GreenFlux T2235-02 User manual

GREENFLUX DUAL SOCKET SMART CHARGING CONTROLLER
INSTALLATION MANUAL
(P/N: T2235-02)
2019-11-05; version 4.6

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Installation Manual; version 4.6; 2019-11-05 Doc.nr. GFX.2017.14201807
The award-winning GreenFlux Smart Charging Controller
turns every charge point into a connected device.
www.greenflux.com
GreenFlux
Assets B.V.
Mauritskade 64
1092AD Amsterdam
The Netherlands
Email: [e-mail]
Web: www.greenflux.com
Tel: [phone]
© 2017 GreenFlux Assets
BV

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Installation Manual; version 4.6; 2019-11-05 Doc.nr. GFX.2017.14201807
CONTENT
Content................................................................................................................... 3
1INTRODUCTION.............................................................................................. 5
2THE SMART CHARGING CONTROLLER CONNECTIONS................................... 6
2.1 GENERAL ............................................................................................... 6
2.2 IDENTIFICATION .................................................................................... 6
2.3 POWER SUPPLY AND RS485.................................................................. 6
2.3.1 POWER.............................................................................................. 7
2.3.2 RS485 ................................................................................................ 7
2.4 INTERNET CONNECTIVITY...................................................................... 8
2.4.1 LAN.................................................................................................... 8
2.4.2 GPRS.................................................................................................. 9
2.4.3 INTERNET (COMBINATION)............................................................... 9
2.5 CHARGING RELAYS .............................................................................. 10
2.6 RFID READER ....................................................................................... 11
2.7 SOCKET CONTROL ............................................................................... 12
2.7.1 SOCKET 1......................................................................................... 12
2.7.2 SOCKET 2......................................................................................... 14
2.7.3 SUPPORTED SERVO LOCK ACTUATORS........................................... 15
2.7.4 SUPPORTED KWH-METERS ............................................................. 16
3ZE/EV READY ................................................................................................ 19
4SERVICE AND SAFETY STATEMENT...............................................................19
4.1 SERVICE................................................................................................19
4.2 SAFETY .................................................................................................19
5LOCAL MANAGEMENT..................................................................................20
5.1 GENERAL..............................................................................................20
5.2 SERVICE DEVICE (LAPTOP) SET UP .......................................................20
5.2.1 IP/SUBNET MASK SETTINGS ON SERVICE DEVICE (WINDOWS) ......20
5.2.2 FIREWALL SETTINGS (“PING” SUPPORT) .........................................22
5.3 USING THE LOCAL MANAGEMENT WEBSITE.......................................23
5.3.1 CONNECTING...................................................................................23
5.3.2 LOGIN ..............................................................................................23
5.3.3 PASSWORD......................................................................................24
5.3.4 HOME PAGE ....................................................................................24
5.3.5 CONFIGURATION PAGE ...................................................................24
5.3.6 LIVE DATA PAGE ..............................................................................25
5.3.7 LOGGING PAGE ...............................................................................26
5.3.8 ADVANCED PAGE ............................................................................27
6INSTALLATION OF THE SMART CHARGING CONTROLLER ............................28
6.1 INSTALLATION PREREQUISITES............................................................28
6.2 INSTALLATION DESCRIPTION SMART CHARGING CONTROLLER..........28
6.3 INSTALLATION ROADMAP ...................................................................29

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6.4 LED INDICATIONS DURING OPERATION.............................................. 29
7SPECIFICATIONS OF THE SMART CHARGING CONTROLLER ......................... 30
7.1 TECHNICAL SPECIFICATIONS ............................................................... 30
7.2 PHYSICAL CHARACTERISTICS ............................................................... 31
7.3 CONNECTOR LAYOUT AND WIRING SPECIFICATION........................... 31
7.3.1 SOCKET CONTROL ........................................................................... 31
7.3.2 RELAY CONTROL.............................................................................. 32
7.3.3 CARD READERS ............................................................................... 32
7.3.4 ADAPTER / RS485............................................................................ 32
7.3.5 INTERNET ........................................................................................ 33
8CONNECTION DIAGRAM .............................................................................. 34

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Installation Manual; version 4.6; 2019-11-05 Doc.nr. GFX.2017.14201807
1INTRODUCTION
This manual describes how to install the Smart Charging Controller in a safe and
correct way. By following the instructions in this manual, the controller can be
installed correctly in the charging station.
The functionality described in this document is made available by the current
latest firmware, version v4.3.2.
The controller serves as central processor and controller for managing and
controlling the charging station hardware. Using the controller, the charging
station can connect to any charging station management platform via OCPP. It is
also possible to use the controller in offline mode. This manual does not describe
the configurations needed for the controller to function, for this we refer to the
GreenFlux Smart Charging Controller Configuration Manual. Configuration
changes can be executed either via OCPP by the charging station management
platform or locally using the local management website tool provided with the
controller (described in Section 5).
To give certain aspects more emphasis, the following two pictograms will be used
in this document:
Warning! This text is important for the (personal) safety and/or the
correct functioning of the system (charging station).
Informative. This text adds extra information to a certain subject.
In case of any questions not covered by this manual, please contact GreenFlux via
[email protected].

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Installation Manual; version 4.6; 2019-11-05 Doc.nr. GFX.2017.14201807
2THE SMART CHARGING CONTROLLER CONNECTIONS
The Smart Charging Controller can be connected to several components inside the
charging station (refer to section 7.3 and section 8 for a schematic overview). To
connect the controller with the different components, there are several
connectors available. Depending on the desired configuration and the possibilities,
all/some of the connectors must be connected. This section describes the different
connectors and their functions. Besides this description, also an electrical wiring
reference is available (CCU wiring reference schematics). This reference offers
additional technical information necessary to install the smart charging controller
in the charging station with minimum configuration and maximum safety.
2.1 GENERAL
Please refer to section 8 for the recommended connection diagram. Use this
diagram for connecting the controller to your charging station hardware. Section
7.3 gives also information about the advised cable type to use for each connection.
2.2 IDENTIFICATION
At the bottom side of the housing the identification / product info label can be
found. On this label, standard product and type information is given.
Serial number and ethernet MAC address are also available with a QRC, enabling
automatic registration of the unit as part of an operational process of a charging
station operator.
Figure 1 Product label
2.3 POWER SUPPLY AND RS485
For these connections, a standard Phoenix connector is used.
Type MC 1,5/4-ST-3,5
(PHOENIX CONTACT 1840382)
Figure 2 Standard screw Phoenix plug small

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2.3.1 POWER
PIN
CONNECTION
+
The +12V connection of the external power supply
-
The Gnd (0V) connection of the external power supply
The controller must be connected to a stabilized 12V adapter
(class III). The nominal power consumption of the controller is
2.75W, but peak power (steering of the servo locks) demands a
12V/2A power source. In the situation that a charging station
with tethered cables is used (so no servo locks), the maximum
power of the adaptor may be lower, depending on the power
consumption of the other components powered by the
controller.
The controller cannot be connected directly to 230V.
Make sure the power “- “connection is always connected to the
Power Earth (PE) of the charging station itself. Failing to do this
may result in damaging the controller!
When choosing the adapter, keep in mind that this adapter also
needs to be able to power the charge connector switch relays
and the connected LED signaling (for a longer period).
2.3.2 RS485
Functionalities for the external RS485 connection will become available in a future
firmware release.
When using the external RS485 port to connect with a device
outside the charging station, the cable must be shielded. The
shield must be connected to the GND (-) pin of the controller.
Where appropriate, the cable ends may need termination by
connecting 120 Ωresistors across N (-) and P (+) connections.
Figure 4 The RS485 connection
Figure 3 The 12V power connection

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2.4 INTERNET CONNECTIVITY
The smart charging controller needs an internet connection to setup an OCPP
connection to a charging station management platform. Depending on the
location of the charging station, it could be preferable to use either a LAN ethernet
connection or a GPRS wireless connection. To establish a connection to a charging
station management platform, several configuration parameters need to be set
correctly. This can be achieved using OCPP or the Local Management tooling
(Section 5). It is also possible to use the smart charging controller in offline mode,
when only limited functionality is required. Further details can also be found in the
GreenFlux Smart Charging Controller Configuration Manual.
For connecting the LAN, mobile antenna and SIM card, following connectors / slots
are available:
Figure 5 The LAN port, GPRS antenna and SIM card holder
2.4.1 LAN
PIN
CONNECTION
LAN
RJ45 Ethernet cable to router
The RJ45 cable needs to be connected to an external
network. When using an ethernet cable for an outdoor
charging station, the cable must be a shielded version
(CAT6). The shielding of the cable must be connected to the
cable connector ground signal (or connector housing).
When connecting the controller to a LAN environment (e.g. a
company network) the network connection needs to be
secured, both physically and by its network configuration thus
assuring there is no unwanted/undesired intervention with
the charging station and/or your LAN network.
It is advisable to always use a mobile connection as backup
(antenna and SIM card installed) in addition to the LAN
connection for robustness.
The LAN network requirements are:
•Allow incoming/outgoing traffic on port 80 (UDP/TCP).
•Have a DHCP server active (to receive an IP address and DNS
information).
•Should not be placed behind a so-called proxy server.

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If these conditions are not met, no Backoffice connection can
be established using the LAN connection.
2.4.2 GPRS
PIN
CONNECTION
GPRS
On this SMA connector a GPRS antenna can be connected
SIM
A micro SIM card can be inserted with the chip point upwards.
Depending on the telecom operator, the area the charging
station is installed and the frequency bands that are used, the
charging station manufacturer needs to select an appropriate
antenna. In selecting an antenna, local requirements regarding
Telecom/FCC/CCC/… must be followed.
Inserting a SIM card is possible with the case closed. To remove
a SIM card, the case needs to be opened. The SIM can then be
removed carefully, by sliding it out of the socket.
Using GPRS is only necessary when there is no LAN connection
available. A GPRS connection is however always recommended
as a backup connection.
Instead of the standard SMA antenna an external antenna (outside the charge
point) can be used, this in case of pore receiving circumstances.
Figure 6 Example of an external GPRS antenna
2.4.3 INTERNET (COMBINATION)
A combination of both network connections (LAN and GPRS) is also possible and
adds robustness for connectivity. Depending on the used internet connections, the
correct configuration also needs to be activated in the cloud platform. More
information on how to do this can be found in the GreenFlux Smart Charging
Controller Configuration Manual.
When both connections are activated, the secondary connection
(the configuration parameters specify which connection is the
primary/secondary) will automatically function as a fallback
connection.

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Installation Manual; version 4.6; 2019-11-05 Doc.nr. GFX.2017.14201807
2.5 CHARGING RELAYS
For this connection, a standard screw/plug Phoenix connector is needed.
Type MSTBT 2,5/4-ST
(PHOENIX CONTACT 1754481)
Figure 7 Standard screw/plug Phoenix plug big
Figure 8 Charging current relay connections
PIN
CONNECTION
(1)
Controls the AC Main contactor relay. for socket 1. The right pin
(of relay control 1) will go to the positive connection of the 12V
adapter. The left pin (of relay control 1) will go the A1
connection of the relay for socket 1 and carries the control
signal. Activating this relay will enable energy delivery to the
connected EV.
(2)
Controls the AC Main contactor relay. for socket 2. The right pin
(of relay control 2) will go to the positive connection of the 12V
adapter. The left pin (of relay control 2) will go the A1
connection of the relay for socket 2 and carries the control
signal. Activating this relay will enable energy delivery to the
connected EV.
The controller must only control relays with a 12-24V control
signal (helper relays). Using a directly 230V controlled relay is
not allowed!
Make sure the actual used contactor relays have at least the
switching capacity value of the nominal value as defined for the
charging station. These values should match controller
configuration settings (please refer to the GreenFlux Smart
Charging Controller Configuration Manual).
Please refer to section 8 (Connection diagram) for connecting the
relays in the correct way.
The used power adapter (see Section 2.3.1) for feeding the relays
must be able to deliver the additional necessary steering power
during longer period.