to the relevant
metering point. Install one current transformer
per phase, i.e. three current transformers: L1,
L2 and L3.
Note: Current is only measured via the current
transformers. The current direction must be
correct. The kWh will NOT increase and the
LED will NOT flash if the current direction is
incorrect. The current and voltage must be
measured on the same phase. A neutral
conductor must be available. Below is an
example of connection in a 3-phase system.
Load
monitor
Current
transformer
Ethernet switch
Charging
stations
Internet
POWER GRID
LOAD

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2.7.4 Cable installation –power
The CGC100 is supplied with 230VAC. The
input power should be connected to an internal
terminal block.
Because the unit is connected to the power
grid, installation must be performed by a
certified electrician.
3 Installation
3.1 Step by step
1. Cable installation.
a. Choose the installation points for
the sub-unit, charging stations and
Ethernet switch.
b. Install the electrical and Ethernet
cables.
c. Install the current transformers in a
location where other loads are to
be measured.
2. Install the units
a. Screw the CHARGESTORM®
Connected units to a wall or a post
and connect the Ethernet cables.
b. Connect the phases alternately on
each charging box. Carefully note
down the phase rotation, which
must be known when the load
balancing is configured in the
software. Documentation
regarding the phase rotation is
sometimes available in advance.
c. Install the sub-unit, CGC100 and
connect the cables.
3. Connect the power.
a. Check the installation before
switching on the power to prevent
the risk of short-circuiting.
b. After the power is switched on, the
charging station should
automatically switch on and a
green indicator light will illuminate.
4. Configure the load balancing:
a. Configure each individual charging
box via the mini USB interface so
that NanoGrid is activated. Verify
that the firmware version is R3.6.1
or higher. Remember to reboot
after changing the configuration
(See manual ref. 1) how to
connect to the local web interface)
b. Configure CGC100 via the mini
USB interface. Activate NanoGrid.
Upload NanoGrid.ini. Reboot. For
a description of the load balancing
file NanoGrid.ini see ref. 3)
Figure 1 Activate NanoGrid
Figure 2 Reboot
Figure 3 Load nanogrid.ini file
5. Option: Internet connection to Charge
Portal
a. See next section
3.2 Options
3.2.1 Internet connection Charge Portal
Customers can access their electrical vehicle
charging statistics via the Internet using
CHARGESTORM® Connected cloud-based
Charge Portal. To access Charge Portal, the

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CGC100 sub-unit must be connected to the
Internet. It can be connected either via 3G or
Ethernet. The way in which the load monitor
connects to the internet and contacts the portal
is described in reference 1). The login details
for the portal must be obtained from CTEK E-
Mobility in advance. You can request the login
details from your sales contact.

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4 Functionality
The load monitor and charging stations can be
used immediately after installation and
commissioning/configuration.
CHARGESTORM® Connected shows the
electric vehicle charging status using symbols.
See user manual, ref. 2).
4.1 Vehicle charging
Connect the charging cable to the vehicle. The
green outlet symbol will change to a flashing
blue battery and charging will begin.
To stop charging, disconnect the cable from
the car.
4.2 Maintenance
The residual current device should be tested
once a year.
4.3 Resetting of personal protective
device
If the personal protective device on the
CHARGESTORM® Connected is triggered,
open the front panel with the key and reset the
device.
5 Testing
After installation, perform the following tests on
all the charging stations (if no other test
instructions are available).
To do this you need access to a chargeable
vehicle, or to a CHARGESTORM® Connected
test box that can simulate charging.
5.1 Testing of electric vehicle
connector
Connect the electric vehicle connector to the
vehicle and verify that charging has started.
The LED indicator turns blue during charging.
5.2 Earth fault testing
Press the test button on the residual current
device in the CHARGESTORM® Connected
and note whether the device trips. If there is an
earth fault, the ‘X’ will turn red.
5.3 Testing the load monitor
Connect electric vehicles to all the units and
check that the sub-unit is showing that the total
current does not exceed the rated current.
Fault reporting
Any faulty units should be sent to:
CTEK E-Mobility Center
Malmgatan 4
S-602 23 Norrkoping
SWEDEN
Tel.: [phone]
Fax: [phone]
Or to your local CHARGESTORM® Connected
distributor.
Include a fault description to help us locate the
fault.