KOSTAD CPC 50 User manual

Modular fast charging station
CPC 50/60|90|120
Operating instructions
12/2020
Introduction
1
Deployment
preparation
4
Commissioning
7
Operation
8
Maintenance
9
Spare parts
10
Disposal
11
Service & Support
A
Technical data and dimensions
B
Documents
C
Description
3
Assembly
5
Connect
6

Legal notice
Warning notice concept
This manual contains information that you must observe for your personal safety and to avoid damage to property. The
instructions for your personal safety are highlighted by a warning triangle, instructions for property damage alone are
without a warning triangle. Depending on the hazard level, the warnings are shown in decreasing order as follows.
If several hazard levels occur, the warning for the highest level is always used. If the warning triangle is used in a warning
against personal injury, a warning against damage to property may also be added to the same warning.
Qualified staff
The product/system associated with this documentation may only be handled by personnel qualified for the respective task
and in compliance with the associated documentation for the respective task, in particular the safety and warning
instructions contained therein. Due to their training and experience, qualified personnel are able to recognise risks and avoid
possible hazards when handling these products/systems.
Intended use of Kostad products
Note the following:
Brands All designations marked with ® are registered trademarks of Siemens AG. The other designations in this document may be
trademarks whose use by third parties for their own purposes may infringe the rights of the owner.
Disclaimer We have checked the contents of this publication for conformity with the hardware and software described. Nevertheless,
deviations cannot be ruled out, so that we cannot guarantee complete conformity. The information in this publication is
checked regularly and any necessary corrections are included in subsequent editions.
Kostad Steuerungsbau GmbH
Parkallee 20
2483 Ebreichsdorf
Austria
Copyright © Siemens AG 2018 - 2020. All
rights reserved.
DANGER
means that deathor serious bodily injury will occur if the appropriate precautions are not taken.
WARNING
means that death or serious bodily injury may occur if the appropriate precautions are not taken.
CAUTION
means that slight bodily injury may occur if the appropriate precautions are not taken.
ATTENTION
means that property damage can occur if the appropriate precautions are not taken.
WARNING
Siemens products may only be used for the applications specified in the catalogue and in the associated technical
documentation. If third-party products and components are used, they must be recommended or approved by Siemens.
Faultless and safe operation of the products requires proper transport, storage, assembly, installation, commissioning,
operation and maintenance. The permissible ambient conditions must be observed. The instructions in the relevant
documentation must be observed.

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Table of contents
1Introduction...........................................................................................................................................................7
1.1 About this guide................................................................................................................................7
1.2 Text features.....................................................................................................................................7
2Safety instructions .................................................................................................................................................9
2.1 Information for the person responsible for the installation.................................................................9
2.2 The five safety rules ..........................................................................................................................9
2.3 Safety instructions........................................................................................................................... 10
2.4 Handling electrostatically sensitive devices (ESD)............................................................................. 13
2.5 Conversions or alterations...............................................................................................................13
2.6 Risks in handling the charging station..............................................................................................13
2.7 Plant identification..........................................................................................................................14
2.8 Warning and information signs........................................................................................................ 14
2.9 Residual risks ..................................................................................................................................15
2.10 Notes on operating the charging cable/plug combination................................................................. 16
3Description .......................................................................................................................................................... 19
3.1 System description..........................................................................................................................19
3.2 Variants / options for the charging station.......................................................................................20
3.3 Charging outlets of the charging station ..........................................................................................28
3.4 Type plate.......................................................................................................................................30
4Deployment preparation...................................................................................................................................... 33
4.1 Storage...........................................................................................................................................33
4.2 Transport........................................................................................................................................ 33
4.2.1 Safety instructions...........................................................................................................................33
4.2.2 Transport with forklift truck ............................................................................................................ 34
4.2.3 Transport with crane.......................................................................................................................35
4.3 Set up............................................................................................................................................. 36
4.3.1 Installation site, positioning.............................................................................................................36
4.3.2 Heat dissipation ..............................................................................................................................37
4.3.3 Foundation ..................................................................................................................................... 37
4.3.4 Ram protection ............................................................................................................................... 40
5Assembly............................................................................................................................................................. 41
5.1 Assembly steps ............................................................................................................................... 41

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Table of contents
6Connect................................................................................................................................................................47
6.1 Power connection............................................................................................................................47
6.1.1 Safety instructions...........................................................................................................................47
6.1.2 Connecting the power supply...........................................................................................................48
6.1.3 Mains voltage and power supply......................................................................................................54
6.1.4 On-site equipotential bonding..........................................................................................................55
6.1.5 Testing the electrical system............................................................................................................55
6.2 Network connection........................................................................................................................56
6.2.1 Ethernet LAN connection.................................................................................................................56
6.2.2 Mobile phone connections (APN).....................................................................................................60
6.2.3 Network communication test...........................................................................................................62
7Commissioning.....................................................................................................................................................63
7.1
Switching the charging station on and off.........................................................................................63
7.2
Residual current and insulation monitoring ......................................................................................67
7.2.1
Fault-current circuit breaker ............................................................................................................67
7.2.2
Earth fault/insulation monitoring.....................................................................................................68
8
Operation
............................................................................................................................................ 73
8.1
Visualisation....................................................................................................................................73
8.2
User area.........................................................................................................................................73
8.2.1
Start image......................................................................................................................................73
8.2.2
Main view........................................................................................................................................74
8.2.2.1
Main view........................................................................................................................................74
8.2.2.2
Menu bar ........................................................................................................................................75
8.2.2.3
Charging point view.........................................................................................................................77
8.2.3
User functions.................................................................................................................................78
8.2.3.1
Start charging..................................................................................................................................78
8.2.3.2
End charging process.......................................................................................................................82
8.2.3.3
Terminating the charging process with a master card.......................................................................82
8.2.3.4
Authorisation procedure..................................................................................................................83
8.2.3.5
Charging point view (detailed view)..................................................................................................84
8.2.4
Change of the display language........................................................................................................94
8.2.5
Customisation of the visualisation....................................................................................................95
8.2.5.1
Wallpaper and screensaver..............................................................................................................96
8.2.5.2
Help pages.......................................................................................................................................98
8.3
Service area...................................................................................................................................100
8.3.1
Service menu.................................................................................................................................100
8.3.2
Display language in the service area...............................................................................................102
8.3.3
Basic menu....................................................................................................................................103
8.3.3.1
Basic menu....................................................................................................................................103
8.3.3.2
Causes of demolition .....................................................................................................................104
8.3.3.3
Configuration changes...................................................................................................................105
8.3.4
Service menu.................................................................................................................................106
8.3.4.1
Station configuration (S) ................................................................................................................106
8.3.4.2
RGB LED (S/O) ...............................................................................................................................107
8.3.4.3
Temperatures (S)...........................................................................................................................111
8.3.4.4
Operator settings (S/O)..................................................................................................................113
8.3.4.5
OCPP (S/O)....................................................................................................................................119

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Table of contents
8.3.4.6 Payment terminal (S/O)................................................................................................................. 128
8.3.4.7 Messages (S)................................................................................................................................. 135
8.3.4.8 Limitations (S)............................................................................................................................... 136
8.3.4.9 RFID Reader (S/O) ......................................................................................................................... 137
8.3.4.10 Performance Management (S/O)................................................................................................... 142
8.3.4.11 MaxChargingTime (S) .................................................................................................................... 148
8.3.4.12 Fan night mode (S) ........................................................................................................................ 149
8.3.4.13 Operating schedule (O).................................................................................................................. 151
8.3.4.14 Software information .................................................................................................................... 155
8.3.4.15 Calibrate (S/O) .............................................................................................................................. 156
8.3.4.16 Plaster picture (S/O)...................................................................................................................... 156
8.3.4.17 System restart (S/O)...................................................................................................................... 158
8.3.4.18 Configuration (S)........................................................................................................................... 158
8.3.4.19 User (S/O)..................................................................................................................................... 160
8.3.4.20 End Runtime (S) ............................................................................................................................ 161
8.3.4.21 Time setting (S/O) ......................................................................................................................... 164
8.3.4.22 PLC diagnosis (S) ........................................................................................................................... 166
8.3.4.23 Maintenance data (S) .................................................................................................................... 167
8.3.4.24 Ext. metering (S)............................................................................................................................ 168
8.3.4.25 Equipment conforming to calibration regulations (ERK) .................................................................. 169
8.3.4.26 Stop Causes (S/O).......................................................................................................................... 171
8.3.4.27 Web Management (S) ................................................................................................................... 172
8.3.4.28 Configuration Management (S)...................................................................................................... 173
8.3.4.29 Test functions (S)........................................................................................................................... 174
8.3.4.30 Simulation (S) ............................................................................................................................... 176
8.3.4.31 Loader Service Menu .................................................................................................................... 186
8.3.4.32 Energy measurement .................................................................................................................... 188
8.3.4.33 Diagnosis ...................................................................................................................................... 188
8.4 Alarm, error and system messages ................................................................................................ 190
8.4.1 Access with Sinema Remote and Smart Server............................................................................... 190
8.4.2 Charging point is not available....................................................................................................... 191
8.4.3 EMERGENCY STOP button..........................................................................................................................192
8.4.4 General error ................................................................................................................................ 194
8.4.5 Control cabinet door open............................................................................................................. 195
8.4.6 Behaviour of the charging station after power failure..................................................................... 196
8.4.6.1 Behaviour at idle ........................................................................................................................... 196
8.4.6.2 Behaviour during ongoing charging processes................................................................................ 196
8.4.7 Behaviour of the charging station after RCD failure (AC charging outlet side) .................................. 196
8.4.8 Troubleshooting and remedy......................................................................................................... 197
8.4.9 Error codes ................................................................................................................................... 198
9Maintenance ..................................................................................................................................................... 203
9.1 Safety instructions......................................................................................................................... 203
9.2 Maintenance and servicing work................................................................................................... 204
9.3 Checking and replacing the filter mats ........................................................................................... 205
9.4 Replacing the fan........................................................................................................................... 206
9.5 Replacing the fan cartridge of the SINAMICS DCP power modules.................................................. 207
9.6 Testing the charging cables and charging plugs.............................................................................. 209
9.7 Exchange of charging cable incl. charging plug................................................................................ 209

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Table of contents
9.8 Replacement of an AC socket (22kVA) ............................................................................................ 218
9.9 Testing the residual current circuit breaker.................................................................................... 219
9.10 Testing the cable cooling recooling unit ......................................................................................... 220
9.11 Cleaning........................................................................................................................................ 220
9.12 Notes on maintenance.................................................................................................................. 221
10 Spare parts......................................................................................................................................................... 223
10.1 Ordering information .................................................................................................................... 223
10.2 List of maintenance and repair parts.............................................................................................. 223
11 Disposal ............................................................................................................................................................. 229
11.1 Reference to chapter Safety instructions........................................................................................ 229
11.2 Temporary decommissioning......................................................................................................... 230
11.3 Final decommissioning .................................................................................................................. 231
11.3.1 Introduction.................................................................................................................................. 231
11.3.2 Country-specific legal regulations .................................................................................................. 231
11.3.3 Preparation for disassembling the charging station........................................................................ 232
11.3.4 Disassembly.................................................................................................................................. 233
11.3.5 Dispose of components................................................................................................................. 234
AService & Support .............................................................................................................................................. 237
A.1 Siemens Industry Online Support .................................................................................................. 237
BTechnical data and dimensions........................................................................................................................... 239
B.1 Technical data............................................................................................................................... 239
B.2 Dimensions................................................................................................................................... 242
CDocuments......................................................................................................................................................... 243
C.1 Kostad Control Engineering Ltd...................................................................................................... 243
C.2 List of abbreviations...................................................................................................................... 243
Index.................................................................................................................................................................. 247

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Introduction1
1.1 About this guide
These operating instructions describe the charging station and inform you about how to use it
- from delivery to disposal. Keep these operating instructions for future reference.
Read these operating instructions before handling the charging station and follow the instructions.
This will ensure hazard-free and fault-free operation as well as a long service life of the charging
station.
1.2 Text features
The warning concept is explained on the back of the inside title. Adhere to all safety-related
information in these instructions and on the product.
In addition, you will find the following text features in these instructions:
1. Instructions for action are presented as a numbered list. Keep to the order of the action steps.
•Enumerations use the list item.
- The dash indicates enumerations in the second level.
Note
A note gives you further information about the product, the handling of the product or the respective
documentation.

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Introduction
1.2 Text features

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Safety instructions 2
2.1 Information for the person responsible for the installation
When using the charging station outside the European Community, observe the country-specific
regulations. Follow the local and industry-specific safetyand installation regulations.
Those responsible for the installation must ensure the following:
•Planning and project work as well as all work on and with the machine is only carried out by
qualified personnel.
•The operating instructions are always available during all work.
•The technical data and the information on the permissible installation, connection, ambient
and operating conditions are consistently observed.
•The specific erection and safety regulations as well as the regulations for the use of
personal protective equipment are observed.
Note
Make use of the support and services of the responsible Customer Support ([e-mail]) for
planning, installation, commissioning and service tasks.
You will find safety instructions in the individual chapters of this document. For your own safety, for
the protection of other persons and to avoid damage to property, it is essential that you comply with
the safety instructions.
Observe the following safety instructions for all activities on and with the charging station.
2.2 The five safety rules
For your personal safety and to avoid damage to property, always observe the safety-relevant
instructions and the following five safety rules according to EN 50110-1 "Working in a de-energised
state" during all work. Apply the five safety rules in the stated order before starting work.
Five safety rules
1. Unlock.
Also switch the auxiliary circuits free, e.g. standstill heating.
2. Secure against being switched on again.
3. Determine the absence of voltage.
4. Earth and short-circuit.
5. Cover or fence off adjacent live parts.

Safety instructions
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2.3 Safety instructions
After completing the work, cancel the measures taken in the reverse order.
2.3 Safety instructions
Safety in the workplace depends on the attention, precaution and common sense of all persons who
install, operate and maintain the machine. In addition to observing the listed safety precautions,
caution should always be exercised in the vicinity of the machine. Always be aware of your safety.
To avoid accidents, also note the following:
•General safety regulations of the respective country of operation
•Specific regulations of the operator and the area of use
•Specific agreements made with the operator
•Separate safety instructions supplied with the machine
•Safety symbols and notices on the machine and its packaging
WARNING
Live parts
Charging stations have live parts.
Removal of covers, improper use of the charging station, incorrect operation or insufficient
maintenance can result in death, serious injury or property damage.
•
Always follow the "FiveSafety Rules" (page 9) when working on the charging station.
•
Only remove covers in accordance with the instructions in this operating manual.
•
Operate the charging station properly.
•
Maintain the charging station regularly and professionally according to the instructions in
the chapter "Maintenance" (page 203).
WARNING
Electric shock in case of damaged equipment
Improper handling can result in damage to equipment. If units are damaged, dangerous voltages
may be present on the housing or exposed components which, if touched, can cause serious injury
or death.
•
During transport, storage and operation, comply with the limit values specified in the technical
data.
•
Check the charging cables and charging plugs for tampering, damage and foreign
objects.
•
Do not use damaged equipment.