Mainpine EPC User manual

EPC CHARGING CONTROLLER
OPERATING INSTRUCTIONS

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TABLE OF CONTENTS
CHAPTER 1 INTRODUCTION
1.1 ABOUT THIS DOCUMENTATION ........................................................3
1.2 Recycling and Disposal ........................................................................3
CHAPTER 2 SAFETY INSTRUCTIONS
2.1 CAUTIONS & DANGERS ..................................................................4
2.2 Fuses ......................................................................................4
2.3 Repairs .....................................................................................4
CHAPTER 3 DESCRIPTION
3.1 EPC FEATURES ............................................................................5
3.2 Application Example ..........................................................................6
3.3 Function Description ........................................................................6 - 7
3.4 LED Display & Troubleshooting .................................................................8
CHAPTER 4 MOUNTING
4.1 MOUNTING ONTO STANDARD RAIL ...................................................9
CHAPTER 5 CONNECTION
5.1 CONNECTING TERMINALS & TERMINAL ASSIGNMENT ......................... 10 - 12
5.2 230 V AC Power Supply .......................................................................13
5.3 Functional Grounding ........................................................................14
5.4 Relay Outputs ..............................................................................14
CHAPTER 6 SERVICE & MAINTENANCE
6.1 REPLACING THE DEVICE ...............................................................15
6.2 Cleaning ...................................................................................15
CHAPTER 7 DIMENSIONAL DRAWINGS
7.1 DIMENSIONAL DRAWINGS .............................................................16

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CHAPTER 1 INTRODUCTION
1.1 ABOUT THIS DOCUMENTATION ........................................................3
1.2 Recycling and Disposal ........................................................................3
CHAPTER 2 SAFETY INSTRUCTIONS
2.1 CAUTIONS & DANGERS ..................................................................4
2.2 Fuses ......................................................................................4
2.3 Repairs .....................................................................................4
CHAPTER 3 DESCRIPTION
3.1 EPC FEATURES ............................................................................5
3.2 Application Example ..........................................................................6
3.3 Function Description ........................................................................6 - 7
3.4 LED Display & Troubleshooting .................................................................8
CHAPTER 4 MOUNTING
4.1 MOUNTING ONTO STANDARD RAIL ...................................................9
CHAPTER 5 CONNECTION
5.1 CONNECTING TERMINALS & TERMINAL ASSIGNMENT ......................... 10 - 12
5.2 230 V AC Power Supply .......................................................................13
5.3 Functional Grounding ........................................................................14
5.4 Relay Outputs ..............................................................................14
CHAPTER 6 SERVICE & MAINTENANCE
6.1 REPLACING THE DEVICE ...............................................................15
6.2 Cleaning ...................................................................................15
CHAPTER 7 DIMENSIONAL DRAWINGS
7.1 DIMENSIONAL DRAWINGS .............................................................16
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1.1 ABOUT THIS DOCUMENTATION
PURPOSE OF THIS DOCUMENTATION
ese Operating Instructions contain all the information you need for commissioning and using the Mainpine EPC charging controller.
ey are intended for use by electrically skilled persons who commission the device.
SCOPE OF VALIDITY OF THIS DOCUMENTATION
is documentation is valid for all components of the Mainpine EPC charging controller specied in these Operating Instructions and
describes the delivery state as of March 2014.
THIS PRODUCT IS BASED ON THE IEC 61851 AND SAE J1772 INTERNATIONAL STANDARDS
TRADEMARKS
Mainpine EPC is a registered trademark of Mainpine, Inc.
1.2 RECYCLING AND DISPOSAL
e Mainpine EPC charging controller is ecologically compatible, and thus suitable for recycling. For environmentally compliant recycling
and disposal of your electronic waste, please contact a company certied for the disposal of such waste.
INTRODUCTION

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2.1 CAUTIONS & DANGERS
CAUTION: PLEASE OBSERVE THE SAFETY INSTRUCTIONS AND LEGAL NOTES
Installation requirements vary by country, state, and jurisdiction. It is the responsibility of the installer to ensure that the legal
installation requirements are met.
DANGER: VOLTAGE HAZARDS
Contact with live components can result in serious injuries. Disconnect the system and all devices from the power supply before
starting work.
2.2 FUSES
WARNING: UNDESIRABLE HEAT GENERATION OR FIRE DUE TO INADEQUATE
FUSING.
e internal fuses are designed only to protect the device itself. e system installer and plant operator are responsible for the
necessary line protection.
e relay outputs are not fused within the device. Without appropriate protection of the relay outputs, overloading can cause
undesirable heat generation or even re. e relay outputs are to be fused externally by the plant constructor.
2.3 REPAIRS
Repairs are not permitted. Defective devices must be disposed of in compliance with environmental requirements.
WARNING: DANGERS ASSOCIATED WITH UNAUTHORIZED OPENING OF THE
DEVICE
Unauthorized opening of the device might place the user in danger or result in substantial damage to property.
CAUTION: INVALIDATION OF THE MANUFACTURER’S WARRANTY DUE TO
UNAUTHORIZED ALTERATIONS TO THE DEVICE
Alterations to the devices are not permitted. Failure to observe this requirement shall constitute a revocation of the manufacturer’s
warranty.
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SAFETY INSTRUCTIONS

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3.1 EPC FEATURES
e Mainpine EPC charging controller is a product which is intended for use in charging stations for electric vehicles.
EPC CHARGING CONTROLLER FEATURES
DEVICE VERSIONS • Mainpine EPC charging controllers have
part numbers in this format:
EPC_(1)_V(2)_(3)A_(4).
• (1) is either “T”, for tethered versions, or
“F”, for free cable versions.
• (2) indicates the hardware revision, e.g.
“21” or “23”
• (3) indicates the maximum charging
capacity, 16, 30, 32, 40, 50, 60, or 63.
• (4) indicates the rmware revision
AREAS OF
APPLICATION & USE
• Controlling the charging procedure of
electric vehicles
• For communication with the electric vehicle
according to IEC 61851 or SAE J1772
MOUNTING Mounting onto standard rail according to
DIN EN 60715
CONNECTION
ELEMENTS
• Relay contacts for switching the load
contactor, interlock, signaling contact (de-
pending on model)
• Operating voltage input
• Vehicle interface
LED Display of the operating state
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DESCRIPTION

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3.2 APPLICATION EXAMPLE
e following shows a schematic application example of an electric vehicle charging post with Mainpine components. For example, feeder
option A has a circuit breaker and an Insta contactor. Feeder option B has a circuit breaker and a SIRIUS power contactor.
3.3 FUNCTION DESCRIPTION
SEQUENCE OF CHARGING PROCESS
1. INITIALIZATION
After the operating voltage is applied, the module carries out initializations and function tests indicated by an LED ashing
sequence (which begins and ends with a two-second white indication) and then waits for vehicle connection.
2. CHARGING PROCESS
e module waits for a charging cable or vehicle to be connected (status A) and continually blinks the blue LED. If an approved
connecting cable has been connected (see Proximity) and status B is indicated by the vehicle, the module changes the LED to be
steady-blue and activates the interlock.
After interlocking, the charging enable P1/P2, P3/P4 or P4/P5 is activated (see Proximity) if the vehicle is signaling status C. e
charging process is activated, and the LED is changed to steady-green. If status D is indicated (ventilation required) then charging
and interlock are deactivated as the EPC does not provide a fan-enable mechanism, and the LED is changed to steady-red.
In the fault condition the charge enable P1/P2, P3/P4, or P5/P6 and the interlock are deactivated and the LED is changed to
continually blink red.
DESCRIPTION
Option
B
Option
A
Digital
E Meter
Ground
Fault
Operated
Circuit
Interrupter
Circuit
Breaker
Miniature
Circuit
Breaker
Insta
Contactor
SIRIUS
Power
Contactor
Socket Outlet
for Charging
Socket Outlet
for Charging
Mainpine
EPC Charging
Controller
Mainpine
EPC Charging
Controller
Surge
Arrester
Type 2
Ground
Fault
Operated
Circuit
Interrupter
Surge
Arrester
Type 2
Digital
E Meter

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3. STATUSES OF THE CHARGING VEHICLE
STATUS A: Vehicle is not connected
STATUS B: Vehicle is connected/not ready to receive energy
STATUS C: Vehicle is connected/ready to receive energy/no ventilation of the charging area is required in buildings
STATUS D: Vehicle is connected/ready to receive energy/ventilation of the charging area is required in buildings
STATUS E: Short-circuit/power supply disconnected from electric vehicle/electricity is not available/other power supply problem
STATUS F: Power supply is not available/other power supply problem
VENTILATION REQUIREMENT
WARNING: SUFFOCATION HAZARD WHEN CHARGING INDOORS
Without ventilation, a danger of suocation can arise due to gas build-up with some battery types when charging indoors. If the
charging process takes place indoors, forced-air ventilation should be installed. e Mainpine EPC charging controller does not mon-
itor the functionality of the forced-air ventilation.
PILOT CIRCUIT
e pilot circuit is used for the bi-directional exchange of information between the charging station and the vehicle. Via this signal, the
charging station indicates to the vehicle the maximum permitted charging current which the vehicle can call up. e operational read-
iness of the charging station is also indicated. Via this signal, the vehicle indicates to the charging station its current state of charging
readiness.
WARNING
Via the pilot signal, the EPC module species the maximum charging current that can be called up by the vehicle. is specied
current must be consistent with the line protection congured for the charging device and the rest of the plant conguration. Failure
to observe this notice can result in injury to persons or property damage.
PROXIMITY
With free cable installations the charging device detects the maximum current carrying capacity of the connected charging cable via the
proximity signal. e activated charging output coded in the pilot signal is no greater than the current carrying capacity of the charging
cable.
To ensure that the charging current does not exceed the rated capacity of the AC main power supply, there are dierent product variants
which each provide dierent maximum charging current presets (16A, 32A, and 63A - free cable; 16A, 30A, 40A, 50A, and 60A - tethered).
e product version that is used must be designed corresponding to the installed line protection of the charging station.
e 32A and 63A versions of the free cable Mainpine EPC charging controller are capable of generating dierent enabling signals depend-
ing on the current carrying capacity that is detected. For charging cables that have a current carrying capacity of 16A according to IEC
61851, relay P1/P2 is activated. e charging circuit that is activated by this must be designed with a suitable line protection for 16A.
For charging cables that have a current carrying capacity of 32A according to IEC 61851, relay P3/P4 is activated. e charging circuit
that is activated by this must be designed with a suitable line protection for 32A. For charging cables that have a current carrying capac-
ity of 63A according to IEC 61851, relay P5/P6 is activated. e charging circuit that is activated by this must be designed with a suitable
line protection for 63A.
DESCRIPTION

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INPUT CURRENT RESISTANCE INFORMATION
e Input Current (IC) resistance restricts the current maximum advertised by the EPC. e IC values are as described below:
MAX no resistor (open, no resistor, IC not connected) MIN no resistor (no resistor, IC connected to ground)
80A 9090 Ω resistor 59A 2210 Ω resistor 39A 959 Ω resistor 19A 412 Ω resistor
79A 8060 Ω resistor 58A 2100 Ω resistor 38A 931 Ω resistor 18A 392 Ω resistor
78A 7320 Ω resistor 57A 2050 Ω resistor 37A 887 Ω resistor 17A 374 Ω resistor
77A 6650 Ω resistor 56A 1960 Ω resistor 36A 845 Ω resistor 16A 348 Ω resistor
76A 6190 Ω resistor 55A 1870 Ω resistor 35A 825 Ω resistor 15A 332 Ω resistor
75A 5620 Ω resistor 54A 1780 Ω resistor 34A 787 Ω resistor 14A 316 Ω resistor
74A 5230 Ω resistor 53A 1690 Ω resistor 33A 750 Ω resistor 13A 301 Ω resistor
73A 4870 Ω resistor 52A 1620 Ω resistor 32A 732 Ω resistor 12A 280 Ω resistor
72A 4530 Ω resistor 51A 1580 Ω resistor 31A 698 Ω resistor 11A 267 Ω resistor
71A 4220 Ω resistor 50A 1500 Ω resistor 30A 665 Ω resistor 10A 249 Ω resistor
70A 4020 Ω resistor 49A 1430 Ω resistor 29A 634 Ω resistor 9A 237 Ω resistor
69A 3740 Ω resistor 48A 1370 Ω resistor 28A 619 Ω resistor 8A 221 Ω resistor
68A 3570 Ω resistor 47A 1330 Ω resistor 27A 590 Ω resistor 7A 205 Ω resistor
67A 3320 Ω resistor 46A 1270 Ω resistor 26A 562 Ω resistor 6A 191 Ω resistor
66A 3160 Ω resistor 45A 1210 Ω resistor 25A 536 Ω resistor
65A 3010 Ω resistor 44A 1180 Ω resistor 24A 511 Ω resistor
64A 2870 Ω resistor 43A 1130 Ω resistor 23A 491 Ω resistor
63A 2670 Ω resistor 42A 1070 Ω resistor 22A 475 Ω resistor
62A 2550 Ω resistor 41A 1050 Ω resistor 21A 453 Ω resistor
61A 2430 Ω resistor 40A 1000 Ω resistor 20A 432 Ω resistor
60A 2320 Ω resistor
Input resistance less than 100-Ω, MIN, will cause the EPC to reduce the advertised current capacity to 7A for ve seconds after which
charging and the interlock will be disabled and the EPC will enter into a forced Status A until input current resistance is increased.
3.4 LED DISPLAY & TROUBLESHOOTING
LED DISPLAY
e EPC has a 3-color LED for displaying operating states and fault conditions. e LED can be lit in blue, green, or red. e meaning of
the individual displays is shown in the following tables:
OPERATING STATES:
LED DESCRIPTION OF OPERATING STATE
COLOR STATUS
NOT LIT NOT LIT Device is not active, switched o
• No power supply
• Device defective
BLUE FLASHING (1 HZ) Device is waiting to be connected to an electric vehicle (Status A)
BLUE STEADY Electric vehicle connected, electric vehicle not ready for charging (Status B)
GREEN STEADY Charging process active (Status C)
RED STEADY Electric vehicle requires ventilation, charging deactivated (Status D)
RED FLASHING (1 HZ) Communication fault detected, charging deactivated (Status F)
DESCRIPTION

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4.1 MOUNTING ONTO STANDARD RAIL
1. Clip the device (a) vertically onto the horizontal DIN rail (b).
2. Swing the device downward until the unlocking slider on the DIN rail clicks into place.
Figure: Mounting onto standard rail
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MOUNTING
(a)
(b)
1. 2.

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Depending on the device version the Mainpine EPC charging controller is connected to the EVSE in the following methods:
WARNING: UNDESIRABLE HEAT GENERATION OR FIRE DUE TO INADEQUATE
FUSING
e internal fuses are designed only to protect the device itself. e system installer and plant operator are responsible for the
necessary line protection.
e relay outputs are not fused within the device. Without appropriate protection of the relay outputs, overloading can cause
undesirable heat generation or even re. e relay outputs are to be fused externally by the plant constructor.
WARNING: VIA THE PILOT SIGNAL, THE MAINPINE EPC CHARGING CONTROLLER
SPECIFIES THE MAXIMUM CHARGING CURRENT THAT CAN BE CALLED UP BY THE
VEHICLE. is specied current must be consistent with the line protection congured for the charging device and the rest of
the plant conguration. Failure to observe this notice can result in injury to persons or property damage.
NOTICE
Connect the terminal (L/N) with the main last.
5.1 CONNECTING TERMINALS & TERMINAL ASSIGNMENT
TETHERED VERSION
“Tethered” means that the charging cable is permanently connected to the
EVSE.
P3-P6 are not present and relay 1 will energize for all charging currents. us,
the RCBO should be rated at the maximum current conguration of the EPC.
5
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CONNECTION