Keba KeContact P20 User manual

KeContact P20
Installation manual
(for the specialist)

© KEBA 2013-2014
Subject to alteration in the course of technical advancement. No guarantee is offered for the accuracy of the information provid-
ed. All rights reserved.
All brand and product names are trademarks of their respective companies. Technical information in this document is subject to
change without notice.
Document: Revision 1.70 / Release date: 20.08.2014 / Article no.: 90064
KEBA AG, Postfach 111, Gewerbepark Urfahr, A-4041 Linz; www.kecontact.com
Comments to this manual
In this manual you will find warnings against possible dangerous situations. The used sym-
bols apply to the following meanings:
!
WARNING!
Indicates a potentially hazardous situation which, if not avoided could result in
death or serious injury.
!
CAUTION!
Indicates a potentially hazardous situation which, if not avoided may result in
minor or moderate injury.
CAUTION
Indicates a situation which, if not avoided could result in property damage.
This symbol reminds you of the possible consequences of touching electro-
statically sensitive components.
Notice
Notes on use of equipment and useful practical tips are identified by “Notice". Notices do not
contain any information that draws attention to potentially dangerous or harmful functions.
►Step of a sequence of operations.

3 / 48
The device is designed in accordance with CE-rules.
The declaration of conformity is being held by KEBA AG.
The device meets the ROHS directive (RL 2011/65/EU).
The declaration of conformity is being held by KEBA AG.
Information on disposal
The symbol with the crossed-out garbage can points out that electrical and elec-
tronic devices including their accessories should not be disposed of in the house-
hold garbage. Information on correct disposal can be found on the product itself, in
the instructions for use or on the packaging.
Depending on their coding, the raw materials are recyclable. By disposing of such
used devices correctly, you can ensure that they can be reused, their raw materials
recycled or put to another use, and you will be making an important contribution to
the protection of our environment.
Disposal of batteries
Batteries or rechargeable batteries are hazardous waste and must be disposed of
in the correct manner.
Although batteries have a low voltage, in the event of a short-circuit, they can still
emit a charge sufficient to ignite flammable materials. Batteries should therefore
not be disposed of together with conductive materials (such as iron filings, wire
wool contaminated with oil etc.).
The latest KeContact P20 firmware can be downloaded from the Internet at
www.kecontact.com (download area).
A new firmware can eg. consider modified standards or improve the compatibility
with new electric vehicles.

Contents
4 / 48
Contents
1Important information.................................................................................................................... 5
1.1 Safety instructions................................................................................................................. 5
1.2 Intended use.......................................................................................................................... 7
1.3 About this manual.................................................................................................................. 7
1.4 Product description................................................................................................................ 8
2Overview ......................................................................................................................................... 9
2.1 Optional equipment (except e-series)................................................................................... 9
2.1.1 Additional optional equipment............................................................................... 10
3Installation guidelines ................................................................................................................. 11
3.1 General criteria for the site selection................................................................................... 11
3.2 Specifications for the electrical connection......................................................................... 12
3.2.1 General ................................................................................................................. 12
3.2.2 Differing requirements for the fulfillment of „Z.E.-Ready®“ (Renault)................... 13
3.3 Space requirements............................................................................................................ 14
4Installation .................................................................................................................................... 15
4.1 Preparing the housing......................................................................................................... 17
4.1.1 Removing the housing cover ................................................................................ 17
4.1.2 Removing/mounting the connector panel cover ................................................... 18
4.2 Preparing the cable insertion .............................................................................................. 19
4.2.1 Cable insertion from above - surface cable routing.............................................. 20
4.2.2 Cable insertion from behind - flush-type cable routing......................................... 20
4.3 Mounting the charging station............................................................................................. 21
4.4 Electrical connection ........................................................................................................... 24
4.4.1 Connection overview with opened connector panel cover ................................... 24
4.4.2 Connecting the mains supply line......................................................................... 25
4.4.3 Enable input [X1] (except e-series)....................................................................... 28
4.4.4 Switch contact output [X2] (except e-series) ........................................................ 29
4.4.5 Terminals [X1/X2] (except e-series) ..................................................................... 30
4.4.6 Ethernet1 connection [ETH] (optional) ................................................................. 31
4.5 DIP-switch settings.............................................................................................................. 33
4.6 Commissioning.................................................................................................................... 37
4.6.1 Commissioning mode/self test.............................................................................. 38
4.6.2 Safety checks........................................................................................................ 39
4.6.3 Mounting the housing cover.................................................................................. 40
5Further technical instructions .................................................................................................... 41
5.1 Programming RFID cards (optional) ................................................................................... 41
5.2 Configure the communication with the EV PLC->Ethernet (optional)................................. 42
5.3 Replacing the fuse............................................................................................................... 42
5.4 Dimensions.......................................................................................................................... 43
5.5 Technical data..................................................................................................................... 44
5.6 Standards and regulations .................................................................................................. 46
6INDEX ............................................................................................................................................ 47

Important information
5 / 48
1 Important information
1.1 Safety instructions
!
WARNING!
Not observing the safety instructions can result in risk of death, injuries and dam-
age to the device! KEBA AG assumes no liability for claims resulting from this!
Electrical hazard!
The installation, commissioning and maintenance of the charging station may
only be performed by correctly trained, qualified and authorized electricians
who are fully responsible for the compliance with existing standards and in-
stallation regulations.
Please observe that an additional overvoltage protection of vehicles or national
regulations can be required.
Also observe that some countries or vehicle manufacturers may require a dif-
ferent triggering characteristic of the fault-current circuit breaker (Type B).
Only connect voltages and circuits in the right-hand connection area (Ethernet,
terminals for control lines) that have a secure separation to dangerous voltag-
es (e.g. sufficient isolation).
Only supply the terminals (X2) from voltage sources which feature safety extra-
low voltage!
Before commissioning, check all screw and terminal connections for firm seat-
ing!
The connector panel cover may never be left open unattended. Mount the con-
nector panel cover if you leave the charging station.
Do not carry out any unauthorized conversion work or modifications to the
charging station!
Repair work to the charging station is not permitted and may only be per-
formed by the manufacturer (replacement of the charging station)!
Do not remove any notices on the device, such as safety symbols, warning
notices, rating plates, nameplates or cable markings!
The charging station does not have its own power switch! The RCD circuit
breaker and the line circuit breaker of the building installation serve as mains
disconnector.
Observe the instructions given for selecting the location and the construction-
al requirements!
If the specifications for the location are not observed, this can result in death,
serious physical injury or equipment damage if the corresponding precaution-
ary measures are not met!

Important information
6 / 48
!
WARNING!
Pull the charging cable only at the plug and not at the cable out of the con-
nector.
Ensure that the charging cable is not mechanically damaged (bent, pinched or
run over) and the connection area does not come into contact with heat
sources, dirt or water.
5 safety rules:
- Shut down all poles and all sides!
- Secure against reactivation!
- Check that the equipment is voltage-free!
- Ground and short-circuit!
- Cover adjacent live parts and restrict access to hazardous areas!
ATTENTION
Risk of damage!
Make sure that the charging station is not damaged by improper handling (an-
choring, housing cover, socket, inner parts etc.).
Do not open the connector panel cover in the rain!
Risk of breaking the plastic housing!
- Countersunk screws may not be used for the mounting!
- The included washers must be used.
- Do not tighten the mounting screws with force.
- The mounting surface must be completely level (max. 1 mm difference be-
tween the support points or mounting points). Warpage of the housing must be
prevented.
Information for technicians who are permitted to open the device:
Risk of damage!
Electronic components can be destroyed if touched!
Before handling components, make sure you perform an electrical discharge
by touching a metallic, grounded object!

Important information
7 / 48
1.2 Intended use
KeContact P20 is a "charging station" for the indoor and outdoor area at which electrically operated
vehicles can be charged (e.g. electric automobiles).
The charging station is designed for installation on a wall or in a floor-mounted column.
The respective national regulations must be observed with regard to the installation and connection
of the charging station.
The intended use of the device always includes the compliance with the environmental conditions
for which this device was developed.
The device was developed, manufactured, inspected and documented in compliance with the rele-
vant safety standards. Therefore, the products do not pose any danger to the health of persons or
a risk of damage to other property or equipment under normal circumstances, provided that the
instructions and safety precautions relating to the intended use are properly observed.
The instructions contained in this manual must be followed precisely in all circumstances. Failure
to do so could result in the creation of potential sources of danger or the disabling of safety devic-
es. Apart from the safety instructions given in this manual, the safety precautions and accident
prevention measures appropriate to the situation in question must also be observed.
Only electrical vehicles or their chargers may be connected. A connection of other loads (e.g. elec-
tric tools) is not permitted!
Due to technical or legal restrictions, not all variants / options are available in all countries.
1.3 About this manual
This manual is valid for devices of the type
KeContact P20
Use of this manual
This installation manual is intended for qualified personnel only
1
.
The figures and explanations contained in this manual refer to a typical device design. The design
of the device may deviate from it.
Please refer to the "KeContact P20 User manual" for information and instructions about operating
the device.
1
Persons who, due to their special training, expertise, and experience, as well as knowledge of current standards, are
able to assess the work performed and the possible hazards.

Important information
8 / 48
1.4 Product description
Example KC-P20-ES240030-000-xxxx
Type plate
Product family
-
Product type
Type / Version
-
see top of the device
KC
-
P
20
-
KeContact
ChargePoint
Type
Design versions
Basic versions
Cable / Socket
Electronics
Electrics
E
S
2
4
0 0
3
0
E…Europe
S…Socket
C…Cable
1…Type 1
2…Type 2
1…13A
2…16A 3…20A 4…32A
00…no cable
01…4m straight 04…6m straight 99…4m spiraled
0...e-series
1...b-series 2...c-series 3...c-series + PLC
0…Contactor
1…Contactor 1-phase
-
Options
-
Optional
Customer code
2-digit
Buttons
Authentication
Left
Right
-
0
0
0
-
xx
0…not populated
0…not populated
R…RFID K…Key switch

Overview
9 / 48
2 Overview
Charging station (application example)
Typical version with charging cable
[A]…Status LED
[B1]…Parking bay for charging plug
[B2]…Standard socket (variants possible)
[C]…Housing cover
[D]…Hanger for charging cable
Note
Depending on the design of the charging sta-
tion, the parking bay may deviate from the form
shown.
2.1 Optional equipment (except e-series)
RFID sensor
RFID sensor
The RFID sensor [R] is used for touchless au-
thorization of a user with MIFARE cards or tags
according to ISO14443.
Key switch
Key switch
The key switch [S] is used for authorizing a
user.

Overview
10 / 48
2.1.1 Additional optional equipment
Network capability
Switch contact (for control of external additional equipment)
Enable input for e.g. ripple control receivers, time switches,…
This permits a scheduled (time-controlled) charging of the vehicle to be realized.
PLC (Power Line Communication) according to GreenPhy standard
Mounting column
3-phases
ZER 1.2 conform
Energy meter

Installation guidelines
11 / 48
3 Installation guidelines
3.1 General criteria for the site selection
The charging station was constructed for the indoor and outdoor area. Accordingly, it is necessary
to ensure the installation conditions and the protection of the device at the installation site.
Take into account the local electrical installation regulations, fire prevention measures and ac-
cident prevention regulations as well as emergency routes at this site.
The charging station must not be installed in potentially explosive zones (EX environment).
Mount the charging station so that it is not located in the direct flow of passersby and so that no
one can trip over connected charging cables and so that the charging cables do not cover or
cross passing pedestrian and motorized traffic.
Do not install the charging station at locations where ammonia or ammonia gas is exposed
(e.g. in or at stables).
The mounting surface must be sufficiently constructed in order to withstand the mechanical
forces.
Do not mount the charging station at locations where falling objects (e.g. hung ladders or au-
tomobile tires) could damage the device.
According to the product standard, the charging station must be located at a height between
0.4 m and 1.5 m.
We recommend mounting the charging station (height of the socket or parking bay) at a height
of 1.2 m. Observe that national regulations can limit this height.
The device may not be exposed to direct spray water (by e.g. neighboring manual carwash
facility, high-pressure cleaner, garden hose).
If possible, the device should be mounted protected from direct rainfall, in order to avoid e.g.
icing, damage because of hail or similar.
If possible, the charging station should be mounted protected from direct sunlight, in order to
avoid the reduction of the charging current or the interruption of the charging procedure due too
high temperatures of the components inside the charging station.
For not weatherproof mounting (e.g. in a parking lot outside), the charging current setting is
changed to 16A, if the temperature is inadmissible exceeded. Subsequently, the charging pro-
cess can also be switched off.
For information about environmental conditions, please refer to the "Technical Data" chap-
ter.
Observe the internationally relevant installation standards (e.g. IEC 60364-1 and IEC 60364-
5-52) and follow the applicable national installation standards and regulations.

Installation guidelines
12 / 48
3.2 Specifications for the electrical connection
3.2.1 General
The charging station is set to 10 amps in the delivery state. Set the maximum EVSE current capac-
ity by setting the DIP-switches in coordination with your installed line circuit breaker (see chapter
“DIP-switch settings”).
The mains supply line must be hardwired to an existing house installation and correspond to the
nationally applicable legal conditions.
Selection of the RCD circuit breaker:
Each charging station must be connected to a separate RCD circuit breaker. No other cir-
cuits may be connected to this RCD circuit breaker.
RCD circuit breaker of at least type A
If the vehicles to be charged are not known (e.g. semi-public area), measures must be met
for protection where direct fault currents (>6mA) occur. This can be realized, for example,
through the use of an RCD type specifically intended for electric vehicles or with a RCD
type B. The vehicle manufacturer specifications must also be observed.
The nominal current INmust be selected to match the line circuit breaker and the fuse.
Dimensioning the Line circuit breaker:
When dimensioning the line circuit breaker also observe the increased environmental temperatures
in the switching cabinet! Under certain circumstances, this may require a reduction of the pread-
justed charging current setting to increase the system availability.
Maximum value according to the type plate data matching to the DIP-switch settings of the
preadjusted charging current value.
Determine the nominal current in accordance with the specifications on the type plate, in
coordination with the desired charging current (DIP switch settings for the pre-adjusted
maximum EVSE current capacity) and the mains supply line.
Dimensioning of the mains supply line:
When dimensioning the mains supply line also observe possible reduction factors and the in-
creased environmental temperatures in the interior connection area of the charging station (see
„Mains supply terminals temperature rating”)! Under certain circumstances, this can lead to an in-
crease of the cable cross-section and to the adaptation of the temperature resistance of the mains
supply line.
Mains disconnector:
The charging station does not have its own power switch. The RCD circuit breaker and the line
circuit breaker of the mains supply line serve as mains disconnector.

Installation guidelines
13 / 48
3.2.2 Differing requirements for the fulfillment of „Z.E.-Ready®“ (Renault)
For the case where the internal switching element (contactor) is no longer able to open, an
additional switch-off capability must be realized. This can be realized with the switch con-
tact output X2 (for details, see chapter "Switch contact output [X2]").
No 13A charging cables may be used.
For 3-phase connection of the KeContact P20, at least a fault-current circuit breaker RCD
type A with DC fault current detection (>6mA) or a fault-current circuit breaker RCD type B
must be used.
Renault recommends the selection of the line circuit breaker according to the following ta-
ble:
Preadjusted charging current
value (DIP-switch setting)
Line circuit breaker
Characteristics
1-phase
3-phases
10A
not allowed!
13A
not allowed!
16A
20A
C
D
20A
25A
C
D
25A
32A
C
D
32A
32A
B
C
The nominal current of the selected line circuit breaker must not exceed the value on the
type plate. If the preadjusted charging current setting and the nominal current are equal, in
particular the temperature in the switching cabinet must be considered (thermal derating of
the line circuit breaker).
Electricity supply earthing system requirements:
In TT and TN systems, the ground resistance of the installation must be lower than
150 ohms.
In IT or TT systems with ground resistance greater than 150 ohms, an isolating transformer
has to be placed in the EVSE (Electric Vehicle Supply Equipment) upstream installation.
This transformer must then be fed into a TN earthing system for which the above men-
tioned criteria apply.
Electricity supplies with IT earthing systems are prohibited.

Installation guidelines
14 / 48
3.3 Space requirements
Space requirements –dimensions in millimeters
Space requirements
For device versions with optional cable hanger,
additional and sufficient free area (y) for the
charging cable to be used is to be accounted
for.
If several charging stations are installed adja-
cent to each other, a distance of at least 200
mm between charging stations must be com-
plied with.

Installation
15 / 48
4 Installation
Scope of supply
e-series
others
Charging station
1 piece
1 piece
Cable hanger (for versions with charging cable)
1 piece
1 piece
Installation manual (for the specialist)
1 piece
1 piece
User manual (for the end customer)
1 piece
1 piece
Drilling template
1 piece
1 piece
Keys for cylinder lock (optional)
-
3 pieces
RFID card (optional)
-
1 piece
Terminal range
(permitted cable diameter)
[1] Cable gland M32x1.5
10 –21 mm
1 piece
1 piece
[2] Lock nut M32x1.5
1 piece
1 piece
[3] Cable gland M16x1.5
4 –10 mm
-
2 pieces
[4] Lock nut M16x1.5
-
2 pieces
[5] Double-membrane seals M32
14 –21 mm
1 piece
2 pieces
[6] Double-membrane seals M20
7 –12 mm
-
2 pieces
[7] Double-membrane seals M16
5 –9 mm
-
2 pieces
Mounting set for wall insulation:
[8] Anchor bolt for M8; Fischer UXR-8
-
4 pieces
[9] Hanger bolts M8x100
-
4 pieces
[10] Nut ISO 10511 - M8
-
4 pieces
[11] Washer ISO 7089 - 8.4
-
8 pieces
Supplied installation materials

Installation
16 / 48
Installation requirements
Before beginning the installation, the installation guidelines must be observed.
Contact person on-site (for access to the mains disconnector in the electrical distribution panel
board).
The electrical connection (mains supply line) must be prepared.
Acclimation:
With a temperature difference of more than 15°C between transport and installation site, the
charging station should be acclimatized for at least two hours unopened.
The immediate opening of the charging station can lead to a formation of water in the inside
and can cause damages when switching on the device. A possible damage could also occur at
a later time after installation.
Ideally, the charging station should be stored at the installation site for a few hours. If this is not
possible, the charging station should not be stored outside overnight or in a vehicle at cold
temperatures (<5°C).
Tool list to handle KC-P20
The following tools are required for the installation:
Flathead screwdriver for mains supply terminals (blade width 5.5 mm)
Flathead screwdriver for terminals X1/X2 (blade width 3.0 mm)
Phillips head screwdriver PH2
Mounting tools for cable glands M16 (width across flats 20mm) and M32 (width across flats
36mm)
LSA+ insertion tool (optional)

Installation
17 / 48
4.1 Preparing the housing
4.1.1 Removing the housing cover
Cover screws
Cover screws
►Unscrew the two cover screws [S] on the
bottom side of the housing cover.
Removing the housing cover
Removing the housing cover
►(1) Pull the housing cover out slightly.
►(2) Slide the housing cover up slightly to
unhinge it.

Installation
18 / 48
4.1.2 Removing/mounting the connector panel cover
Removing the connector panel cover
Removing the connector panel cover
►Unscrew the four screws with which the
connector panel cover is mounted and
remove the connector panel cover.
Notice
Remove the dry bag from the connector panel
and dispose it of properly.
Information for reassembly
Connector panel cover removed
Mounting the connector panel cover
►Insert the connector panel cover again.
►Mount the connector panel cover again
using the four screws.
Housing mark
Housing mark
►Tighten the four screws until the mark on
the connector panel cover is even with the
housing surface.
The connector panel cover must seal the
housing properly.
Self-tapping screws require more force
(min. 2.5 Nm to max. 5 Nm).

Installation
19 / 48
4.2 Preparing the cable insertion
There are two possibilities available for the cable insertion:
Cable insertion from above (surface cable routing)
Cable insertion from behind (flush-type cable routing)
Preparations
►Remove the connector panel cover (see Chapter "Removing/mounting the cable panel
cover").
►Populate the charging station with the required cable glands or seals (if an open cable
insertion opening is not used any more).
Breaking out the cable insertion openings
Breaking out the cable insertion openings
►Place the housing on on a stable support
pad and use a hammer and flathead
screwdriver to carefully break out the
required cable insertion openings.
►Then insert the corresponding
feedthroughs (cable glands or double-
membrane seals)

Installation
20 / 48
4.2.1 Cable insertion from above - surface cable routing
Cable insertion openings - top view
[A]…Cable gland M32 (mains supply line)
[B]…Cable gland M16
(for control line/Ethernet)
[C]…Cable gland M16
(for control line/Ethernet)
4.2.2 Cable insertion from behind - flush-type cable routing
Cable insertion openings - front view
[A]…Feedthrough / double-membrane seals
M32 (mains supply line)
[B]…Feedthrough / double-membrane seals
M20 (for control line/Ethernet)
[C]…Feedthrough / double-membrane seals
M20 (for control line/Ethernet)