EXICOM POWER SOLUTIONS Harmony Series User manual

Preface
This document is valid for the harmony series EV Charger.
The pictured devices used in this document are visual examples. The figures and explanations contained in
this document refer to a typical device design.
We recommend always keeping the charging station updated to the most recent software version, as this
contains functional enhancements and product improvement.
Purpose of this Guide
The document de
scribes the user guide for harmony series EV Charger.
INTRODUCTION
User Manual for Harmony Series EV Charger
This document is valid for the harmony series EV Charger.
The pictured devices used in this document are visual examples. The figures and explanations contained in
this document refer to a typical device design.
The devices used by you may differ in their appearance
We recommend always keeping the charging station updated to the most recent software version, as this
contains functional enhancements and product improvement.
scribes the user guide for harmony series EV Charger.
User Manual for Harmony Series EV Charger
The pictured devices used in this document are visual examples. The figures and explanations contained in
The devices used by you may differ in their appearance
We recommend always keeping the charging station updated to the most recent software version, as this

Harmony series EV Charger complies with IEC 61851
charger are certified. The charger complied with all the norms as per the safety standard. For user safety,
all chargin
g stations are equipped with a ground fault detector to reduce the risk of shock. Users are never
exposed to dangerous voltages or currents since connector pins are not energized until the connector is
inserted properly in the EV charging socket and commun
and the charging station. Besides, the connector is sealed to protect the live components from the
weather.
Representation of Safety Instructions
At various points in this document, you may notice notes and
hazards. The symbols used have the following meaning:
Danger
Some components of the charger carry hazardous voltage in operation. Direct or
indirect contact through moist objects with these components will result
Attention
Means that damage to property can occur if the corresponding safety measures are not
taken.
ESD
This symbol reminds you of the possible consequences of touching elect
sensitive components
Ground Protection
SAFETY MEASURES AND INSTRUCTIONS
Harmony series EV Charger complies with IEC 61851
-
1, Safety Standard. All the components used in the
charger are certified. The charger complied with all the norms as per the safety standard. For user safety,
g stations are equipped with a ground fault detector to reduce the risk of shock. Users are never
exposed to dangerous voltages or currents since connector pins are not energized until the connector is
inserted properly in the EV charging socket and commun
ication has been established between the vehicle
and the charging station. Besides, the connector is sealed to protect the live components from the
Representation of Safety Instructions
At various points in this document, you may notice notes and
precautionary warnings regarding possible
hazards. The symbols used have the following meaning:
Some components of the charger carry hazardous voltage in operation. Direct or
indirect contact through moist objects with these components will result
Means that damage to property can occur if the corresponding safety measures are not
This symbol reminds you of the possible consequences of touching elect
sensitive components
SAFETY MEASURES AND INSTRUCTIONS
1, Safety Standard. All the components used in the
charger are certified. The charger complied with all the norms as per the safety standard. For user safety,
g stations are equipped with a ground fault detector to reduce the risk of shock. Users are never
exposed to dangerous voltages or currents since connector pins are not energized until the connector is
ication has been established between the vehicle
and the charging station. Besides, the connector is sealed to protect the live components from the
precautionary warnings regarding possible
Some components of the charger carry hazardous voltage in operation. Direct or
indirect contact through moist objects with these components will result
in fatal injury.
Means that damage to property can occur if the corresponding safety measures are not
This symbol reminds you of the possible consequences of touching elect
rostatically
This symbol reminds you of that the equipment is properly grounded.

Prohibited Areas
Any non-company’s technical personnel or non-company's authorized technical personnel do not open the
cover, otherwise, you will have the risk of electric shock, and lose the warranty qualification.
Safety Precautions
 Make sure that the equipment is well-grounded to avoid electric shock before opening the
equipment.
 Do not modify, add, or alter any part of this product without consulting the backend team.
 Please make sure the input voltage, frequency and other conditions have conformed to equipment
requirements before power on.
 To ensure the service life of the equipment and stable operation, the equipment shall not be used
in volatile gas or flammable environment.
Do’s & Don’ts
 Do not touch any live part in the system while when the system is ON.
 Do not make any changes in the system without consulting the backend team.
 Do not make any false commitment/explanations to the customer for any issue.
 Do understand the problem scenario before troubleshooting the issue.
 Do carry all required tools to site & spares for troubleshooting.
 Do understand the system first before troubleshooting it.

Required Tools
 Multimeter, Clamp meter.
 SD Card, U-Drive.
 USB-RS232 serial tool, USB-UART serial tool.
 LAN Cable, IXXAT CAN Converter, LAPTOP.

While reading this documents you might see few abbreviations as mentioned below,
S. No Abbreviations Full Forms
1 EVSE Electric vehicle supply equipment
2 EVDC Electric vehicle direct current
3 EVAC Electric vehicle alternating current
4 EV Electric Vehicle
5 A Ampere
6 Ah Ampere hour
7 MCB Miniature Circuit Breaker
8 MCCB Molded Case Circuit Breaker
9 Comm. Communication
10 CAN Controlled Area Network
11 SMR Switch Mode rectifier
12 SOC State of health
13 kWh Kilo Watt hour
14 DC Direct Current
ABBREVIATIONS

15 CCS Combined Charging System
16 CHAdeMO Charge de Move
17 Batt. Battery
18 USB Universal Serial Bus
19 VAC Voltage Alternating current
20 VDC Voltage Direct Current

Harmony – Fast charger solution is Exicom’s most innovative design and a true representation of
interoperability. The system has three connectors - CCS, CHAdeMO& AC TYPE 2: 142kW (DC: 120kW
+ AC: 22kW). All three gun’s cab used at the same time for charging three vehicles at the same time.
Technical details are explained below,
Dimensional Information
Below given is the system dimensional information for harmony system,
i) 60, 82, 120 and 142kW
PRODUCT OVERVIEW

ii) 180 kW
iii) 240 kW
System Architecture
Harmony – Fast charger solution is Exicom’s most innovative design and a true representation of
interoperability. The system has three connectors - CCS, CHAdeMO& AC TYPE 2: 142kW (DC: 120kW
+ AC: 22kW).
All guns can be used in Parallel for charging. The charger is equipped with multiple components as
shown below,

1 Housing Cover 7 Key Operated Lock
2 LED Bar 8 LCD Display
3 RFID Reader 9 Emergency Switch
4 Cable Gland 10 Charging Cable
5 Charging Gun Plug 11 SMR’s Cover
6 Ventilation 12 Charging Gun Dummy Socket

Technical Specifications
Parameters 60 kW 82 kW 120 kW 142 kW 142 kW
240
kW
Power Input
Input Voltage 415 VAC, 3 Phase/ L1, L2, L3, N, PE
Input Voltage
Range 320VAC to 520VAC
Input Frequency
Range
45Hz
-
55Hz
THD
< 5 %
Power Factor > 0.98
Power Output
DC Output
Voltage Rating 200 - 750 VDC (1000VDC on Request)
Max. DC Output
Current 125 A per output 200 A per output
DC Power Rating 60KW 120kw 120kw
Max. AC Output
Current - 32A - 32A -
AC Power Rating - 22KW - 22Kw -
Output Plug * * * * *
Number of Plug 1 or 2 3 1 or 2 3 1 or 2
Efficiency ≥95% for 50% ≤ load ≤ 100% at Nominal IP Voltage
Protection and
Safety Safety Parameter
current, Under voltage, Over voltage, Residual current, Surge
protection, Short circuit, Over temperature, Ground fault,
Insulation
Battery Backup 1 hour (optional)

User
Interface and
control Display 7" LCD Touch Screen
Support Language English
Emergency Switch Available (Mushroom red switch)
Charging
operation Cyclic
Charge Option Auto Charge, Mode Selection (Time/Power/SOC)
Visual Indication Presence of supply, State of Charging, Error
User
Authentication RFID/APP/OTP/QR (as per requirement)
Communi
cation
EVSE and EVCC **
EVSE and CMS
(Billing and
Payment
Service) Ethernet (standard); 3G/4G (optional), OCPP v1.6J (Optional)
Operating
Temperature -20°C to 75°C (derating from 55°C)
Environmental
Storage
Temperature -20°C to 80°C
Altitude 5% to 95%
Humidity
(Non-
Condensing)
Upto 2000 meters

Mechanical
IP Rating IP 54
Cooling Forced air cooling
Dimension (H
x W x D) (mm) ~1850x650x513
1850x715
.4x633
1850x715
.4x746.7
Charging Cable
length >4.5 meter (standard)
Interface
7" Touch Screen LCD
Certifications
ARAI *** *** *** Available ***
IEC61851 *** *** *** Available ***
CE *** *** *** Available ***
*The system is available with both configuration i.e. single and dual gun.
**The change in dimensions as per Exicom’s latest design.
***Certfications has been taken for highest rating in the series of Harmony Charger.
Key features
Below mentioned are the key features of this charger,
 Complies with IEC61851 International EV Charger standards.
 Highly modular and compact design.
 Built in 7 inches LCD touch screen & RFID for user interaction
 User-friendly and interactive design for domestic and public applications.
 Easy installation.
 Robust for all weather conditions with IP 54 protection.
 Simultaneous charging of three EV.

Output configurations & Protocols
Same system cabinet is designed to support all types of protocol standards available with maximum
up to three guns. The output configurations are explained below,
Protocol Combinations 60 kW 82 kW 120 kW 142 kW 180 kW 240 kW
CCS 2 + CHAdeMO + Type 2  
CCS 2 + GBT + Type 2


CCS 2 + CHAdeMO  
CCS 2 + GBT   

CCS 2 + CCS 2   

GBT + GBT   

CCS 2  
GB/T  

EVSE to EVCC Communication Protocols
Charging Standards Applicable protocols
CCS 2 PLC in CCS 2 (DIN 70121 & ISO 15118)
GB/T CAN in GB/T 27930
CHAdeMO
CAN in CHAdeMO v 1.2
Rectifier/SMR Module
EV series high efficient rectifier/SMR modules are designed to convert AC mains to regulated DC for
powering electric vehicles. They are high efficiency converters with nearly unity power factor and
draw nearly sinusoidal current from the mains. The output range is from 200V-750V / 1000V DC.
General SMRview,

SMR LED Indications
Indicator Light Normal
State Abnormal State Cause of Abnormality
Operation indicator
Light(Green) ON
OFF Input power not available
Flash Communicating with the system’s controller
Alarm indicator
Light(Yellow) OFF
ON
AC input overvoltage, Internal over-
temperature,Abnormal bus voltage(self-
recoveryif alarm is cleared)
Flash Communication failed with system’s
controller
Fault indicator
Light(Red) OFF
ON
Output overvoltage, Output short circuit,
Internal address conflict and Internal bus
fault
Flash Fan Fault
Efficiency Vs output load graph

Controller Card
The combination of pilot controller and upper controller card is heart of the EV charger and it
controls the system’s overall functionalities. The backend OCPP server communication and user
interface display is controlled by the upper controller whereas the CCS, CHAdeMO, GBT and AC type
2 charging communication is controlled by the pilot controller card.
Basic Pilot control card’s function,
 Electric vehicle communication with ISO/DIN protocol as per CCS 2 standards.
 Electric vehicle communication with GBT protocol as per GBT standards.
 Electric vehicle communication with CHAdeMO protocol as per CHAdeMO standards.
 Electric vehicle communication with AC type 2 protocol as per IEC61851-1 standards.
 SMR/Rectifier communication and control.
 AC/DC output switching control.
Basic Upper control card’s function,
 OCPP server communication.
 User interface display control.
 AC/DC metering control.
 RFID board communication.
MCCB & RCDs
As per the system requirements dedicated MCCB, MCB are RCBO are used for protections of the
system as per safety standards decided by IEC61851 EV Charging standards.
SPD
The EV Chargers are equipped with Class C SPD which provides protection against sudden impulse in
the input supply. It grounds any voltage impulse above its rated capacity.

The Harmony series EV chargers are designed to be installed on the floor. The correct site survey is to
be done before installation the charger at any location. Proper installation is absolutely necessary
and to be conducted as per the below details,
WIRE STRIPPING INSTRUCIONS
Caution:
Copper lusg are to be used at site refer Annexure-I for details.
Use of lugs and cable as per Exicom guidelines else Exicom is not responsible for any
damage.
INSTALLATION INSTRUCTIONS

Site Selection Criteria
The charging station was constructed for the indoor and outdoor area. Accordingly, it is necessary to
ensure the correct set-up requirements and the protection of the device at the installation site. The
following criteria must be taken into account when selecting a location,
 Take into account the local electrical installation regulations, fire prevention measures and
accident prevention regulations as well as emergency routes at this site.
 The charging station may not be installed in potentially explosive atmospheres.
 Install the charging station so that it is not located in the direct flow of passersby and so that no
one can trip over connected charging cables and so that the charging cables do not cover or cross
passing pedestrian and motorized traffic
 Do not install the charging station at locations where it is exposed to ammonia gas.
 Do not install the charging station at locations where falling objects could damage the device
Required Installation Tool
Take into account the local electrical installation regulations, fire prevention measures and accident
prevention regulations as well as emergency routes at this site.
 Phillips head screwdriver. (Refer for ANNEXURE-I for size)
 Mounting tools for cable screw connection. (Refer for ANNEXURE-I for size)
 Cable Crimping tools.
 Multi-meter.
 Clamp-meter.
 Screwdriver set.
 Allen key set.

Input Power & Cable and MCB/MCCB requirements
Sr no Item Specifications
1 AC Supply System 3-Phase, 5 Wire AC system (3Ph+N+E)
2 Nominal Input voltage 3Ø, 415VAC (Range: 320VAC to 520VAC)
3 Input Frequency 50Hz
4 Input Power 70KVA-160KVA (As per the System Capacity)
5 Neutral to earth Voltage <1.0 VAC
Sr no Item Quantity
1 4C Copper high voltage XPLE Armored Power HRFR Cable, length of cable
should not exceed 10m from Power Board to DB (Branded cable to be
used) (Refer Annexure-1 for details)
1
2 1C earth Wire/Strip green/yellow color. Length of cable should not exceed
10m from DB/Earth Strip(Refer Annexure-1 for details)
1
3 Lug For (L1, L2, L3, N) *For distribution end, procure lug as per distribution
specs. (Refer Annexure-1 for details)
6
4 Lug (PE) (Refer Annexure-1 for details) 2
5 Flexible pipe for power wiring routing. Pipe diameter as per cable
maximum size.
1
6 MCCB in distribution box. (Refer Annexure-1 for details)
1
Note: Cable specification as per max distance.

EV Charger Installation details
The Charger is designed to be installed on the floor. The below pictures from figure No. 2-A to figure
No. 2-O will guide for the foundation to be prepared for charger and installations of charger on that
foundation,
(i) 60, 82, 120 and 142 kW
*Foundationsizemayvaryaspersite
requirement orselection.
Fig No. 2-A: Front View Fig No. 2-B: Rear View