KEMPOWER C Series User manual

C-Station, C-Series, S-Series
Charging System
OPERATING MANUAL

CONTENTS
1
1
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2
2
3
3
3
3
4
5
5
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7
8
10
12
13
13
14
16
16
17
19
20
20
21
22
23
24
25
26
1 IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Main risk factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Operational Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Disclaimer on products and services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Charging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 S-Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 S-Series AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 C-Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 C-Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Connector types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Charging of electric vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Adaptive EV Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 Adaptive EV charging with democratic approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2 Adaptive EV charging with arrival priority approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Derating of the system in hot conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 MECHANICAL DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Satellite post . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 CPU C501/C801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 CPU C502/C802 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 CPU C503/C803 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 C-Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 IMPORTANT SAFETY INSTRUCTIONS
1.1 General
SAVE THESE INSTRUCTIONS.
This manual contains important safety instructions for the C-Station, C-Series and S-
Series, that shall be followed during installation, operation and maintenance of the unit.
Items in the manual that require particular attention in order to minimize damage and harm
are indicated with the below symbols. Read these sections carefully and follow their
instructions.
Table 1. Safety signs.
Note symbol: Gives useful information to the user.
Mandatory symbol: Describes a mandatory action.
Caution symbol: Describes a situation that may result in damage to the
equipment or system.
Warning symbol: Describes a potentially dangerous situation. If not avoided,
it will result in wounds or fatal injury.
1.2 Main risk factors
Warning! Do not turn OFF the charger if charging is ongoing as it may cause issues to the
vehicle. Follow user guide instructions for correct ending of the charging.
Warning! Only qualified service personnel are allowed to carry out maintenance or
installation work.
Warning! Only an authorized electrician is allowed to carry out electrical work.
Warning! Never release the charging cable from your hand when moving it to or from the
vehicle to prevent damaging the plug or vehicle. After charging place the plug back onto its
holder.
Caution! Do not use the device before it is properly installed and approved for use on the
site in question.
Caution! Always follow local and general safety regulations and procedures.
Caution! Do not use any pressure washing devices or compressed air to clean the device.
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Warning! Before opening or removing hatches, doors or cover plates, turn the main switch
to OFF position, turn off the power supply and wait about 2 minutes before continuing.
Ensure that the device is not energized before continuing.
Warning! Disconnecting the C-Series Charging Power Unit does not cut the AC supply to
the AC Satellite!
1.3 Operational Safety
It is mandatory to read this operating manual and follow its instructions.
The charging voltage is not present at the charging connector pins when the device
is not charging.
Any electrical work on the charging unit is only allowed to be carried out by an
authorized electrician.
Important notes for safe use
Straighten any loops in the cables.
Do not wrap the cables around the body.
Make sure that faulty and damaged cables and charging connectors are changed
immediately as they can cause risk of electical shock or fire.
The cable, plugs and other electric devices may be installed or replaced only by an
authorized electrician.
In case of any abnormal behavior of the equipment, such as smoke coming from the
CPU during normal use, stop the use instantly, turn the charger off and contact a
MANUFACTURER service representative to arrange an inspection.
1.4 Environment
The device shall be installed in a location whereas the ingress protection (IP)
classification and ambient operating conditions are within the limits to that of the
device.
Do not expose the device to high temperatures, as this may cause damage to the
device.
If possible, the charger unit should be mounted in such a location that protects it
from direct sunlight to prevent overheating and ageing of the technical parts.
Make sure the airflow to and from the CPU is unrestricted.
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2 INTRODUCTION
2.1 Disclaimer on products and services
Disclaimer
While every effort has been made to ensure that the information contained in this
guide is accurate and complete, no liability can be accepted for any errors or
omissions. MANUFACTURER reserves the right to change the specification of the
product described at any time without prior notice. Do not copy, record, reproduce
or transmit the contents of this guide without prior permission from
MANUFACTURER.
2.2 Notice
This manual provides information on the MANUFACTURER’s charging station and may
refer into one or more standards that may generally apply to charging systems.
Such a reference does not always equal that all of the MANUFACTURER solutions adopt
that standard.
On the component level the reader should refer to the component specifications for the
particular components.
MANUFACTURER may have one or more patents or pending applications protecting the
intellectual property rights mentioned on this operating manual.
All of the information in this manual is subject to change without notice and should not be
constructed as a commitment by MANUFACTURER. This manual is originally written in
English. Other language versions are translated from that document and
MANUFACTURER cannot be held liable for errors in translation.
MANUFACTURER assumes no responsibility for any errors that may appear in the
charging system if local rules and demands have been neglected. In no event shall
MANUFACTURER be liable for direct, indirect, special, incidental or consequential
damages of any nature or kind arising from the use of this manual, nor shall
MANUFACTURER be liable for incidental or consequential damages arising from use of
any software or hardware mentioned in this manual.
2.3 Warranty
The warranty Period is defined in purchase Agreement. Warranty is related to delivered
product (parts) only. Any other material, labor, accommodation and traveling costs are not
included. See more detailed information in the MANUFACTURER warranty terms and
conditions.
MANUFACTURER’s Charging System delivery typically consists one DC cabinet and
Satellite posts with connectivity Plug or integrated C-Station. Charging hardware and
software together with power grid, data communication network, various electric vehicles,
charging operators and users comprises a complex entity. Neither supplier liability nor
warranty does not include any consequential damages, see warranty and disclaimer on
products and services.
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Consumable parts, like cables and connectors are not included in the warranty.
2.4 Manufacturer
Kempower Oy
Hennalankatu 71
15810 Lahti, Finland
[phone]
[e-mail]
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3 DEVICE
3.1 Charging system
Due to the modular design of the Charging Power Unit (CPU) and flexibly located Satellite
posts, charging service sites can be customized to provide the best possible charging
result according to your application. Each CPU cabinet provides up to 200 kW of charging
power from four power modules into one or up to eight charging plugs on Satellite posts.
Features:
Charging Power Unit for fixed installation.
Maximum output power 200 kW (or optionally 4x40 kW).
Output voltage 500 V or 800 V (depending on the power module used).
CPU can distribute power to a maximum of eight satellite posts.
Satellite posts with CCS1, CCS2, ChaDeMo and Type 2 AC charging plugs
available.
Satellite posts feature 7" touch screen with on-screen user guidance.
User authentication via RFID (Radio-Frequency Identification) on each Satellite post.
The function can be switched on or off.
Internet cloud connection via built-in Wi-Fi and mobile data (3G/4G) connection.
Charge status LED indicators on each Satellite post.
Charging system is designed for a stand-alone operation with minimal maintenance and
communication to the back-end system. All functions are enabled when online.
3.2 S-Series
S-Series is operated from a Satellite post, which may be assembled with different
combination of charging plugs/socket.
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1. Charging cable support system
2. Welcome light
3. Touch screen user interface
4. RFID reader
5. Function buttons ( 2 )
6. Charging plugs and plug holders (1 – 2)
7. Status light bars (2)
Figure 1. Main points of the satellite post.
Depending on selected Satellite post, one or two charging cable support system springs
are providing cable support that prevents cable from touching the ground, when the plug is
in the holder.
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Figure 2. Charging status.
Status LEDs on the charge post indicate different states : Green- Charger ready to be used
(1), Blue- Charging and state of charge (2), Red- Fault.
3.3 S-Series AC
Three types of S-Series AC Satellites are available:
2 x AC sockets.
CHAdeMO on the left-hand-side and AC socket on the right-hand-side.
AC socket on the left-hand-side and CCS2 on the right side.
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1. Touch screen user interface.
2. RFID reader.
3. Function buttons (2).
4. AC plug holders (1–2).
Figure 3. AC Satellite.
3.4 C-Series
The C-Series, also known as "cabinet". The Charging Power Unit (CPU) consists typically 1
– 4 power modules, 0-1 Dynamic Power Module, Control module and Mains module which
are fitted into racks of the cabinet.
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1. 3G/GSM Antenna
2. Lifting lugs (4 pcs.)
3. Cooling outlet
4. Power module 1 – 4
5. Power module channel status indicator
6. Power module circuit breaker
7. Power distribution module (optional)
8. Control module
9. ETH 1 (Eth RJ-45)
10. USB
11. ETH 1 - 8 to Sat/Cab (Eth RJ-45) to Satellite posts
12. Reset
13. Spare
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14. Main switch front cover plate
15. Aux power circuit breaker
16. Main circuit breaker
Figure 4. Main points of the cabinet.
3.5 C-Station
C-Station charging system consists one or two charging outlets.
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1. 4G antenna
2. Charging cable support system
3. Touch screen user interface
4. RFID reader
5. Function buttons (2)
6. Charging outlets 1 - 2 plug and plug holder
7. Power modules 1 - 4
8. Place for power distribution module
9. Control module
10. MCB Auxiliary
11. Main circuit/overload breaker
Figure 5. Main points of the C-Station.
Cable support system spring is providing cable support that prevents cable to touch the
ground when the plug is on the holder.
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3.6 Connector types
Figure 6. 1 = CCS (Type 2), 2 = CHAdeMO, 3 = Type 2
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4 OPERATING INSTRUCTIONS
4.1 User Interface
On each Satellite post the touch screen provides user interface.
The touch screen has seven main active fields.
1. Charging start procedure status. The different steps of the charging initialization are
shown in here.
2. Satellite post ID and status e.g. S1, status colors Green (ready), Blue (charging),
Red (fault).
3. RFID activated. Show tag.
4. Charging protocol.
5. Activity button.
6. Info button.
7. Stop button (requires authorization when authorization is activated).
Figure 7. Start view of the touch screen.
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1. Satellite post ID
2. Info
3. Charging protocol and available charging power
4. Battery SoC, charged energy and remaining time
5. Battery SoC (press battery for more detailed info)
6. QR code for mobile following
7. Activity button
8. Stop
Figure 8. The touch screen has seven main active fields that change during each session.
4.2 Charging of electric vehicle
Prior to start DC charging the user needs to authorize charging session of the selected
Satellite post. Authorization can be based RFID card or tag.
Charging session
1. Select the correct charging plug that is appropriate to your vehicle.
2. Attach the plug to the vehicle and ensure that the charging plug is properly inside the
socket.
3. User indentification (if enabled).
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4. Charging initialization starts automatically in CCS charging. Start button must be
pressed in CHAdeMO charging.
Figure 9. Using the Satellite post.
5. Follow the Satellite post’s on-screen instructions.
The charging status can be seen with smartphone by scanning QR-code from touch
screen.
Once the authorization is completed, the session starts automatically as the
handshake procedure between vehicle and the charger is finished. 4-step “donut -
indicator” indicates safety steps on the touch screen.
1st step; cable is in vehicle locked.
2nd step; communication has been established - vehicle communicates with the
charger.
3rd step; isolation test starts - safety checks starts.
4 th step; isolation test passed - safety checks completed and charging session
starts.
6. You may follow the charging progress with your smartphone by scanning the QR-
code from the charger display. Touch screen may indicate SOC level, how much
energy was delivered, an estimate of the range, and charging time. The charging
status is indicated on appropriate side of the Satellite post on the light bars.
7. If the charging sequence is interrupted the charging stops into fault status by
indicating appropriate side of the Satellite post in red color (until connector is
disconnected) and the display also red background color on top indication bar.
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8. Ending of the charging sequence can be due to following.
Battery is full - charging ends automatically when SOC level of the battery has been
achieved.
User presses stop button on the display or physical button below the display. Stop
requires authorization when activated.
Note that a new charging session requires plug to be disconnected.
9. Return the charging plug to its holder. The Satellite post indicator LED's changes
blue color to green and it is ready to start charging again. Charging session
information remains on the touch screen for 10 more seconds.
4.3 Adaptive EV Charging
Each Charging Power Unit (CPU) consist of 1-12 power modules, with 2 independent
power channels on each module and optional dynamic module that can route the power
channels in any order to a maximum of eight charging outputs. To utilize full potential of
each DC charger, dynamic power management is one of the key elements on Adaptive EV
charging.
Compared to the traditional static charging, Adaptive EV charging can benefit from re-
routing the power channels even during each charging session. It enables true flexibility to
DC charging and improved OPEX as charging service power levels can also be adjusted to
match with real-time energy price level as well as to eliminate possible power peaks in
advance.
The S-series and C-station with Adaptive EV charging systems offer two options to manage
power channels:
democratic
arrival priority.
4.3.1 Adaptive EV charging with democratic approach
On the democratic power management, each charging output is granted with 25 or 50 kW
from the beginning of each charging session, thus on an empty charging area, the first
vehicle receives maximum power until next vehicle starts to charge. That starting power
level is depending on the number of power modules versus number of charging outputs
and their charging cable sizes.
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Figure 10. A simplified example of democratic power management.
On a simple case - at the beginning as all EVs are charging on outputs 1-4, each EV
receives 25% of the cabinet’s charging power. When the EVs on outputs 2 and 4 end
charging, remaining charging power 50% is available and is routed to EVs on outputs 1
and 3 (both receives +25%).
When the EV on output 1 ends charging the remining power (50%) is routed to the EV at
output 3 if it can accept more power it will receive 100%. Depending on charging
application the dynamic power management - routing of charging power works both ways.
Charging power is also reduced when more vehicles are plugged for charging.
On such a democratic power management when the CPU has 200 kW maximum power
and four outputs, as if the first EV is able to receive the charge at 150 kW power level it
starts at that level. As if the next EV also demands 150 kW both EVs receive only 100 kW.
And when the third arrives the power is split into three equal parts to 3 x 50 kW where 50
kW is booked to reserve. And when the fourth EV arrives it will receive the remaining 50
kW charging power.
4.3.2 Adaptive EV charging with arrival priority approach
On the arrival priority power management, the first arriving EV is granted with maximum
charging power from the beginning to the end of its session. Arrival priority power
management in turn targets on getting the first vehicle ready as fast as possible to free
capacity for the next vehicles arriving and to minimize charging queues. The highest
starting power level is depending on the charging points output capacity and maximum
charging power level that the EV can accept and on the charging system power capacity.
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Figure 11. A simplified example of arrival priority power management.
On a simple case - at the beginning as the first EV starts to charge at 75% (150 kW), when
the next EV starts to charge at output 3 it receives 25% (50 kW). As the third driver starts
to charge on output 2 the first arrived still receives 75% and second and third receive only
12.5% (25 kW each). By the time the first EV ends its charging session, that power is first
routed to output 3 and remaining 25% (50 kW) to output 2. When the fourth EV starts to
charge, charging power is divided to half to two single channels (25 kW) for both 2 and 4
outputs. And as the EV on output 3 ends its session that power is routed to EV on outputs
2 (75%) and 4 (25%).
Figure 12. When the EV that arrived earliest ends its charging session, power channels are re-routed to remaining EVs on arrival priority
order.
In both power management cases, democratic and arrival priority, when there is free power
for charging available the CPU communicates with each vehicle and offers additional
power. During that communication, each EVs BMS confirms if additional power level is
acceptable. After that asynchronous conversation, a selected number of power channels
are re-routed to specific EVs.
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