IES Keywatt 19 User manual

User Manual
Keywatt 19 Trolley
www.ies-synergy.com
DUM016199-EN_V002b

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User Manual DIM016199-EN
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The information provided in this documentation contains general descriptions and/or technical characteristics
of the performance of the products contained herein. This documentation is not intended as a substitute for
and is not to be used for determining suitability or reliability of these products for specific user applications. It
is the duty of any such user or integrator to perform the appropriate and complete risk analysis, evaluation and
testing of the products with respect to the relevant specific application or use thereof. Neither IES Synergy nor
any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information contained herein.
If you have any suggestions for improvements or amendments or have found errors in this publication, please
notify us.
You agree not to reproduce, other than for your own personal, noncommercial use, all or part of this document
on any medium whatsoever without permission of IES Synergy, given in writing. You also agree not to establish
any hypertext links to this document or its content. IES Synergy does not grant any right or license for the per-
sonal and noncommercial use of the document or its content, except for a non-exclusive license to consult it on
an “as is” basis, at your own risk. All other rights are reserved.
All pertinent state, regional, and local safety regulations must be observed when installing and using this prod-
uct. For reasons of safety and to help ensure compliance with documented system data, only the manufacturer
should perform repairs to components.
When devices are used for applications with technical safety requirements, the relevant instructions must be
followed.
Failure to use IES Synergy software or approved software with our hardware products may result in injury,
harm, or improper operating results.
Failure to observe this information can result in injury or equipment damage.
© 2020 IES Synergy. All rights reserved.

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Table of content
1. Safety notes 4
Notice 4
Please note 4
2. About the manual 5
Purpose of this manual 5
Document scope 5
Related documents 5
User comments 5
3. General Safety instructions 6
4. Overview 7
External view 7
Internal door view 8
5. Specification 9
Technical specification 9
Compliance 11
6. Handling and storage instructions 12
Storage 12
Transport 12
7. Installation 13
Visual inspection 13
Installation rules 13
Plug connections 14
AC input connector 14
DC output connector 15
8. Charger operation 16
Front panel 16
Rear Panel 16
Starting up 17
Charge with COMBO 1 or COMBO 2 connector 19
Charge with CHADEMO connector 23
Charge with GB connector 26
Charge error messages 29
Emergency Stop messages 29
List of error messages 30
9. Cleaning 32
10. Protecting the environment 33
Recycling Packaging 33
End-of-Life Recycling 33

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1. Safety notes
Notice
Read these instructions carefully, and look at the equipment to become familiar with the device before trying
to install, operate, or maintain it. The following special messages may appear throughout this documentation
or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies
a procedure.
The addition of this symbol to a Danger hazard statements indicates that an electrical hazard
exists, wich result in personal injury if the instructions are not followed.
This is the safety alert symbol. It is used to alert you to potential personnal injury hazards. Obey
all safety messages that follow this symbol to avoid possible injury or death.
IDANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
ous injury.
IWARNING
WARNING indicates a potentially hazardous situation which, if not avoided, can result in death or seri-
ous injury.
ICAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, can result in minor or mod-
erate injury.
NOTICE
NOTICE is used to address practices not related to physical injury.
Please note
Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No
responsibility is assumed by IES Synergy for any consequences arising out of the use of this material.
A qualified person is one who has skills and knowledge related to the construction and operation of electrical
equipment and its installation, and has received safety training to recognize and avoid the hazards involved.

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2. About the manual
Purpose of this manual
Technical documentation is an integral part of a product. Until it is disposed of, always keep the technical docu-
mentation close to the unit at hand, as it contains important information. Provide technical documentation to
the person concerned if you sell, assign or lend the product.
This guide aims to provide informations needed for installation, use and end-of life of the charger Keywatt 19
Trolley. This guide must be read in integrality with others related documents. This guide is intended for users
of the charging station.
Document scope
This guide concerns the following charging station :
• Art/N : TROLLEY 19KW DC CHARGER
Related documents
Document title Reference
User Manual DUM016199-EN
Service Manual
User comments
We invite you to write us to communicate any inaccuracies or omissions, or to make general comments or sug-
gestions regarding the quality of this manual.

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3. General Safety instructions
NOTICE
SAVE THIS MANUAL
• To ensure proper and safe operation, please read these user instructions carefully and
keep them for future reference.
• This manual contains important instructions for the DC quick charger that shall be followed
during installation, operation and maintenance of the unit.
• This equipment shall be installed, adjusted, and serviced by qualified electrical personnel
familiar with the construction and operation of this type of equipment and associated
hazards.
Failure to follow these instructions may result in death, serious injury or equipment
damage.
IDANGER
RISK OF ELECTRIC SHOCK, INJURY, AND/OR BURNING
• Only qualified, trained and authorized people will repair, replace or adjust this equipment.
• Do not let a child play near the product.
• This charger may only be used on a non-flammable surface such as concrete or similar.
• Do not open the front cover at any time while input power is present.
• Do not operate the unit while the cabinet door is opened or unlocked.
• Do not use this product if the cables (input or output) are frayed, have damaged insulation
or any other signs of damage.
• Do not use this product if the enclosure or the Electrical Vehicle Supply Equipment (EVSE)
connectors are broken, cracked, opened or shows any other indication of damage.
• Do not use a cord extension set or second cable assembly in addition to the cable assembly
for the connection of the EV to the EVSE.
Failure to follow these instructions will result in death or serious injury

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4. Overview
External view
1
2
3
4
5
6
7
Position Description
1 Start button
2 Stop button
3 Display
4 Cord bracket
5 Indicator light
6 Indicator light
7 Emergency stop button
Note: May change depending on version or technical modification

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Internal door view
1
2
3
4
5
Position Description
1 DC output Harting connector
2 Ethernet socket
3 USB socket
4 AC input Harting connector
5 Mains input switch
Note: May change depending on version or technical modification

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5. Specification
Technical specification
Mains supplies 3-phase L1/L2/L3 + GND 3x400VAC (19kW)
Mains 3-phase voltage range VAC 400 VAC ± 10%
Earthed electrical system TT or TN
Frequency range f 50/60 Hz ± 10%
Maximum input current IAC 32A Max
Power Factor PF 0,93 Nom
Efficiency ɳ94 % Nom
Harmonic current @ nominal network voltage THDi 37 % Max
Internal AC input protection
Inrush current limitation per phase IINRUSH LIMIT < 3 x IAC Max
Rated Current Circuit Breaker IBREAK Rating 50A typ
Breaking capacity of breaker IBREAK Capacity 6kA Max
Max earth leakage current ILEAKAGE < 3,5 mA Max
Emergency button connection Yes
Overvoltage (IEC60664-1) OV III
Insulation protection Class (IEC6103) Class II 2500VAC Min
Internal DC Output
Output voltage VDC_max 500 VDC Max
VDC_min 200 VDC Min
Output current IDC_max 60A (1)(2) Max
IDC_min 1A Min
Max Output Power POUT 19kW Max
Output connector (charging station side) Swapped vehicle cable
Car Plug coupler COMBO1 / COMBO2 / CHAdeMO / GB
Output cable length - 4 Meters
Internal DC output protection
Hardware and software short circuit protection Yes
Over current protection - 100A
Over voltage protection adjustable + 10 % Max
Internal over temperature protection - 60 °C
Reverse polarity protection Yes
DC output Contactor Yes (2 poles)
Rated Current Fuse (output) IFUSE 100 A
Galvanic isolation Vinput / output 4000 VDC
Max time for DC line discharge < 60V T<60V 1 s
Embedded Insulation device
Response time (tan) < 3sec. for asymmetrical fault
< 62sec. for symmetrical fault
Self test time At power on and every 60s during charge

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Embedded Insulation device
Internal resistance Ri of the measuring circuit
1.5Mohms permanent
750Kohms continuous measurement
300Kohms during simultaneous switching measurement
Measurement method Continuous and switching measurement resistor method
Measuring current Im < 1,4mA at RF=0
Measurement range (Ran) 20Kohms…300Kohms
Relative uncertainty ±15%
Line L+/L- Voltage (Un) DC 200V…500V
System leakage capacity Ce ≤ 1µF : response value (Ran) and time (tan) are not guar-
anteed for capacity above 1µF
Parallelization
IWarning: Do not connect the insulation monitor de-
vice (IMD) in parallel !!
Response value (Ran) and time (tan) are not guaranteed.
General & dimensions
External dimensions (mm) H x W x D 945 x 507 x 45 mm
Weight (without cable, or bracket) kg 48kg Max
Type of installation Trolley (2 wheels)
Protection type (EN60529) IP IP54
Cooling systems Heatsink with forced air flow by fans IP54
without air filter
Noise (1m, all direction) Db(A) 65dbA (1m)
Climatic & Environment constraints
Operating temperature (with derating) -20°C to +40°C(3)
Storage temperature -40°C to +70°C
Relative humidity (without condensation) RH 10% to 95%
Installation altitude Alt 2 000m Max
Norms & standards
EC Low voltage EC directive (LVD) 2014/35/EU
EC Electromagnetic Directive (EMC) 2014/30/EU
Electric vehicle conductive charging system part 1
General requirement IEC 61851-1
Electric vehicle conductive charging system part 23
DC Electric vehicle charging station IEC 61851-23
EMC requirement for OFF board electric vehicle charging
system IEC 61851-21-2
Insulation Monitor Device (IMD) IEC 61557-1 & IEC 61557-8
RoHS 2015/863/EU
Declaration of conformity CE(4) Yes
(1) Max output current will be adapted versus maximum carrying current of the vehicle plug.
(2) Output current can be even reduced with the power derating versus temperature.
(3) Potential derating above 25°C.
(4) CE marking affixed on the product attest the conformity of the product with applicable requirements of rele-
vent Community harmonization legislation.

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Compliance

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6. Handling and storage instructions
Storage
The charging stations are supplied in individual wood crate. When commissioning the product, all the protec-
tion for transport must be removed before energization.
Keep the charging station in its original packaging in an appropriate place:
• placed on dry ground or on a sheet to protect it from damp,
• sheltered from dust, inclement weather and sunlight.
Storage temperature: -40°C to +70°C
Humidity: 10% to 95% without condensation
During prolonged storage, check the state of the charging station packaging regularly.
Do not store the charging station for more than a year without powering it up, to avoid the deterioration of
non-energized electronic components.
Transport
Throughout the transport phase, take all necessary measures to keep the pallet stable.
NOTICE
RISK OF DAMAGE TO THE CHARGING STATION
• Improper storage or handling may cause damage to the unit.
Failure to follow these instructions can result in equipment damage.
ICAUTION
RISK OF INJURY DUE TO DROPPING OR FALLING
• Follow specified procedures for hoisting operations.
• Take measures to prevent falling when you carry or transfer the unit.
Failure to follow these instructions will result in minor or moderate injury.

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7. Installation
Visual inspection
Before switching on the power, check that the charging station has not suffered any damage during transport.
If there is any sign of damage, do not connect the charging station to the input power supply.
To do so would lead to a risk of electric shock and injury.
Installation rules
It is advisable to leave 40cm free space on each side of the charging station if it is surrounded by a wall.
This free space is mandatory for charging station’s ventilation. Never blockair flow.
40cm
40cm
40cm
Note: All pertinent state, regional, and local safety regulations must be observed when installing and using this
device.
Note: The manufacturer cannot be held responsible for failure to follow the instructions given in this instruc-
tion sheet.
NOTICE
PREMATURE AGEING OF THE CHARGING STATION
• Do not install charging stations outside where they are exposed to direct sunlight and
inclement weather.
Failure to follow these instructions can result in accelerate power derating.

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Plug connections
IWARNING
HAZARD OF ELECTRIC SHOCK OR DAMAGE TO THE CHARGING STATION
• Hazardous voltages may be present on both the charger input and output connections.
• Do not use this product if the cables (input or output) are frayed, have damaged insulation
or any other signs of damage.
• A cord extension set or second cable assembly or adaptator must not be used in addition
to the coupler/cable assembly for the connection into the vehicle.
Failure to follow these instructions will result in death or serious injury.
AC input connector
Use the AC input cable ref FLPLA012536 for this equipment.
5-wire plug :
MENNEKES AM-TOP 32A 3P+N+T 400V plug
4m FLPLA012536
If the power cable is damaged it must be replaced with a new cable.
IWARNING
HAZARD OF ELECTRIC SHOCK OR DAMAGE TO THE CHARGING STATION
• To protect against electric shocks in the event of a fault, make sure that the protective
earth conductor of the mains power supply is correctly connected before switching on the
power.
• The input must be connected to the power supply by a CCID (Charging Circuit Interrupting
Device) rated 32A with an opening contact gap for all poles that provides full disconnection
in Category III overvoltage.
Failure to follow these instructions will result in death or serious injury.

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DC output connector
IWARNING
HAZARD OF ELECTRIC SHOCK OR DAMAGE TO THE CHARGING STATION
• Lethal voltage. The DC source may supply 500V continuous voltage. Touching the
connected circuit or the output terminal when the power is on may cause death.
• A cord extension set or second cable assembly or adaptator must not be used in addition
to the coupler/cable assembly for the connection into the vehicle.
Failure to follow these instructions will result in death or serious injury.
Output cable and connector types are:
COMBO 1 Output cable
4m FLPLA015693
6m FLPLA015180
COMBO 2 Output cable
4m FLPLA015491
6m FLPLA012681
CHADEMO Output cable
4m FLPLA015492
6m FLPLA015433
GB Output cable
4m FLPLA015383

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8. Charger operation
Front panel
Rear Panel
All external circuits connected to the product with USB or ethernet socket must be SELV (Safety Extra Low
Voltage) and Limited Power Sources less than 15VA and meeting the requirements of Chapters 2.2 and 2.5 of
IEC60950-1:2005+/A1:2010+/A2:2013 and N60950-1:2006+/A11:2009+/A1:2010+/A12:2011+/A2:2013.
Mains input switch is not a safety isolating switch.

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Starting up
IWARNING
RISK OF ELECTRIC SHOCK, INJURY, AND/OR BURNING
Make sure no vehicle is connected before starting up the charger.
Failure to follow these instructions can result in death or serious injury
Turn the disconnecting device to the position “I ON” to power up the charger.
The charger displays its name after a startup phase represented by “...” :
...
XS20 Keywatt Combo
Chademo DC Charger
Choose the charging mode
with the STOP button
Combo 2 selected
Confirm with the START button
Combo 1 selected
Confirm with the START button
CHAdeMO selected
Confirm with the START button
GB selected
Confirm with the START button

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If the charger does not start:
1. Remove the cables connected to the charger.
2. Remove the T25 fastening screws (x6) ❶ of the circuit breaker access cover.
3. Remove the access cover ❷ to the circuit breakers ❸.
❸
❷
❶
4. Check that the circuit breakers (3-phase input circuit breaker ❶, RCD breaker ❷ and 12/24 V supplies cir-
cuit breaker ❸) are in upper position, if not, put them back to upper position using a flat-head screwdriver
to access the switches.
❸
❷
❶
5. Reinstall the access cover.
6. Tighten the T25 fastening screws of the circuit breaker access cover.
7. Reconnect the cables to the charger.
8. Check that the charger starts. If it is still not starting, contact the after sales service at support@ies-synergy.
com

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Charge with COMBO 1 or COMBO 2 connector
The charger performs an internal check and initialisation.
Please wait for a few seconds.
Initialisation...
→ The Start button flashes for 1 second.
When initialisation is successful:
Connect vehicle
to start charge.
9In case of error (two types of internal fault):
Pwr module failure
0 OK and 2 Fail
No power module
Step 2 Start a new charge
Connect the charging plug to the vehicle (secure firmly).
→ The charge status indicator flashes for 1 second.
The charger is waiting to communicate with the vehicle.
Vehicle connected
Wait for EV communication
Communication in progress…
Communication has been established.

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Then the charger performs the insulation test.
INSULATION TEST...
↓
INSUL. TEST COMPLETED
successfully
9If there is an insulation failure:
Cancel charge...
INSULATION FAILURE!!
Then the charger performs the pre-charge phase.
PRECHARGING...
1000 mA 320V
↓
CHARGING…
When the pre-charge target is reached and after receiving permission to charge, the charger displays:
CHARGING…
Charging is now in progress.
CHARGING 30min
23A 360V 40%