EXP EXP180K2-FD User manual

EXP180K2-FD Fast DC Charger
User Manual
Ver: V1.1
Released time: 2020-12-10
BOM: 201040154
Shenzhen Infypower Co.,Ltd
All rights reserved. This Manual may be subject to change without notice.
www.infypower.com
Service hotline:：[phone]

Important safety instructions
➢Please read the operating instructions and notes carefully before starting operation. In order 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.
➢During the various operations of our products and equipment, it is necessary to comply with
relevant National Safety Regulations and strictly observe the precautions and special safety
instructions of the relevant equipment provided by Infypower .
Electrical Safety
High Voltage
Danger
Since some parts of this power system are under high voltage during operation,
it is fatal for direct contact or indirect contact with these parts, for example through
wet objects.
➢It is necessary to comply with relevant National Safety Regulations during installation of the
Portable DC Charger. Personnel who install and maintain this equipment must be qualified to work
with high DC voltage up to 1000Vdc and 3-phase AC voltage up to 500Vac.
➢It is strictly forbidden to wear watches, bracelets, bangles, rings and other conductive objects on
the wrist during installation and maintenance.
➢If there is water inside the DC Charger enclosure, AC power and DC connector must be
disconnected immediately. During operation in a humid environment, water should be strictly
prevented from entering the equipment.
➢During installation, it is strictly forbidden to operate the DC Charger and an “Operation prohibited”
signboard must be used.
Danger
Construction operation of high voltage lines may cause fire or electric shock.
The wiring area and the area where the line passes through for AC cables must
comply with National regulations and norms. Only personnel who are qualified
to work with high DC and AC voltages are allowed to install and maintain the
DC Charger.
Tools
Warning
Special tools must be used during various operations of high DC and AC
voltages.
Thunderstorm
Danger
It is strictly forbidden to carry out live installation and maintenance work during
thunderstorms.

A strong electromagnetic field will be produced in the atmosphere under the thunderstorm.
Therefore, the equipment should be well grounded to avoid damage to the equipment due to
lightning strikes.
Static Electricity
Caution
Static electricity generated by the human body may damage electrostatic
sensitive components on the circuit boards, such as the large-scale integrated
circuit (IC), etc. Before any handling of patch boards, circuit boards and IC
chips, it is necessary to wear an anti-static wrist strap with the anti-static wrist
strap wire connected to Ground to avoid damage to sensitive components due
to static electricity generated by the human body.
Short circuit
Danger
During operation, it is strictly forbidden to short-circuit the positive and negative
of the DC Charger DC distribution or short-circuit any DC distribution polarity to
Ground. The DC Charger is a high voltage DC power supply, and short circuit
may cause damage to the DC Charger and personal safety hazards.
➢During 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 compact and attention should be paid to planning
cable routing etc. before starting any installation work.
➢Insulated tools must be used.
➢During live work, attention should be paid to keeping hands, arms tools etc. away from live
high voltage parts to avoid accidents.
Others
Sharp Corners of Objects
Warning
During the handling of equipment by hand, it is necessary to wear protective
gloves to prevent injuries caused by sharp objects.
Power Cable
Caution
Make sure that the cable label is correct before the connection of cables.
Signal Cables
Caution
Signal cables should be kept away from power cables, with a minimum
distance of 100mm.
EV Charging Plug
Caution
Which adaptors or conversion adapters are not allowed to be used.
That cord extension sets are not allowed to be used.

TABLE OF CONTENTS
1 GENERAL PRODUCT DESCRIPTION ......................................................................................................................... 2
2 GENERAL CHARACTERISTIC ..................................................................................................................................... 3
2.1Technical characteristics ...........................................................................................................................................................3
2.2 Model description.....................................................................................................................................................................3
2.3 Standards ..................................................................................................................................................................................4
3 PRODUCT PARTS PRESENTATION ........................................................................................................................... 5
4INSTALLATION .......................................................................................................................................................... 6
4.1 Safety and compliance..............................................................................................................................................................6
4.2 Grounding instructions .............................................................................................................................................................6
4.3 Unpacking and visual inspection ..............................................................................................................................................6
4.4 Assembly/placing instructions..................................................................................................................................................6
4.4.1 Preparation of concrete foundation ..............................................................................................................................7
4.4.2 Cabinet Installation ......................................................................................................................................................8
4.4.3 Power cables connections.............................................................................................................................................9
4.4.4 Power Module Installation .........................................................................................................................................11
5 START-UP................................................................................................................................................................... 12
5.1 Verification and inspection.....................................................................................................................................................12
5.2 Switch on.............................................................................................................................................................................12
6 USER MANUAL........................................................................................................................................................... 13
6.1 Output connector ....................................................................................................................................................................13
6.2 Operation instructions ...............................................................................................................................错误!未定义书签。
6.3 Ethernet and OCCP setting........................................................................................................................错误!未定义书签。
6.4 LTE setting................................................................................................................................................错误!未定义书签。
6.5 Charger software update............................................................................................................................错误!未定义书签。
Appendix 1 Engineering and Technical Parameters ......................................................................................................... 13
Appendix 2 Schematic Diagram ........................................................................................................................................ 29
Appendix 3 Error codes and possible solutions................................................................................................................. 30

1 GENERAL PRODUCT DESCRIPTION
➢The EXP180K2-FD is able to fast charge all electric vehicles compliant with combined charging
system (CCS) standard.
➢IP55 for severe environment using，-30℃~45℃ ambient temperature full power charging.
➢Depending on the battery capacity, EXP180K2-HD can charge properly equipped electric
vehicles from 0% to 80% in roughly 30 minutes, output power up to 180kW，output voltage
from 150V to 1000V, constant power from 300V to 1000V.
➢The battery charging state is displayed on the HMI and the charging cycle finishes by itself or
can be interrupted by user command.
➢EXP180K2-HD is user friendly and safe. After user identification, it only requires coupling the
charger’s output plug in the EV for automatic starting if all safety features are accomplished.
➢Full safety function with output contactor and fuse，ESD，SPD，leakage switch，insulation
detector，software logic for multiple protection.
➢LTE wireless modem support, RFID authorization and Mobile App payment support

2 GENERAL CHARACTERISTIC
2.1Technical characteristics
EXP180K2-HD technical characteristics are indicated in the Table 1.
This system has two DC output connection (CCS2).
Table 1 Technical Characteristics
Technical Data
Description
Remarks
Nominal Input
Phases/Lines
3 phases + neutral + PE
Voltage
380/400 Vac (+/-10%)
Frequency
50 Hz/ 60Hz
Current
Max 288A
Power
180kW
Power factor
≥0.99
System Efficiency
≥ 94.5% (Full load and rated input and output)
DC Output
CCS2
Voltage
150~1000Vdc
Current
200A (limited by the gun capacity)
Nominal Power
180kW
Cabinet
Dimensions(W*D*H)
700*750*1750（mm）
Weight
290 kg (excluding power module, power module is 21kg/pcs)
Protection Degree
IP55，IK10
HMI and
Command Unit
Local interface
TFT Color touch display 7”
Communication
Router 3G/4G (GSM, CDMA or LTE)
Protocol
OCPP1.6 J specification
Environment
conditions
Operating temperature 1
-25°C~+50°C
Transportation/storage
temperature
-40°C~+70°C
humidity
5%RH~95%RH
Place of installation
Outdoor 2
Altitude
2000m
Sound Noise
≤65dB (nominal input/output power, the environment
temperature is 25°C.)
Atmospheric pressure
80KPa~110KPa
Overvoltage category
II
Protection class
Class I
Note 1: The DC Charger provides full output power up to 45°C, output power derating 5% / °C above 45°C.
Note 2: The protection level of the DC Charger is IP55. But for charging safety it should not be used during rain or snow if water
can reach the charger connector.
Specifications are subject to change, without prior notice.
2.2 Model description
Model
Configuration
Remarks
EXP180K2-FD-EU
CCS-2 + CCS-2
180KW

2.3 Standards
The EXP180K2 DC Charger complies with the following standards:
Table 2 –EXP180K2 Applicable Standards
Technical Data
CE
Remarks
Applicable
Standards
IEC 61851-11
IEC 61851-232
IEC 61851-243
EN 61851-14
EN 61851-235
EN 61851-246
1 IEC 61851-1 2017: Electric vehicle conductive charging system. Part 1: General Requirements
2 IEC 61851-23 2014: Electric vehicle conductive charging system - Part 23: DC electric vehicle
charging station
3 IEC 61851-24 2014: Electric vehicle conductive charging system - Part 24: Digital communication
between a DC EV charging station and an electric vehicle for control of DC
charging
4 EN 61851-1 2019: Electric vehicle conductive charging system. Part 1: General Requirements
5 EN 61851-23 2014: Electric vehicle conductive charging system - Part 23: DC electric vehicle
charging station
6 EN 61851-24 2014: Electric vehicle conductive charging system - Part 24: Digital communication
between a DC EV charging station and an electric vehicle for control of DC
charging

3 PRODUCT PARTS PRESENTATION
The charging system is composed of DC charging cabinet and DC charging connector. The
System can be installed outdoors (But for safety reasons, it should not be used during rain or snow if
water can reach the charger DC connector).
The EXP180K2 series fast DC Charger has various possible output combinations as showed
below:

4 INSTALLATION
4.1 Safety and compliance
Since the working voltage inside the charging system is very high and the current is very large, the
following rules should always be observed to ensure personal safety:
➢Only personnel who have received the training of the charging system and fully mastered the
knowledge of the charging system can install the charging system. During installation, always
observe the safety precautions mentioned in this document and all relevant National Safety
Regulations.
➢It is necessary to make sure that the charging system DC output is disconnected in the case of
operation inside the charging system. The mains input of the charging system must also be
disconnected.
4.2 Grounding instructions
An equipment grounding conductor or a grounded, metal, and permanent wiring system is required
for the EXP180K2 charger connection. This should be run with circuit conductors and connected to
the equipment grounding bar or lead on the EXP180K2 charger.
4.3 Unpacking and visual inspection
➢Check if the exterior packaging has been damaged by mechanical impacts or any accidents
during transportation
➢If applicable, check if the exterior panels of the EXP180K2 are in perfect condition
➢Check if the interior of the Quick Charger Station is clean
➢Check if the door of the Quick Charger Station is working properly
➢Check for proper Quick Charger Station protective ground connection point, which should be
interconnected with the low voltage switchboard ground connection during the installation
4.4 Assembly/placing instructions
➢As shown in the figure below, the concrete foundation should be made, and the height of the
base should not be less than 200 mm.
➢It is recommended to reserve a Φ 90 plastic pipe at the cable entrance, and the height of the pipe
extending out of the foundation horizontal plane shall not be more than 80mm.
➢As shown in the figure below, mark the installation holes of four M12 expansion bolts on the
concrete foundation.
➢Open 4 holes on the concrete foundation, select the percussion bit of Ф 16mm type, and use the
percussion drill to drill the holes perpendicular to the ground at the above marked hole position,
with the drilling depth of 60mm ~ 80mm.
➢Use four M12 × 60 expansion bolts equipped with attached accessories, slightly tighten the bolts,
vertically put them into the hole, and knock them with a rubber hammer until all the expansion
pipes enter the installation hole.
➢Screw off the bolt, spring pad and flat pad in turn counterclockwise.

4.4.1 Preparation of concrete foundation
EXP180K2 concrete foundation view

4.4.2 Cabinet Installation
➢As shown in the figure below, the protective covers on both sides of the steel base of the cabinet
can be removed, and the cabinet can be transported to the concrete foundation by forklift.
➢Align the installation hole of the cabinet base and fix the cabinet on the concrete foundation with
expansion bolts.
EXP180K2 cabinet installation View
EXP180K2 Top View

4.4.3 Power cables connections
End terminals for input wiring: 5(five) end terminals up to 3phases+neutral+protective ground.
Table4-AC input wiring cables choose
NO.
The section for
AC feed cables
Amperage
at 380Vac
Max. Power
of charger
Specification of
terminal screw
Reserved length
inside cabinet
1
3*150+2*95mm2
288A
180kW
L1/L2/L3/N is M10
PE is M8
0.5m
Notes:
➢The AC feed power cables to the charger are not included.
➢The AC feed power cables should be no less than 90℃ temperature resistant grade.
➢The protective MCCB must be installed on the customer's distribution cabinet, and the upper
MCCB capacity shall not be less than 1.25 times of the input current.
➢It is recommended that the upper MCCB should not be equipped with RCD function.
➢This system is to be connected to a grounded, metal, permanent wiring system; or an equipment-
grounding conductor is to be run with circuit conductors and connected to equipment-grounding
terminal or lead on battery charger.
Note: Before electrical connection, all switches shall be placed in the disconnection position.
UPPER AC INPUT
EXP180K2

※PE: Earth Bus Bar
※Copper bar: Power main input: L1 L2 L3 N
※Q1: AC Input MCB For Rectifier Module
※Q2: AC Input RCD For Auxiliary Power
※Q3: AC GUN output- power main input MCB
※Q4: AC GUN output- power main input RCD

4.4.4 Power Module Installation
Step-1: Open the front door. Plug the power module(s) into the module slot(s) inside the cabinet, before plug the power
module(s) must be noticed the install position，and locknut tightly.
※Step-2: If pull the module out, It is very heavy, it is best to hold it by hand
※Step-3: power modules address setting, follow the below picture.
Caution
The module is heavy, Please be careful when moving the module
If the system is configured to less180kW output power, then some power
modules will be removed. The empty power module slots must be
covered by blanking plates. Otherwise, the system thermal management
will not function correctly.

5START-UP
5.1 Verification and inspection
➢Check if the bolts of the AC and protective ground cables of the EXP180K2 are correctly tightened
to the specified torque
➢Check the resistance between the EXP180K2 protective ground and the low voltage switchboard
ground connection; the value must be according to local codes.
➢Grid AC with L1/L2/L3/N/PE wiring or DC+/DC-/PE wiring for DC input.
➢Power modules panel address setting is correct.
➢Before switching ON all the fuses and circuit breakers, check the supply voltage between lines:
it must be 380/400V ±10% 50/60Hz.
5.2 Switch on
➢Switch on the circuit breakers in the charging pile, Q1 and Q2 in turn.
Before attempting to install or start up the charger, must ensure that the safety instructions in this manual
have been carefully read and observed by technically competent personnel. Keep this manual with the
charger for future reference.
This charger must not be started or put into use without having been commissioned by a fully
trained and authorized person.
AC Input MCB For Rectifier Module (Q1)
AC Input RCD For Auxiliary Power(Q2)

6 USER MANUAL
The EXP180K2 operation depends on its output connections: CCS. During the charging process,
the Human Machine Interface (HMI), will give instructions and will signal different stages. These
sequences are shown in this chapter.
6.1 Output connector
The EXP180K2 is prepared to charge electric vehicles according to the mentioned charging systems
6.2 Operation instructions
The DC Charger is operated via the LCD/Touch screen on the panel. Charging can be started by RFID Card,
by scanning the QR Code (need operation platform and ethernet support), by use OTP password input or just one key
to charge by setting the charging mode.
6.2.1 LCD display and operating interface
System power on initial display interface, then it jumps to next.
Charging connector selection display interface, need to click the READY button to choose the connector.
Notes: if we do the setting in display interface: the Param Set/Charger System/Local Authorize Enabled, and
disabled it, then after we click the READY button, we will directly start the charging process.
Combo TYPE2
CCS2 Connector Handing

Then swipe the RFID or scan QR Code or use OTP by input the password to start the charging process.
OTP password display interface:

The user can choose BMS/TIME/ENERGY/SOC charging termination methods in the next display interface:
Then input or select the value int the next display interface, the middle icon is auto, that means it will according the
actual EV full charging requirement to finish the charging process.
After enter a relevant value, then push <OK> button go into charging preparing interface.
The LCD will show the current status between the DC Charger and EV Car. After <hand shake>, <PWM>，<Matching>，
<Configure>，<Self-check>，<Pre-charge>, if all steps are ok, and all mutual are ok, charging will start. User can
interrupt the charging process by click the Cancel button.
In the charging display interface, the LCD shows the charging energy, used time, remain time, and the current
charging voltage, charging current, also we can see the true voltage and current requirement from the EV BMS.

The user need waiting for automatic charge termination before the setting value has been reached, or
terminated by swiping the RFID card again. Or click the<CANCEL>button to stop the charging process, if it is OTP
mod, need to input the password again.
After finish, the next display interface will show the charging summary information, energy, used amount, used
time, end SOC, then push<BACK>button to go back to main connector choice display interface.
On the bottom of the Summary Table, there is the charging stop code, ”401”, we can through this code to verify
the basic abnormal charging stop reason.

6.2.2 Information LCD interface
Touch the icon <en>on the menu of the main display interface, we can go to Language selection.
Also we can click <?> to go into the information display interface, we can get the system information, current system
alarm information and charging records.
And we can touch <More> to see more detail charger and charging information.
We need firstly input the password then can get the right to access these high level information.
This information is main for maintenance target, normally don’t open to the normal user.
User Level: Engineer, Password: 151719
User Level: Administrator, Password: 135792068