EV-Vision EXP120K1-HT Instruction Manual

EXP120K1-HT 120KW DC Charger
User / Installer manual
English
Ver: V1.0
Update: 2019-08-07
BOM: 201040117 EXP120K1-HT
Power configurations: 30KW, with 15KW increment up to 120KW
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EXP120K1-HT 120KW DC Charger
•Safety notes
To avoid accidents, read the user manual and installation instructions before using the charger. The “Caution,
Attention, Warning and DangerI instructions in the product manual and on the product itself do not represent all safety
warnings to be taken into account, but are intended to reinforce precautions for use.
During the various equipment operations it is necessary to comply with the National Safety Regulations and to
observe the safety instructions of the equipment provided by EV-Vision.
•Electrical safety
- High voltage
Compliance with National Safety Standards must be complied with during charger installation. Technicians
installing and servicing this equipment must be qualified to work with high DC voltage up to 750 Vdc and three phase AC
voltage up to 500 Vac.
It is stricly forbidden to wear watches, metal bracelets, rings or other electrically conductive objects on your hand,
wrist and body during the installation and maintenance of the equipment.
If there is water inside, the AC power and DC connector should be disconnected immediately. During operations
in humid environments water should not enter the equipment.
During operations, it is stricly forbidden to operate the DC chergar without using a “Prohibited Use” sign.
- Tools
- Lightning storms
The storm creates a strong electromagnetic field, the euqipment will need to be well installed to prevent damage
during lightning.
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EXP120K1-HT 120KW DC Charger
- Static electricity
- Short circuit
Durring work with the high voltage DC output, it is necessary to strictly check the polarity of cables and interface terminals. The
space for DC power distribution work is compsct and attention should be paid to planning cable routing before any installation work.
Insulations tools must be used.
During the work care should be taken to keep hands, arms, tools and other objects away from high voltage parts
to prevent accidents.
•Others
- Objects with sharp edges
- Power cables
- Signal cables
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EXP120K1-HT 120KW DC Charger
Contents
Cap. 1 - Visão global.............................................................................................................................................................6
1.1 Product name and model.......................................................................................................................................6
1.2 Appearance and configuration...............................................................................................................................6
1.3 Technical parameters.............................................................................................................................................7
1.4 Performance indicators..........................................................................................................................................8
1.5 Main features.........................................................................................................................................................9
1.6 Aplications..............................................................................................................................................................9
1.7 Output voltage and current curve ( for one power module )..................................................................................9
Cap. 2 - Instalation..............................................................................................................................................................10
2.1 Safety rules...........................................................................................................................................................10
2.2 Installation preparation.........................................................................................................................................10
2.3 Power cables connection.....................................................................................................................................11
2.4 Power module installation.....................................................................................................................................12
2.5 Configure power module.......................................................................................................................................13
2.6 Power ON process...............................................................................................................................................13
Chapter. 3 - Operating.........................................................................................................................................................14
3.1 LCD screen and user interface.............................................................................................................................14
3.2 Select system language........................................................................................................................................18
3.3 Ethernet and OCCP configuration........................................................................................................................21
3.4 Definitions LTE ( Wireless )...................................................................................................................................22
3.5 Software update....................................................................................................................................................23
Appendix 1 – Engineering and technical parameters..........................................................................................................24
Appendix 2 – Schematic diagram.......................................................................................................................................25
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EXP120K1-HT 120KW DC Charger
Cap. 1 - Visão global
The EX120K1 – HT serial DC charger wis specially designed for CCS type 2, CHAdeMo with fast charging and
AC type 2. Have a easy use interface and have IP65 protection, that allows its use in outdoor environments. Is
compatible with 500V and 750V, easy to set up with charging power between 30 and 120 KW.
1.1 Product name and model
Tha charging system is composed of DC and AC charge guns. The system may be installed outdoors, but for
safety reasons it should not be used during rain or snow as water may reach the chergar gun connector.
The system can be configured for different charger gun configurations, two DC and one AC. The DC can be
configured for CC2 and/or CHAdeMO, which can be configured for the same gun type.
1.2 Appearance and configuration
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EXP120K1-HT 120KW DC Charger
Configuration:
CCS2 CHAdeMO AC tipo 2
Component Description
Charge controller IMMSU-D charging controller + PLC controller + insulation detector
Upper controller IMMU2
Power module REG75030G or REG50040G – optional configuration: 1~8 pcs
DC charging gun 200A CCS-2 / 125A CHAdeMO
AC charging gun 32A type 2 AC
DC power distribution
Standard system 120KW.
The positive and negative DC output are provide with NO contractors and fuse protection.
The charger module has a built-in discharge circuit.
AC connector distribution AC connector breaker and contactor, type B RCD (opcional)
Temperature control system Heat exchange system
Card reader RFID
Metering 2 DC energy meter and 1 AC energy meter
HMI 7 inch TFT touch screen display and 5 LED indicators
Módem wireless LTE 1 wireless communication ( optional, insert the LTE modem card into IMMU2 upper
controller), 1 LAN
1.3 Technical parameters
Parameter Description
Condiciones
ambientales
Operating temperature
1
-20°C~+45°C
Transportation / storage temperature -40°C~+70°C
Relative humidity 5%RH~95%RH (with condensation)
Atmospheric pressure 80KPa~110KPa
Overvoltage category II
Altitude 2000 m
Impact resistante
The impact resistance is 20J (5Kg, 0.4m). After the impact
the performance must not be affected. Make sure that the
IP class has not been affected, check the door fixing point
are not damaged and the internal components are not in
contact with any parts.
Mechanical
parameters
Dimensions (W × H ×D) 700 x 1750 x 760（mm）
Weight (kg) 210Kg (without power module), power module weight
11kg each.
Note 1: The DC charger provides full output power up to 45ºC, output power decrease 5% above 45ºC.
The protection level of the DC chergar is IP65. But for charging safety it should not be used during rain or snow if water can
reach the charger connector.
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EXP120K1-HT 120KW DC Charger
1.4 Performance indicators
Indicators Description Observations
Input number of phases Three-phase and four-line + PE
Input voltage range 400 VAC (+/-10%)
Input frequency 50 Hz/ 60Hz
Max input power 120KW + 20kW
Max input current 233A
System efficiency Total charge ≥94%
Power factor ≥0.99
Harmonic current ≤3% (under certain operating conditions)
Output current accuracy ≤±0.5%
Output current accuracy ≤±0.5%
Ripple coefficient ≤±0.2%
Current sharing ≤±3%
Ground detection ≤30mA
Noise ≤65dB (nominal input / output power, environment temperature
25°C.)
Minimum ingress protection IP 65
Operating mode Vertical operation
Maintenance access Front maintenance access for system and right-side
maintenance access for power modules.
RoHS The system meets R5 requirements in the RoHS directive
Hot plug
The system power modules are quick-connect and do not
need to restart the entire system, however the DC output must
be turned off during the entire power module exchange. After
disconnecting a power module, a break os at least 10 seconds
must be given before reconnecting it. Care should be taken
when replacing the module, inserting it slowly to avoid
mechanical damage to the pins that make the module contact
to the rest of the equipment.
AC output power 22KW
AC output voltage 400 VAC (+/- 10%)
AC output current 32A
AC connection – 1 piece Mode-3 type 2
DC output power 120KW
DC output default voltage 600Vdc (when REG75030G power module is use )
500Vdc (when REG50040G power module is use )
DC output voltage range
150Vdc~750Vdc, tolerance ± 1Vdc (when REG75030G power
module is use)
150Vdc~550Vdc, tolerance ± 1Vdc (when REG50040G power
module is use)
DC output current
Maximum load current ≤200A (when REG75030G power
module is use)
Maximum load current ≤200A (when REG50040G power
module is use)
DC connection – 2 units 2 x CCS COMBO 2 or 1 x CCS COMBO 2 + 1 x CHAdeMO
DC distribution voltage drop ≤500mV (a 25°C ambient temperature)
General IEC 61851-1-2017
IEC 62196-1-2012
Security (LV) IEC 60950-1
EMC IEC 61851-21-2
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Power distribution unit
Standards System indicators

EXP120K1-HT 120KW DC Charger
1.5 Main features
- Optional configuration, as two DC CCS combo 2 or CCS combo 2 + CHAdeMO and one AC.
- Compatible with 15KW~120KW/500V and 750V output.
℃ ℃ - IP65 for use in multiple environments, -30 ~45 ambient temperature for full power charging.
- Complete safety function with fuse and output contactor, EPO, SPD, leakage switch, isolation detector and
multiple protection software.
- Optional AC connector RCD-B standard.
- 7 inch display with simple interface.
- Various ways of cherging: automatic charge, time charge, fee charge, charge rate, power charge and %
charge.
- Internal high precision DC energy meter.
- LAN and inner LTE wireless comm support, RFID authorization and Mobile App payment support.
1.6 Aplications
- EV Bus park station
- Retail and commercial parking spaces
- Hightway rest areas
- Service stations
- Workplaces
- Residence
1.7 Output voltage and current curve ( for one power module )
REG75030G REG75030G
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EXP120K1-HT 120KW DC Charger
Cap. 2 - Instalation
2.1 Safety rules
As the working voltage and current inside the system is very high, the following rules must be taken into account
to ensure your personal safety:
1 – Only qualified tchnicians who have EV charging training can install the system. During the installation always
observe the safety precautions mentioned in this document and all National Safety Standards.
2 – Make sure that the DC output of the charging system is switched off for operation inside the charger system.
The main input of the charging system must be also be off.
2.2 Installation preparation
• Unpack the equipment for inspection.
When the equipment arrives at the installation site, the packaging should be opened for inspection. During the
inspection open the packaging and with the list of items, check one by one to make sure the equipment is complete.
Then check the equipment serial number, packaging, quantity, acessory types to sure they are compliance.
• Cable preparation.
Cable selection must be in accordance with national regulations. We recommend using RVVZ type cables as AC
cables with the rated voltage of 550 / 750 Vac or higher and a minimum temperature of 70ºC. Technicians / users
determine a sectional area of the charger input and output cables according to table 2-1
Table 2-1 Cable section selection of charging integrated cabinet
Connector name
Allowable
maximum
current
Minimim
sectional
area
Maximum voltage
drop leght <0.5V with
minimum sectional
area
Maximum
sectional area
Maximum leght <0.5V
voltage drop and
maximum sectional
area
Carregador
armário DC com
entrada AC
233A 70mm
2
5m 95mm
2
10m
Note: When the wiring distance is less than 30 meters, it is recommended to estimate the sectional area of the
used line according to a current density of 2,5A / mm
2
.
The ground cable cross-section should be consistent with the most power distribution cables, but not less than
35mm
2
. The screw on the ground bus is the M8.
Note: It is not usual to use a separate ground wire. Normally 5W standard cables (3Ph + N + PE) are used as
show in picture 2.3. the diagram on page 25 should be updated to be in line with the arrangement of the AC input
terminal.
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EXP120K1-HT 120KW DC Charger
2.3 Power cables connection
∅ Note: Before the electrical connection, all switches and fuses mus be off.
Input AC cable requirements
1. The AC cable is selected in accordance with national regulations based on DC charger output power ( 120KW )
and AC output ( 22KW ), ate the place of installation should have overload protection on the AC distribution cable.
The local AC distribution should be prepared for overload, short circuit, and lightning strike. The rating of the
overcurrent protection device shall not be less than 1.5 to 2 times the actual input power rating of the DC charger.
The use of damaged cables is not allowed.
Step by step connections:
1 – Grid AC input connection wiring ( L1, L2, L3, N, PE) to main breaker.
2 – check all switch in the system are off status ( System main breaker, AC output breaker, aux power input
braker)
3 – Plug in the power modules as needes. If have empty slots, must use panel to cover them.
4 – With the cables connected you should check the voltage and the cable connections are well made,
especiallu the N and PE cables, otherwise it will cause serious damage to the device and the operator.
5 – Turn on the input circuit breaker.
6 – Check all controllers and meters, LCD / LED. Everyone should be working.
7 – Turn on the AC output breaker to activate the AC gun.
8 – Turn on the main breaker to activate the power input on the power modules.
9 – Check the system information on the LCD panel and if there are no alarms on the LED panel.
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EXP120K1-HT 120KW DC Charger
2.4 Power module installation
The power module and the charger are shipped separately to prevent damage during shipment.
After installing the charger it is necessary to install the power module in the slot inside the charger. To install the
power module you do not need to turn off the AC input. The connectors on the back of the module are sensitive to
chocks, must be carefull on the installation and to avoid sudden shocks and/or movements when placing or removing
them.
After removing a module you should wait, 10 seconds minimum. before you can perform this operation. Since the
system is built for configurable output power, inside have 8 power modules slots, the modules are placed as shown in the
figure below.
Note: If the system is configured for less than 8 modules, then the empty slots must be covered with the sealing
plate, for the thermal system to work well and maintain internal cooling of the charger system.
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EXP120K1-HT 120KW DC Charger
2.5 Configure power module
For the dual gun system, the power modules need to be divided into two groups, Group A and Group B,
corresponding to DC-1 Gun A and DC-2 Gun B, respectively. This is required for module grouping when the two guns
operate simultaneously. Once the configurations are complete, the module can function perfectly in the correct power
distribution even if only one gun is used.
For modules installed in group DC-1/A, it is necessary to change the setting to 1 on the module panel, for
modules placed in group DC-2/B, it is necessary to change the setting to 2 on the module panel, show in figure below.
Group DC-1 / A Group DC-2 / B
The DC-1 Group and DC-2 Group modules should not be badly grouped otherwise, and even though the
equipment is charging normally, the output current will be out of control, resulting in abnormal charging.
•4G Wireless router/modem installation
The system is equipped with technology that supports 3G/4G wireless communication. Customers can connect
their local SIM card and 3G/4G network card to the controller to use this function.
3G/4G wireless communications require configuration according to your local network operator.
To configure the upper controller detailed information is required.
2.6 Power ON process
1 - Grill AC with L1/L2/L3/N/PE wiring.
Attention: Must check the wiring and voltage are all ok.
2 – Power module panel address setting.
Attention: Must configure correctly according to module groups.
3 – Insert the modules in the slots.
Attention: For the slot without module shall be covered with sealing plate.
4 – Turn on the main circuit breaker.
5 – Turn on the auxiliary circuit breaker.
Attention: If everything is OK the whole system will turn on.
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EXP120K1-HT 120KW DC Charger
Chapter. 3 - Operating
The DC charger is operated throught touch panel LCD. The charger can be started with the RFID card, for which
you will need to enter the QR Code ( requires operating platform and Ethernet support ) or use the OTP manually
3.1 LCD screen and user interface
On the screen select the pistol you want to use by clicking the corresponding “READY” button.
Note: If we configure the display interface, parameter set / Charger system / local authorization enabled and activate,
afterclicking on the “READY” button, we start the loading process directly.
Then swipe the RFID card or scan the QR Code or use the OTP by entering the password to start the upload.
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EXP120K1-HT 120KW DC Charger
Interface to scan ODT password:
In the following interface the user can choose one of the following load modes, by time / by % / by amount / by kWh or
automatic:
According to your choise, then in the next interface you will have to enter the desired values. In automatic mode the
parameters are according to EV loading requirements.
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EXP120K1-HT 120KW DC Charger
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EXP120K1-HT 120KW DC Charger
After entering the desired value press the OK button to validate and go to the next menu.
The LCD will show the current status between DC charger and EV car. If all parameters entered are correct,
loading will start. At any time the user can cancel the operation by selecting the “CANCEL” button.
The LCD shows all information of its active charging.
You need to wait for charging, when you reach the end you will need to re-pass the RFID cardo or click “CANCEL”
to interrupt the charging process. If you are in OTP mode you must re-enter the password.
After charging is complete, the following menu display a service report ( energy and quantity used, charging time
and final % ). then click on the “BACK” button to return to the loading gun's initial interface of choice.
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EXP120K1-HT 120KW DC Charger
3.2 Select system language.
Click on the icon <EN> in the main interface to enter the language setting menu.
Click on the icon < ! > to enter information menu, we can get system information, active alarms and billing
records.
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EXP120K1-HT 120KW DC Charger
Clicking in < MORE > will give you access to detailed and technical information about the interface. For this you
need to enter the password to this menu. This information is for service technicians to have access, the user does not
need this eccess.
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EXP120K1-HT 120KW DC Charger
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