Hardy Barth cPP2 User manual

The smart charging pole
cPP2
Installaon and operang manual
Installation and operating manual cPP2 charging pole
Version: 1.0.2
English

Contact Details
Manufacturer: eCharge Hardy Barth GmbH
Leinbergstraße 14
92262 Birgland Schwend
Phone: [phone]
Fax: [phone]
Web: www.echarge.de
Mail: support echarge.de
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Table of contents
Contact Details........................................................................................................2
Important information..........................................................................................4
Safety instructions in this manual..............................................................................................................4
Safety instructions on the device...............................................................................................................5
General safety notices....................................................................................................................................5
Instructions for use / Maintenance...........................................................................................................7
Introduction..............................................................................................................9
Product description.........................................................................................................................................9
Identification of the product variant......................................................................................................11
Scope of delivery............................................................................................................................................12
Available accessories (optional)...............................................................................................................12
Dimensional drawings and dimensions................................................................................................14
charging pole..................................................................................................................................................14
Pedestal.............................................................................................................................................................15
Foundation.......................................................................................................................................................16
Assembly and installation.................................................................................17
Requirements for the assembly site.......................................................................................................17
Socket installation.........................................................................................................................................18
Electrical installation of the charging pole..........................................................................................21
Commissioning and charging.........................................................................24
Safety instructions for operation.............................................................................................................24
Charging process...........................................................................................................................................25
Charge control................................................................................................................................................27
RFID module....................................................................................................................................................28
Operating state.....................................................................................................29
Status LED........................................................................................................................................................29
Malfunctions and solutions........................................................................................................................30
Technical data........................................................................................................31
Standards & Guidelines...............................................................................................................................32
Warranty / Guarantee.........................................................................................33
Notes........................................................................................................................35
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Important information
Safety instructions in this manual
This instruction manual contains important information for installation and putting into
operation of all charging stations of type cPP2. Please make sure to read and follow the
provided safety notices in any circumstances.
In particular, the warnings and safety measures clearly marked in this manual must be
followed. The associated symbols carry the following meanings:
Danger!
Life threatening electrical voltages occur. Actions marked with this symbol MUST
NEVER be performed.
Caution!
Sections marked with this symbol indicate additional hazards that may result in damage
to the device or other consumers. Actions marked with this symbol must be performed
by qualified personnel and with SPECIAL CARE.
Notice!
Sections marked with this symbol indicate important information and particularities
which are necessary for a proper functioning device.
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Safety instructions on the device
Additional safety and operating instructions are attached to and inside the charging
station. These symbols have the following meaning:
Attention!
The cPP2 charging station may only be opened by qualified personnel who are familiar
with the instruction manual (this document).
Attention!
Life-threatening electrical voltages occur inside the housing.
General safety notices
Before using the cPP2 charging station, read these operating instructions carefully and
follow all instructions and warnings.
Installation, commissioning, maintenance and repair of the charging station must only be
carried out by qualified personnel.
The eCharge Hardy Barth GmbH does not assume liability for any damage of property
or physical injuries caused by non compliance of the assembly and manual instructions,
by usage of non authorized replacement parts or accessories or by deploying non
qualified professional staff.
This charging station corresponds to the current state of the art and complies with all
current safety requirements, guidelines and standards. The safety instructions in this
manual are intended to ensure proper installation at the place of use and safe operation.
Non-compliance or failure to comply with the safety information and instructions
in these installation instructions may result in electric shock, fire or serious injury.
Usage of the charging station is only allowed if the installation has been carried out
flawlessly and professional staff has taken it into operation. Malfunctions which threaten
the safety of persons, connected users or the device itself must be removed by qualified
or authorized staff only.
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In case of a substandard installation or a malfunction caused by substandard installation,
please contact first the company that has carried out the installation. If the errors still
cannot be rectified, please contact the technical support of eCharge.
Via Mail [email protected]
Via phone [phone]
Please make sure to store this manual in a safe and always accessible place.
The service case occurs when...
•...the housing has been mechanically damaged
•...the housing cover has been removed or can no longer be closed or locked.
•...adequate protection against splash water and/or foreign bodies no longer seems to be
provided.
•...the charging sockets and/or the external charging cables have been functionally or
visibly damaged.
•...the charging station does not function properly or has been damaged in some other
way.
Also note the following:
•The cPP2 is protected against spray and splash water according to IP 44. However,
it should not be installed in the immediate vicinity of flowing or jet water.
•The cPP2 charging pole must not be installed in an explosive environment (EX area).
•The cPP2 charging pole must not be installed in areas subject to flooding.
•Please note that the cPP2 charging pole must never be mounted directly on
asphalt: for safe and proper mechanical installation, a concrete foundation must be
provided in any case, the specifications of which must comply with the
requirements stated on page 16.
•The charging pole must be mounted on a suitable pedestal: The pedestal is offered
by eCharge in three sizes as optional accessories (see page 12).
•Note that additional overvoltage protection may be required by a connected
vehicle and/or by national regulations.
•Please note that in some countries (other than Germany) and/or due to various
vehicle manufacturers, tripping characteristics of the fault current circuit breaker
(type B) can be required. Please contact your distributor to learn about the
requirements.
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Instructions for use / Maintenance
Observe the following instructions for use or maintenance of your charging station:
•This device must ALWAYS be connected to the protective conductor of the power
supply!
•Ensure that the rated voltage and current of the device comply with the specifications
for your local power grid and that the rated power is not exceeded during charging
operation.
•At all times, observe the locally applicable safety regulations for the country in which
you are operating the charging station.
•To disconnect the charging station completely from the mains, the supply line must
always be interrupted via the upstream circuit breaker(s).
•Never install and operate the charging station in confined spaces. In particular, it must
be ensured that vehicles can be parked at the prescribed distance from the charging
station for charging operation and can be connected to the charging cable without
tension.
•Make sure that the front door of the charging pole is always locked to prevent
unauthorized opening of the housing. Keep the key for opening the door in a place
known only to authorized users.
•NEVER make any modifications to the housing or the internal circuitry of the device:
Violation is a fundamental breach of the warranty fundamentally violates the terms of
the warranty and voids the warranty with immediate effect.
•There are no maintenance parts in the device for the user.
•Have the device repaired and/or installed by qualified personnel only.
ATTENTION!
This cPP2 charging station is intended for connection and operation on
230V / 400V and 50 Hz mains voltage. The supply line must be fed into the
housing via a suitable cable duct or pipe on the underside.
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•Use a dry or slightly damp, well wrung cloth to clean the charging station. Do not use
aggressive cleaning agents, waxes or solvents (such as cleaning gasoline or paint
thinner), as these can cloud the displays or damage the paintwork.
•DO NOT clean the cPP2 charging station with a high pressure washer or similar device
that applies high pressure to the surface of the housing.
•Check the charging sockets of your cPP2 charging station and the optionally available
charging cables at regular intervals for any damage. If the optionally available charging
cables show any damage, please have them replaced immediately: Further charging is
not permitted from this moment on.
DANGER!
If you notice any damage to the housing, the charging sockets or the
associated charging cables after installation, you must take the charging
station out of service immediately. Contact the service department of
eCharge!
•The respective local regulations for the operation of electrical equipment apply at all
times.
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Introduction
Thank you for choosing the cPP2 charging pole from eCharge Hardy Barth GmbH! With
this charging station you invest in an innovative and future proof solution for the public
sector to charge your electric vehicle reliably and intelligently.
The charging stations of the cPP2 series are delivered pre configured for a minimum of
technical and temporal installation effort, with an appropriately prepared installation site.
For a particularly quick and easy installation, eCharge offers you a suitable prefabricated
foundation, which has been specially designed for the installation of the cPP2 and is
available separately. (page 16 ff)
Our charging stations are subject to permanent further development and comply with
the regulations and standards applicable throughout Europe for the charging of electric
vehicles. Please also read the section "Standards & Guidelines" on page 32.
Product description
Your cPP2 charging station allows safe and convenient charging of electric vehicles in
accordance with the IEC 61851 1 standard, Mode 3. Depending on the variant in
question, the cPP2 is always designed for the fastest possible charging of the connected
electric vehicles in terms of circuit design, cable diameter and connections.
Thanks to access control via the Charge Controller, charging operations can be managed
easily and in a controlled manner. The versatile setting parameters thus facilitate, for
example, the charging operation of several vehicles by limiting the respective charging
current.
An integrated MID energy meter provides precise information about the current
charging power at each charging point. The determined data on active and past charging
operations can then be made available in real time on a smartphone, tablet or PC in the
internal network and can be transferred as required.
In combination with a compatible inverter or additional eCB1 MP+, the cPP2 charging
station also allows 100% use of solar power from an existing photovoltaic system for
charging your electric vehicle. Furthermore, in combination with a compatible smart
energy meter, such as our eCB1 MP+, the cPP2 enables dynamic load management, for
example, to avoid peak loads or limit the maximum current when using multiple charging
points simultaneously.
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Via the two status indicators on the top of the housing and the LEDs in the central
control panel for charging registration and release, the user is informed at all times
about the current status of the charging station and the respective charging point.
Should a malfunction occur during operation or registration, the error is displayed via the
upper LEDs.
The cPP2 offers charging sockets type 2 according to IEC 62196 2 as standard. eCharge
offers you charging cables type 2 in various designs and lengths for this purpose.
Optionally, the cPP2 is also available with an additional protective contact socket: For
more information, please contact your sales partner.
In all our products, we place maximum importance on safety for the user. Therefore, in
addition to internal line and residual current circuit breakers, the cPP2 charging station
also offers DC residual current detection, which, in combination with the installation's
protective devices, ensures careful protection against short circuits, electric shocks and
other hazards. Access to the internal switchgear is secured via the swivel handle on the
side, and can only be opened by authorized users with a key.
NOTE!
A cylinder lock is NOT pre installed in the double cylinder swivel handle of
the charging pole ex works. A corresponding 40 or 45 profile half cylinder
must be purchased from a specialist retailer or via eCharge and installed in
the swivel handle according to the specifications of the respective
manufacturer. It is strongly recommended to NEVER operate the cPP2 in public areas
WITHOUT a CYLINDER LOCK installed.
The sturdy housing of the cPP2 is prepared for IP44 protection and can be installed in a
suitable outdoor installation position using a concrete foundation manufactured by the
operator or optionally available from eCharge. Information on our accessories can be
found on page 12.
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Identification of the product variant
The cPP2 series comprises several variants that differ in terms of charging sockets and
charging power and thus serve different application profiles. For identification of the
variant, there is a product type plate on the outside and inside of the housing.
CAUTION: The charging station may only be opened by qualified personnel.
The model designation (cPP2 xTyy..) and the values for the mains connection (voltage,
mains frequency, current) are particularly relevant for identification.
For detailed information on the cPP2 charging stations, please refer to the "Technical
data" section on page 31.
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Figure 1: Nameplate cPP2

Scope of delivery
Your cPP2 charging station is delivered with various components that are necessary for
assembly and proper operation. Therefore, immediately after unpacking, check whether
the following basic components are included:
Components Quantity Description
cPP2 charging pole 1 charging pole, consisting of metal housing
with lockable panel
Installation and operating
manual
1 Manual with information on the charging
station, instructions for mechanical and
electrical assembly and commissioning of the
charging station.
(this document)
Wiring plan 1 Schematic view of the line connections and
wiring of the internal electronics
Testing report 1 Test report of the test launch at the factory
RFID cards 5 eCharge Hardy Barth Mifare RFID cards
Available accessories (optional)
eCharge Hardy Barth GmbH offers following accessories for your cPP2 charging pole.
For more information or information about available accessories and the further delivery
program of eCharge, please visit our website at: www.echarge.de
Figure Description Item No.
Concrete foundation
for secure mounting of the charging pole via four
supplied hexagonal bolts with internal threaded rod
anchors RD12, concrete grade C30/37 (XC4/XF1/WF),
supply line via integrated HT pipe, incl. 2 ring hooks for
transport
L x W x H: 426 x 338 x 800 mm; weight: ca. 300 kg
3M40420
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Figure Description Item No.
Pedestal 200
Metal pedastal, tall version, for mounting the charging
pole on the optionally available concrete foundation
using four screws supplied.
L x W x H: 369 x 237 x 200 mm; weight: ca. 6,5 kg
3M40431
Pedestal 100
Metal pedestal, medium high design, for mounting the
charging pole on the optionally available concrete
foundation using four supplied screws.
L x W x H: 369 x 237 x 200 mm; weight: ca. 6,5 kg
3M40434
Pedestal 40
Metal pedestal, flat version, for mounting the charging
pole on the optionally available concrete foundation
using four supplied screws.
L x W x H: 369 x 173 x 40 mm, weight: ca. 2,5 kg
3M40430
Charging cable IEC Type 2
for connection to all charging stations and vehicles with
charging socket according to IEC 62196 Type 2, 240 / 415
V AC, 16 A or 32 A
Spiral and smooth cable in various lengths
Splash proof IP44
3M4050X
eCB1 MP+
Smart energy meter, for example for PV excess charging
or for limiting the maximum current in the house
connection.
3M40405
Dry granulate
For dehumidifying the interior of the charging station.
Minimizes the chance of undesirable effects due to
condensation and seepage water penetration.
(Recommended)
3M40460
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Dimensional drawings and dimensions
The cPP2 charging pole is delivered fully assembled and tested. All dimensions as well as
the mounting points are shown in the following dimensional drawings.
charging pole
Front and side view of the cPP2 series incl. pedestal
(all dimensions in mm, pedestal not included in delivery)
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Pedestal
For mounting the charging pole, eCharge offers three optionally available pedestals:
Pedestal height: Item number: Application area:
200 mm 3M40431 For mounting on a foundation sunk into the
ground
100 mm 3M40434 For mounting on a foundation that is flush with
the ground
40 mm 3M40430
Top and side view of the plinths:
*depending on plinth height
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Foundation
For the necessary stability and safety during ground installation, eCharge offers the
prefabricated foundation 3M40420. The foundation contains a pipeline that ensures the
protection of the supply line. The concrete of our foundation meets the strength class C
30/37 and exposure classes XC4, XF1 and WF.
Technical drawing concrete foundation (all data in mm):
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Assembly and installation
Attention:
The assembly, installation and initial commissioning of the charging
station must be exclusively by qualified Specialized personnel take place.
The cPP2 charging pole is an electrotechnical device and is therefore subject to certain
specifications for indoor and outdoor installation. Although the housing of the cPP2
complies with the regulations described for protection class IP44, you must take the
following environmental conditions into account in particular:
•For safe operation of your charging station, minimum distances to other technical
installations must be taken into account: For more information, please contact
your electrical installation company or your sales partner.
•The charging station must be mounted so that it is freely accessible to persons
authorized to operate it.
•Select the mounting location so that you can easily reach the charging socket on
the vehicle with the optionally available charging cable of the cPP2: The cable
must NEVER be under tension when connected to the vehicle.
Requirements for the assembly site
The cPP2 charging pole was developed for indoor and outdoor use. For proper charging,
you as the operator must observe the following specifications for the location and
installation.
•Consider all local regulations for electrical installations, for fire prevention as well as
for accident prevention.
•All specifications for the installation of low voltage systems according to
DIN VDE 0100.
•The mounting surface must have sufficient strength to withstand the mechanical
loads and thus must not be installed directly on the asphalt or a concrete floor. A
concrete foundation with suitable specifications must be used. We offer a suitable
concrete foundation for this purpose (see S16).
•The soil at the mounting location must allow drainage of any liquids that enter the
pedestal.
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•A sufficiently dimensioned supply line for the power supply must be provided at the
mounting position. The supply line must be laid in the ground in coordination with
the pipe opening on the concrete foundation. If necessary, the supply line must be
protected against mechanical effects in the area in front of the foundation (by a
suitable hose or pipe).
•For mechanical protection, suitable collision protection must be provided to protect
the end user from a possible collision with the charging pole.
•One parking position for an end user must be provided on each side of the
charging pole. The minimum distance between the vehicle and the charging pole
should not be less than 45 cm and not more than 100 cm.
•Select the location of the charging pole so that it is easily accessible for emergency
vehicles.
•The cPP2 charging pole should not be installed in areas with a high volume of
people or on thoroughfares. In particular, ensure that the charging cables are laid in
a clearly visible position and that passers by or walkways are NOT obstructed by the
cables.
•In principle, the cPP2 is designed for operation in high ambient temperatures.
Nevertheless, it is recommended that, if possible, the charging pole is mounted so
that it is protected from direct sunlight: This prevents excessive heating of the
housing. Further information on ambient conditions can be found in the "Technical
data" section on page 31.
Socket installation
DANGER!
During the entire assembly, the circuit breakers for all supply lines to the
cPP2 must be deactivated: The supply lines must IN EVERY CASE BE
CURRENTLESS and may only be reconnected to the mains for the final
electrical commissioning.
NOTE!
To dehumidify the interior of the cPP2, we recommend filling the entire
pedestal area with dry granules: Minimizes the chance of undesirable
effects due to condensation and seepage water penetration.
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If you have not chosen our concrete foundation (3M40420), please contact your supplier
for a professional foundation installation.
For the concrete foundation (3M40420) with the stainless steel pedestals 40mm
(3M40430), 100mm (3M40434) or 200mm (3M40431), the following installation
instructions apply:
1. Once you have found an installation site that meets the
requirements (see page 17), the first step is to dig a hole
of size 0.45 m x 0.36 m x 0.8 m (L x W x H).
Make sure that the supply line is either from right or
left must be fed and suitably on which in the
foundation the intended pipeline. Straighten The
foundation must be level (horizontal).
2. Lower the concrete foundation into the hole and guide the supply cable upwards
through the guide embedded in the concrete foundation. Make sure that the cables
protrude far enough so that an electrical connection can be made without any
problems.
3. Now mount the pedestal (e.g. 40 mm) on top of the
concrete foundation and screw it tight with the enclosed
M12 screws. For the prescribed strength class 8.8, the
tightening torque should be about 90 Nm.
4. Then close the gaps next to the concrete foundation
(e.g. with soil). Make sure that the pedestal remains level
(horizontal).
5. Now place the cPP2 charging station on the stainless
steel pedestal. To do this, open the housing panel of the
charging pole via the swivel handle on the left side of the
cPP2. Place the charging pole in position above the
mounted pedestal. Insert the supply cables via the cable
opening in the base of the charging pole. Place the
charging pole on the pedestal so that the through holes
in the base plate of the charging pole are directly above
the threads in the pedestal. Screw the charging pole into
the pedestal with the four M8 x 20 hexagonal bolts supplied using the open end
wrench.
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The following installation instructions apply to the concrete foundation (3M40420) with
the 200 mm stainless steel pedestal (3M40431):
1. Once you have found an installation site that meets
the requirements (see page 17), the first step is to dig a
hole of size 0.8 to 0.96 m x 0.45 m x 0.36 m (H x L x W).
Make sure that the supply line must be fed either
from the right or from the left and that it meets
the pipeline provided in the foundation. Align the
foundation so that it is level (horizontal).
2. Lower the concrete foundation into the hole and guide the supply cable upwards
through the guide embedded in the concrete foundation. Make sure that the cables
protrude far enough so that an electrical connection can be made without any
problems.
3. Now mount the stainless steel pedestal 200 mm
(3M40431) on top of the concrete foundation and screw
it tight with the enclosed M12 screws. For the prescribed
strength class 8.8, the tightening torque should be about
90 Nm.
4. Then close the gaps next to the concrete foundation (e.g.
with soil). Make sure that the pedestal remains level
(horizontal).
5. Now place the cPP2 charging station on the stainless
steel pedestal. To do this, open the housing panel of the
charging pole via the swivel handle on the left side of the
cPP2. Place the charging pole in position above the
mounted pedestal. Insert the supply cables via the cable
opening in the base of the charging pole. Place the
charging pole on the pedestal so that the through holes
in the base plate of the charging pole are directly above
the threads in the pedestal. Screw the charging pole into
the pedestal with the four M8 x 20 hexagonal bolts supplied using the open end
wrench.
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