Ingeteam INGEREV RAPID ST Series User manual

INGEREV RAPID ST
200 - 400
Installation and Operation Manual

ABX2011IQM01_
01/2021
Ingeteam Power Technology, S.A. - Energy
Avda. Ciudad de la Innovación, 13
31621 SARRIGUREN (Navarra) - Spain
Tel.: [phone]
Fax.: [phone]
e-mail: electricmobility[email protected]
Service Call Center: [phone]

ABX2011IQM01_ - Installation and Operation Manual
INGEREV RAPID ST
Installation and Operation Manual
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Ingeteam

ABX2011IQM01_ - Installation and Operation Manual
The copy, distribution or use of this document or of its content requires written authorisation. Any breach thereof will be reported for
damages. All rights reserved including those of patent rights or design registration.
The conformity of the document content with the hardware described has been checked. However, discrepancies may exist. Liability
will not be assumed for total concordance. The information contained in this document is regularly reviewed and it is possible that
there may be changes in subsequent editions. Other functions may be available which are not covered by this document.
This document may be changed. The copy, distribution or use of this document or of its content requires written authorization. Any
breach thereof will be reported for damages. All rights reserved including those of patent rights or design registration.
The conformity of the document content with the hardware described has been checked. However, discrepancies may exist. Liability
will not be assumed for total concordance. The information contained in this document is regularly reviewed and it is possible that
there may be changes in subsequent editions. Other functions may be available which are not covered by this document.
This document may be changed.
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ABX2011IQM01_ - Installation and Operation Manual
Important safety instructions
This section describes the safety warnings and the personal protective equipment and symbols used in the unit.
Safety conditions
General warnings
DANGER
Opening the enclosure does not imply there is no voltage inside.
The risk of electric shock exists even after disconnecting from the grid and from the Power inverters.
Only qualified personnel may open it, following the instructions in this manual.
It is strictly forbidden to gain access to the inside of the electrical panel through any other point than the
access cover provided for this purpose. Always gain access when the unit is voltage-free.
CAUTION
The operations described in the manual may be performed only by qualified personnel.
The status of qualified personnel referred to in this manual will be, as a minimum, that which meets all the
standards, regulations and laws regarding safety applicable to the tasks of installing and operating this unit.
The responsibility for designating qualified personnel will always fall to the company to which the personnel
belong. It is necessary to decide which workers are suitable or not for carrying out specific work to preserve their
safety at the same time as complying with occupational safety legislation.
These companies are responsible for providing appropriate training in electrical equipment to their personnel
and for familiarizing them with the contents of this manual.
All applicable safety-related legislation for electrical work must be complied with. Danger of electric shock.
Compliance with the safety instructions set out in this manual or in the suggested legislation does not imply
exemption from other specific standards for the installation, place, country or other circumstances that affect
the unit.
You must consider the set of conditions listed throughout this document as minimum requirements. It is always
preferable to shut off the AC and DC power supplies. There may be faults in the installation that cause the
unwanted return of voltage. Danger of electric shock.
According to basic safety standards, the complete unit must be suitable to protect exposed workers against the
risk of direct and indirect contact. In any case the electrical parts of the work equipment must comply with the
provisions of the corresponding specific regulations.
According to basic safety standards, the electrical installation shall not entail a fire or explosion risk. Workers
must be duly protected against the risk of accidents caused by direct or indirect contact. The electrical
installation and protection devices must take into account the voltage, the external conditions and the
competence of persons who have access to parts of the installation.
To check the absence of voltage, it is compulsory to use measurement devices with category III-1100 V.
INFO
These instructions must be easily accessible close to the unit and located within reach of all users.
Before installation and start-up, please read these safety instructions and warnings carefully as well as all the
warning notices located on the unit. Ensure that all the warnings signs are perfectly legible and that those which
are damaged or have disappeared are restored.
Protection against direct contact is by means of the enclosure.
The unit has been tested according to the applicable regulations to comply with the safety requirements, the
values for insulation clearances and leakage paths for the voltages used.
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Important safety instructions Ingeteam

ABX2011IQM01_ - Installation and Operation Manual
Potential hazards for people
DANGER
Electric shock.
The equipment may remain charged after disconnecting the AC and DC power.
Carefully follow the mandatory steps in the manual for removing the voltage.
Explosion.
There is a very low risk of explosion in very specific cases of malfunction.
The casing will protect people and property from the explosion only if it is correctly closed.
Crushing and joint injuries.
Always follow the indications in the manual on moving and placing the unit.
The weight of this unit can cause serious injury and even death if not handled correctly.
High temperature.
The flow of outlet air can reach high temperatures which can cause injury to anybody exposed to it.
Potential hazards for the equipment
DANGER
Cooling.
The unit requires particle-free air flow while it is operating.
Keeping the unit in the upright position and the inlets free of obstacles is essential for this air flow to reach the
inside.
Do not touch boards or electronic components. The more sensitive components can be damaged or destroyed by
static electricity.
Do not disconnect or connect any terminal while the unit is operating. Disconnect and check for absence of
voltage first.
With the aim of avoiding premature wear of the screwed joints on the unit’s housing panels, removal and
installation of the screws must be done manually.
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Important safety instructions
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ABX2011IQM01_ - Installation and Operation Manual
Personal Protective Equipment (PPE)
When working on the unit, use the following safety equipment recommended by Ingeteam as a minimum.
Name Description
Safety footwear In compliance with standard UNE-EN-ISO 20345:2012 ANSI Z41.1-1991
Helmet with face shield In compliance with standard UNE-EN 397:1995, ANSI Z89.1-2014,provided
there are elements with voltage directly accessible.
Working clothes Close-fitting, non-flammable, 100% cotton
Dielectric gloves In compliance with standard EN 60903:2005 ASTM D 120-87
Tools and / or equipment used in live work must have at least Category III-1100 Volts insulation.
Should the country’s regulations demand another kind of personal protection, you should appropriately supplement
the equipment recommended by Ingeteam.
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Contents
Ingeteam
Contents
Important safety instructions ....................................................................................................................... 5
Safety conditions................................................................................................................................... 5
Personal Protective Equipment (PPE) ...................................................................................................... 7
Contents ................................................................................................................................................... 8
1. About this manual................................................................................................................................ 10
1.1. Scope and nomenclature .............................................................................................................. 10
1.2. Recipients................................................................................................................................... 10
1.3. Symbols...................................................................................................................................... 10
2. Unit description................................................................................................................................... 11
2.1. Overview ..................................................................................................................................... 11
2.2. Main parts of the charging station ................................................................................................. 12
2.3. Power modules (BPM) .................................................................................................................. 12
2.4. Charging standards ...................................................................................................................... 14
2.5. Models........................................................................................................................................ 14
2.6. Enclosure opening ....................................................................................................................... 15
2.7. Accessories fitted as standard ....................................................................................................... 16
2.8. Optional accesories ...................................................................................................................... 17
2.9. Electrical safety........................................................................................................................... 17
2.9.1. Overvoltage Category (OVC)................................................................................................... 17
2.10. Noise pollution .......................................................................................................................... 17
2.11. Electrical diagram of the auxiliary power supply ............................................................................ 18
2.12. Electrical diagram of the DC power circuit.................................................................................... 19
2.13. Specification table ..................................................................................................................... 21
2.14. Cable inlets............................................................................................................................... 22
3. Transportation and handling of the unit .................................................................................................. 23
3.1. Unpacking .................................................................................................................................. 23
3.2. Handling..................................................................................................................................... 23
4. Unit reception and storage .................................................................................................................... 25
4.1. Reception ................................................................................................................................... 25
4.2. Unit identification........................................................................................................................ 25
4.3. Transport damage ........................................................................................................................ 25
4.4. Conservation................................................................................................................................ 25
5. Preparation for installing the unit .......................................................................................................... 26
5.1. Environment................................................................................................................................ 26
5.2. Environmental conditions ............................................................................................................. 26
5.3. Type of grid for the AC auxiliary system .......................................................................................... 28
5.4. External disconnection system ...................................................................................................... 29
6. Installing the unit ................................................................................................................................ 30
6.1. General requirements for installation ............................................................................................. 30
6.2. Fastening the unit........................................................................................................................ 30
7. AC auxiliary circuit connection .............................................................................................................. 35
7.1. Safety instructions for the AC auxiliary circuit connection ................................................................ 35
7.2. Wiring requirements for the AC auxiliary circuit connection.............................................................. 35
7.3. AC auxiliary circuit connection process .......................................................................................... 35
8. DC power circuit connection.................................................................................................................. 37
8.1. Safety instructions for the DC power circuit connection ................................................................... 37
8.2. Wiring requirements for the DC power circuit connection ................................................................. 37
8.3. Proceso de conexión del circuito de potencia DC............................................................................. 38
9. Start-up .............................................................................................................................................. 39
9.1. Visual inspection ......................................................................................................................... 39
9.2. Checking the functional insulation of the DC power circuit............................................................... 39
9.3. Auxiliary circuit energization ......................................................................................................... 40
9.4. Checking the direction of rotation of the pump ............................................................................... 40
9.5. Energizing the DC power circuit..................................................................................................... 40

ABX2011IQM01_ - Installation and Operation Manual 9
Contents Ingeteam
10. Unit disconnection............................................................................................................................. 41
11. Waste handling .................................................................................................................................. 42

ABX2011IQM01_ - Installation and Operation Manual
1. About this manual
The purpose of this manual is to describe the INGEREV RAPID ST units and to provide appropriate information for
their correct reception, installation, start-up, maintenance and operation.
1.1. Scope and nomenclature
This manual is applicable to the following units:
Complete name Abbreviation
INGEREV RAPID ST200 One ST200 One
INGEREV RAPID ST200 Duo ST200 Duo
INGEREV RAPID ST400 Duo ST400 Duo
1.2. Recipients
This document is intended for qualified personnel.
The status of qualified personnel referred to in this manual will be, as a minimum, that which meets all the
standards, regulations and laws regarding safety applicable to the tasks of installing and operating this unit.
The responsibility for designating qualified personnel will always fall to the company to which the personnel
belong. It is necessary to decide which workers are suitable or not for carrying out specific work to preserve their
safety at the same time as complying with occupational safety legislation.
These companies are responsible for providing appropriate training in electrical equipment to their personnel and
for familiarizing them with the contents of this manual.
1.3. Symbols
Throughout this manual we include warnings to highlight certain information. Relative to the nature of the text,
there are three types of warnings:
DANGER This indicates a hazard to personnel or the charger.
CAUTION Indicates importance.
INFO Additional information or references to other parts of the document or documents.
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ABX2011IQM01_ - Installation and Operation Manual
2. Unit description
2.1. Overview
The INGEREV RAPID ST are multi-standard ultra-fast charging chargers designed for the realization of large
charging stations (combined power greater than 750kW).
This recharging stations are characterized by making a distribution in direct voltage from a main rectifier
equipment. This unit (-A1) is connected to the AC power grid through a dedicated transformation center and
generates an internal DC voltage network that is distributed to all load terminals in the installation.
INGECON SUN Power
inverter
DC switch INGEREV RAPID ST
CHAdEMO
250 ~ 500Vdc, MAX 200A
CHAdEMO
250 ~ 500Vdc, MAX 200A
CHAdEMO
250 ~ 500Vdc, MAX 200A
CHAdEMO
250 ~ 500Vdc, MAX 200A
CCS
250 ~ 500Vdc, MAX 500A
500 ~ 1000Vdc, MAX 400A
CCS
250 ~ 500Vdc, MAX 500A
500 ~ 1000Vdc, MAX 400A
CCS
250 ~ 500Vdc, MAX 500A
500 ~ 1000Vdc, MAX 400A
CCS
250 ~ 500Vdc, MAX 500A
500 ~ 1000Vdc, MAX 400A
INGEREV RAPID ST
INGEREV RAPID ST
INGEREV RAPID ST
DC switch
DC switch
DC switch
Auxiliary
supply
Transformer
Ultra fast charging installation type diagram
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ABX2011IQM01_ - Installation and Operation Manual
The charging terminals include isolated DC / DC power converters (called BPM) that adapt the DC main voltage to
the needs of the car at all times.
2.2. Main parts of the charging station
A
B
C
D
E
F
A. Ambient LED lighting
B. 21” screen with Full HD resolution for
commercial purposes (optional)
C. Interaction touch screen (Human-Machine
Interface, HMI)
D. RFID card reader
E. Emergency button
F. Charging connectors
The INGEREV RAPID ST family, with its different models, is compatible with mode 4 of the CHAdeMO and CCS
standards in direct current.
2.3. Power modules (BPM)
The BPMs are the modules that include the power electronics in charge of transforming the energy supplied to
the vehicle. They have been specifically designed for electric vehicle charging applications and incorporate the
latest semiconductor technology. As a result of all this, it is possible to reduce the volume of the modules to the
maximum, obtaining a high power density.
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ABX2011IQM01_ - Installation and Operation Manual
Basic Power Module (BPM)
INGEREV RAPID ST chargers incorporate the DC/DC BPM since an external device generates the DC network and
the charger only has to adapt the voltage level to the requirements of the car. The BPM DC/DC have two DC/DC
converters in parallel.
BPM DC/DC
Auxiliary services entrance
Voltage 24Vdc
Rated current 5A
Rated power 200kW
DC power entance
Voltage 575~750V
Rated current 300A
Output (DC)
Voltage range 50~920V
Maximum current 300A (50~500Vdc) / 200A (600~920Vdc)
General information
Refrigeration system Liquid cooling with quick shots without dripping
Galvanic isolation Included by high frequency transformer
Semiconductors Full SiC Technology
Stand-by consumption < 10W
Operating temperature -25ºC~60ºC
Humidity 0~95% (without condensation)
Weight 100kg
Dimensions (Width x Depth x Height) 520x690x430mm
Protection class IP00
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ABX2011IQM01_ - Installation and Operation Manual
2.4. Charging standards
The INGEREV RAPID ST family of chargers is compatible with the two available DC charging standards (CCS and
CHAdeMO).
CCS
PE
DC+ DC-
CP PP
PP: Proximity Pilot
CP: Control Pilot
PE: Protective Earth
DC+
DC-
CHAdeMO
1
1
4
4
3
6
6+
-
5
5
12 V
12 V
2
2
7
7
10
10
9
9
8
8
Power lines
Charging station side Vehicle side
Control lines
CAN BUS
2.5. Models
The INGEREV RAPID ST family of chargers comprises several models depending on the number of charging points,
their available power and the charging standards.
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ABX2011IQM01_ - Installation and Operation Manual
The ST200 chargers include a single power unit (BPM) while the ST400 have two power units.
Type and number of connectors Simultaneous charging
CCS CHAdeMO
INGEREV RAPID ST200 One 1 -
INGEREV RAPID ST200 Duo 1 1
INGEREV RAPID ST400 Duo 1 1
INGEREV RAPID ST400 Duo 2 -
Available // Not available
2.6. Enclosure opening
DANGER
To access the interior of the station, it must be in a stopped state.
If the auxiliary system is powered, the fan or pump may start while the station is open.
There is a risk of burns due to the heating element, located at the bottom of the station.
To gain access to the inside of the charging station, the enclosure has three doors (one on the side, front and rear)
and an access from the top.
Opening of the different entrances to the charging station
The upper access is opened by screws. Side and rear doors with key lock and several quarter-turn locks.
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ABX2011IQM01_ - Installation and Operation Manual
To open the front door it is necessary to access two quarter-turn locks from inside the station, accessing these
through the side door.
Location of access to the two front door unlock latches
2.7. Accessories fitted as standard
• Ethernet communication.
• Local communication with other INGEREV stations.
• OCPP support.
• Authentication through RFID/NFC cards.
• Screen interface.
• Highly resistant steel envelope against adverse environmental conditions.
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2.8. Optional accesories
These units can incorporate the following optional accessories:
• 3G communication.
• Wi-Fi communication.
• 21 ”screen with Full HD resolution for commercial purposes.
2.9. Electrical safety
Interesting design quantities for electrical safety are disclosed below.
2.9.1. Overvoltage Category (OVC)
These units have been designed with an OVC III overvoltage category in AC.
2.10. Noise pollution
Operation of this unit generates a humming noise. Do not place them in an inhabited room, or on light supports
that can amplify that hum. The mounting surface must be firm and suitable for the weight of the unit.
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2.11. Electrical diagram of the auxiliary power supply
To supply the auxiliary services of the unit, it is necessary to supply a three-phase 400V supply (AC) with neutral
and protective conductor (PE). The protection elements of the auxiliary systems are described below.
FC1 FB1 FC3 FC4
FC2
FB2
FC1 - Circuit breaker 16A Curve C. Protects auxiliary
systems.
FB1 - 30mA 16A Type B differential switch. Protects
auxiliary systems.
FC2 - 6.3 A motor protection switch. Protects the
cooling pump circuit.
FC3 - Circuit breaker 4 A Curve C. Protects the main
fan circuit and the heating.
FC4 - Circuit breaker 10 A Curve C. Protects DC power
supplies.
FB2 – 6 A magnetothermic switch and 30 mA
differential that protects the Schuko socket.
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ABX2011IQM01_ - Installation and Operation Manual
FC1
16A
FB1
30mA
M01
4A
TA1
24Vdc
TA2
CHADeMO
12Vdc
TA3
GENERAL
12Vdc
XD3 XD3 XD5
FC2
6,3A
Ir = 4~6,3A
FC3
4A
Curve C
FC4
10A
Curve C
FB2
30mA
KF1
230Vac
Water pump
Ground fault detector
Cooling/heating
230 Vac service plug
230Vac
12Vdc 12Vdc 12Vdc
Single line of the auxiliary system
2.12. Electrical diagram of the DC power circuit
The INGEREV RAPID ST family units are connected to a direct voltage (DC) distribution network. DC voltage
isolating elements are located outside the unit and are part of the customer’s installation.
In order to avoid opening the unit without having disconnected the direct voltage, a limit switch is included whose
contact must be wired with the minimum coil of the corresponding disconnector. In this way, in case of opening
the unit door, the disconnector supplying said unit will trip, thus being isolated from the DC network.
CAUTION
Opening the unit enclosure does not imply the absence of dangerous voltages inside.
This applies mainly to the DC power circuit. Due to the presence of capacities, dangerous DC voltages can
exist even several minutes after the supply has been disconnected. It is essential to wait 10 minutes between
disconnecting the DC power and opening the unit door.
The power modules (-U10 and –U20) are connected to the DC distribution busbars (points 2 and 3). The output of
the modules is connected to the hose selection contactors (-Kout1 and -Kout2) using high-density cables. Parallel
contactors (-Kpar) allow both power modules to be connected to only one of the charging sockets.
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Unit description Ingeteam

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U10 U20
2x70mm2
yellow
2x70mm2
yellow
70mm2
yellow
70mm2
yellow
120mm2
yellow
120mm2
yellow
W01 W02
XCCS XCHA
1x70/2x35mm2
yellow
1x70/2x35mm2
yellow
KOUT1 KOUT2
KPAR
DC BUSBAR
Single line of the DC power circuit
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