Schrack Technik i-CHARGE CION User manual

Operating Manual
Charging Station for Charging Battery Electric Vehicles (BEV)
i-CHARGE CION
Operating Manual V1.4

© Schrack Technik GmbH
2021 All rights reserved
We have verified that the content of this documentation matches the hardware and software described therein. Nevertheless, deviations,
remaining errors and omissions cannot be ruled out. Therefore, we expressly do not accept any liability for damage that may result
therefrom. However, the information in this publication is checked regularly and necessary corrections will be included in subsequent
versions.
We are grateful for any suggested improvements submitted.
Technical information subject to change.

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Content
1 Introduction..................................................................................................................................... 8
1.1 Preamble ................................................................................................................................. 8
1.2 Manufacturer contact details.................................................................................................. 8
1.3 Markings.................................................................................................................................. 9
1.4 Technical Data ....................................................................................................................... 10
1.4.1 General .......................................................................................................................... 10
1.4.2 Home ............................................................................................................................. 10
1.4.3 Semipublic ..................................................................................................................... 11
1.4.4 Online Master................................................................................................................ 11
1.4.5 Online Slave................................................................................................................... 11
1.4.6 RFID reader.................................................................................................................... 11
1.5 Warranty and liability............................................................................................................ 12
1.6 Content and scope of this documentation............................................................................ 13
1.7 Validity................................................................................................................................... 13
1.8 Recommendation.................................................................................................................. 13
2 Limits of use................................................................................................................................... 14
2.1 Intended use.......................................................................................................................... 14
2.2 Reasonably foreseeable misuse ............................................................................................ 14
2.3 Operating conditions............................................................................................................. 15
2.4 Target group and prior knowledge........................................................................................ 15
2.5 Principle................................................................................................................................. 16
3 Safety............................................................................................................................................. 17
3.1 Classification of document conventions ............................................................................... 17
3.1.1 Warnings and safety instructions.................................................................................. 17
3.1.2 Instructions.................................................................................................................... 18
3.1.3 Information.................................................................................................................... 18
3.2 Signal words and safety instructions used ............................................................................ 18
3.3 Warning, mandatory and prohibitory signs used.................................................................. 19
3.3.1 Warning signs ................................................................................................................ 19
3.3.2 Mandatory signs............................................................................................................ 19
3.3.3 Prohibitory signs............................................................................................................ 19
3.4 General safety instructions ................................................................................................... 20
3.5 General regulations............................................................................................................... 20
3.6 Warning, mandatory and prohibitory signs on the product ................................................. 21
3.7 Safety elements..................................................................................................................... 22

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4 Installation/ Initial operation ........................................................................................................ 23
4.1 Transport............................................................................................................................... 23
4.2 Installation conditions........................................................................................................... 23
4.3 Storage .................................................................................................................................. 23
4.4 Installation site ...................................................................................................................... 23
4.5 Mounting............................................................................................................................... 24
4.5.1 Scope of delivery ........................................................................................................... 25
4.5.2 Wall mounting and electrical connection ..................................................................... 26
4.6 Installation regulations.......................................................................................................... 40
4.7 Initial operation..................................................................................................................... 41
4.8 Operator handover................................................................................................................ 41
5 Operation ...................................................................................................................................... 42
5.1 Operating elements............................................................................................................... 42
5.1.1 Charging socket ............................................................................................................. 43
5.1.2 Charging cable ............................................................................................................... 44
5.2 Display elements –LED status display................................................................................... 45
5.2.1 CION Home (EMCIONxxx-)............................................................................................. 45
5.2.2 CION Semipublic & Public (EMCIONxxxO/R/S).............................................................. 48
6 Configuration................................................................................................................................. 55
6.1 Configuration of Charge Controller for Home and Semipublic models ................................ 55
6.1.1 12 V DC actuator (external activation).......................................................................... 56
6.1.2 Integration of photovoltaic & smart home systems ..................................................... 56
6.2 Configuration of Charge Controller for Public models.......................................................... 59
6.2.1 Load management Master/Slave .................................................................................. 60
7 Maintenance.................................................................................................................................. 61
7.1 Inspection.............................................................................................................................. 61
7.2 Cleaning................................................................................................................................. 62
7.3 Servicing ................................................................................................................................ 62
7.4 Spare and wear parts ............................................................................................................ 63
7.5 Repair .................................................................................................................................... 63
7.6 Periodic inspection................................................................................................................ 64
7.7 Shutdown .............................................................................................................................. 64
7.8 Dismantling............................................................................................................................ 64
7.9 Disposal ................................................................................................................................. 65
8 Recommended back-up fuse......................................................................................................... 66
9 Appendix........................................................................................................................................ 68

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9.1 Drawings - drill template....................................................................................................... 68
9.2 Spare and wear parts ............................................................................................................ 69
9.3 Unit table............................................................................................................................... 69
9.4 Packaging icons...................................................................................................................... 70
9.5 Notes ..................................................................................................................................... 71
Table of Figures
Figure 1 CE mark symbol ......................................................................................................................... 9
Figure 2 Positioning the drill template on the wall............................................................................... 26
Figure 3 Drilling the holes in the wall.................................................................................................... 27
Figure 4 Inserting the wall plugs ........................................................................................................... 28
Figure 5 Opening the cover................................................................................................................... 29
Figure 6 Removing the connection cable.............................................................................................. 30
Figure 7 and 8 Drilling the cable inlets from the rear I and from below II............................................ 31
Figure 9 and 10 Cable insertion from the rear I and from below II....................................................... 32
Figure 11 Mounting the wall box on the wall ....................................................................................... 33
Figure 12 Connecting the feed to the terminal block - 3-phase connection ........................................ 34
Figure 13 Connecting the feed to the terminal block - 1-phase connection ........................................ 35
Figure 14 Checking the correct feed line position - correct.................................................................. 36
Figure 15 Checking the correct feed line position - incorrect............................................................... 36
Figure 16 Checking the cable attachment............................................................................................. 37
Figure 17 Connecting the connection cable (RFID reader, LED board)................................................. 38
Figure 18 Mounting the cover............................................................................................................... 39
Figure 19 Charging socket ..................................................................................................................... 43
Figure 20 Charging cable ....................................................................................................................... 44
Figure 21 Home - Stand-by operation................................................................................................... 45
Figure 22 Home - Connecting the BEV .................................................................................................. 46
Figure 23 Home - Charging complete.................................................................................................... 46
Figure 24 Home - Charging error........................................................................................................... 47
Figure 25 Home - Charging paused ....................................................................................................... 47
Figure 26 Public - Station initialising ..................................................................................................... 48
Figure 27 Semipublic & Public - Ready.................................................................................................. 49
Figure 28 Semipublic & Public - Authentication.................................................................................... 50
Figure 29 Semipublic & Public - Charging in progress........................................................................... 51
Figure 30 Semipublic & Public - Charging complete/paused ................................................................ 51
Figure 31 Semipublic - Teach charge card............................................................................................. 52
Figure 32 Semipublic - Teach charge card completed........................................................................... 53
Figure 33 Semipublic & Public - Error message..................................................................................... 54
Figure 34 DIP switch Charge Controller Home & Semipublic................................................................ 55
Figure 35 Charge Controller schematic 0-10 V interface ...................................................................... 57
Figure 36 Charge Controller schematic Modbus RTU ........................................................................... 58
Figure 37 DIP switch Charge Controller Public...................................................................................... 59
Figure 38 Master/Slave wiring schematic ............................................................................................. 60
Figure 39 Back-up fuse schematic RCCB + MCB.................................................................................... 66
Figure 40 Back-up fuse schematic RCBO............................................................................................... 67
Figure 41 Drill template......................................................................................................................... 68

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Table of Tables
Table 1 Contact details............................................................................................................................ 8
Table 2 Markings ..................................................................................................................................... 9
Table 3 Technical data CION - General.................................................................................................. 10
Table 4 Technical data - CION Home..................................................................................................... 10
Table 5 Technical data - CION Semipublic............................................................................................. 11
Table 6 Technical data - CION Online, Master ...................................................................................... 11
Table 7 Technical data -CION Online, Slave........................................................................................... 11
Table 8 Technical data - RFID reader..................................................................................................... 11
Table 9 Operating conditions ................................................................................................................ 15
Table 10 Warning signs ......................................................................................................................... 19
Table 11 Mandatory signs ..................................................................................................................... 19
Table 12 Prohibitory signs..................................................................................................................... 19
Table 13 Pictograms on the product..................................................................................................... 21
Table 14 DIP switch settings Charge Controller Home & Semipublic ................................................... 55
Table 15 Modbus RTU register Charge Controller Home & Semipublic................................................ 59
Table 16 DIP switch settings Charge Controller Public.......................................................................... 60
Table 17 Spare and wear parts.............................................................................................................. 69
Table 18 Unit table................................................................................................................................ 69
Table 19 Packaging icons....................................................................................................................... 70

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Versions
Versions
Date
Description
1.0
23.04.2020
Operating Manual CION V1.0
1.1
19.05.2020
Extension of Configurations
1.2
05.08.2020
Extension of Modbus config.
Clarification 1~/3~ operation
1.3
22.09.2020
Extension of actuator, optional
ventilation requirement
1.4
28.01.2021
Correction Online CION
Documentation created by:
docu solutions Siegfried Winterheller
Unterer Bründlweg 15, 8054 Graz
[email protected]t
[phone]
Copyright©
The original documentation and this translation is protected by copyright. In case of discrepancies the
German original version shall take precedence. All rights, in particular the rights to copy, distribute and
translate, are reserved. No part of this manual may be reproduced in any form or stored, processed,
copied or distributed using electronic systems without written permission from Schrack Technik
GmbH. Violations may result in criminal prosecution.
© 2021 Schrack Technik GmbH

Operating Manual Introduction
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1 Introduction
With this charging station you have acquired a state-of-the-art product as regards safety for
operators and operating reliability. Nevertheless, this charging station may pose hazards if it
is misused or not used as intended (for details, see chapter 3), even though this documentation
points out hazards by means of safety instructions wherever applicable.
1.1 Preamble
The present documentation supports the safe working on and with the charging station. It
contains safety instructions which must be strictly observed!
All people working on and with the charging station, must have the documentation readily
available during work and observe the information and instructions relevant to them.
The documentation must always be provided complete and must be perfectly readable.
1.2 Manufacturer contact details
If the product shows malfunctions the cause of which you cannot remedy with the help of this
documentation, please contact Schrack Technik GmbH
.
Manufacturer
Schrack Technik GmbH
Adress
Seybelgasse 13, A - 1230 Vienna, Austria
Telephone
[phone]
Email
[email protected]om
Website
www.schrack.com
Table 1 Contact details

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1.3 Markings
This product is unequivocally marked by the content of the rating plate.
Example of a rating plate EMCION22PR:
Rating plate on inside –80 x 60 mm
Rating plate on outside –50 x 23 mm
Table 2 Markings
CE marking acc. To:
•Directive 2014/35/EU of the European Parliament and of the Council relating to the
making available on the market of electrical equipment designed for use within
certain voltage limits
•Directive 2014/30/EU of the European Parliament and of the Council relating to
electromagnetic compatibility
•Directive 2014/53/EU of the European Parliament and of the Council relating to the
making available on the market of radio equipment
Directive 2011/65/EU of the European Parliament and of the Council relating to the
restriction of the use of certain hazardous substances in electrical and electronic
equipment
The product is provided with the CE mark in accordance with the
requirements of the European Union for marking products.
The corresponding declaration of conformity is available from
Schrack Technik GmbH and can be downloaded from
www.schrack.at/emobility/.
Figure 1 CE mark symbol

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1.4 Technical Data
1.4.1 General
Order Number
EMCION11Cx
EMCION22Cx
EMCION22Px
Charging point
TYPE 2 cable 5 m
3.7 - 11 kW
TYPE 2 cable 5 m
3.7 - 22 kW
TYPE 2 socket
3.7 - 22 kW
Charging current
levels*
1~: 13 A; 16 A
3~: 13 A; 16 A
1~: 13 A; 16 A
3~: 13 A; 16 A; 20 A; 32 A
Supply*
1~/N/PE; 230 V; 16 A
3~/N/PE; 400 V; 16 A
1~/N/PE; 230 V; 16 A
3~/N/PE; 400 V; 32 A
Back-up fuse**
MCB 3-pole C 16 A*
RCCB type A 30 mA or
RCBO 3-pole C 16 A
type A 30 mA
MCB 3-pole C 32 A*
RCCB type A 30 mA or
RCBO 3-pole C 32 A type A 30 mA
Rated output**
11 kVA
22 kVA
Temperature range
-30 °C to 50 °C
-30 °C to 50 °C (up to 16 A)
-30 °C to 40 °C (up to 32 A)
Enclosure
materials
Polycarbonate (PC), front: light grey, rear: blue grey
Ratings
IK10; IP54
Supply
Max. clamping cross section 5x10 mm² (suitable for copper and
aluminium conductors)
Cable inlet
Included M20, M25 and M32 sealing glands (max. cross section
21 mm) for supply and control line from below
Included stepped gland max. cross section 21 mm for supply line
from the rear
Dimensions
H490 x W274 x D180 mm
‘At max. load depending on 1- or 3-phase power supply. Charging current/power can be
set on site.
‘‘ For 3-phase power supply line and at maximum charging current.
Table 3 Technical data CION - General
1.4.2 Home
Order Number
EMCION11C-
EMCION22C-
EMCION22P-
Weight
4.5 kg
5.7 kg
3.5 kg
Authentication
-
Payment
-
Load management
MODBUS RTU via RS485; 0-10 V interface; 12 V actuator
Safety element
Integrated 6 mA DC residual current detection
Table 4 Technical data - CION Home

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1.4.3 Semipublic
Order Number
EMCION11CR
EMCION22CR
EMCION22PR
Weight
4.5 kg
5.7 kg
3.5 kg
Authentication
Local RFID via RS232
Payment
-
Load management
MODBUS RTU via RS485; 0-10 V interface; 12 V actuator
Safety element
Integrated 6 mA DC residual current detection
Table 5 Technical data - CION Semipublic
1.4.4 Online Master
Order Number
EMCIONS1CO
EMCIONS2CO
EMCIONS2PO
Weight
4.8 kg
6 kg
3.8 kg
Authentication
RFID via RS232; QR code (by charging station operator/backend)
Payment
OCPP 1.5 via GSM/GPRS/3G
Load management
0-5 V interface; defined total power
Safety element
Integrated 6 mA DC residual current detection
Table 6 Technical data - CION Online, Master
1.4.5 Online Slave
Order Number
EMCIONS1CS
EMCIONS2CS
EMCIONS2PS
Weight
4.8 kg
6 kg
3.8 kg
Authentication
RFID via RS232; QR code (by charging station operator/backend)
Payment
OCPP 1.5 via RS485 on Master (EMCIONxxxO)
Load management
0-5 V interface; defined total power
Safety element
Integrated 6 mA DC residual current detection
Table 7 Technical data -CION Online, Slave
1.4.6 RFID reader
Order Number
EMCIONxxxR / EMCIONxxxO / EMCIONxxxS
Interfaces
RS232
Standard
ISO 14443 (A and B)
Table 8 Technical data - RFID reader
Further technical data are available in the respective data sheets and in the appendix to this
Operating Manual. The data sheets are available online for download at
www.schrack.at/emobility/.

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1.5 Warranty and liability
The warranty period of the charging station is 2 years and begins on the date of the initial
operation. This operating manual serves to ensure fault-free and safe use of the product;
compliance with its content is a prerequisite for the fulfilment of any warranty claims.
Excluded from the warranty are such defects that result from any arrangement and assembly
not effected by the seller, insufficient equipment, failure to observe the installation
requirements and conditions of use, excessive load on the components beyond the capacities
specified by the seller, negligent or incorrect handling and use of unsuitable operating
materials; this also applies to defects that are attributable to material provided by the buyer.
Wear parts as specified in appendix 9.2 are also excluded from the warranty.
The seller shall only be liable for damage outside the scope of application of the Product
Liability Act if intent or gross negligence can be proven against him, within the scope of the
statutory provisions.
Claims for damages expire in particular in the event of:
•Inappropriate use
•Modifications or additions, if this has not been agreed and approved in writing with
Schrack Technik GmbH
•Repairs carried out improperly
•Disasters, foreign body impact and force majeure
The seller is also not liable for damage caused by the actions of third parties, atmospheric
discharges, overvoltage and chemical influences. The warranty does not apply to the
replacement of parts that are subject to natural wear and tear.
In addition, warranty and compensation claims are exclusively subject to the General Terms
of Delivery issued by The Austrian Electrical and Electronics Industry Association.
They are published in German and can be downloaded at www.feei.at. We will provide you
with a copy on request. Deliveries are made under retention of title.

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1.6 Content and scope of this documentation
This documentation contains information that is relevant to ensure that working with the
product is as safe as possible. Observing the instructions in this document helps to avoid
hazards and prevents the product from sustaining damage. In addition to this operating
manual, is it mandatory to observe the regulations for the prevention of accidents and for
environmental protection applicable in the country and the location where the product is
installed.
1.7 Validity
This manual exclusively applies to the specific product with the designation i-CHARGE CION
from the company Schrack Technik GmbH. The product was placed on the market by Schrack
Technik GmbH.
1.8 Recommendation
We recommend to have repairs and maintenance made by either the company Schrack
Technik GmbH or by our certified i-CHARGE Partners, who are familiar with and trained in our
products and can therefore offer the best service to you.

Operating Manual Limits of use
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2 Limits of use
2.1 Intended use
This charging station is an electrical equipment designed for charging battery electric vehicles
(BEV). Plugs and sockets according to EN 62196 (alternating current charging, mode 3) are
used for charging BEVs. The charging station is suitable for use indoors and outdoors.
The product is built according to the state of the art and the generally accepted safety
regulations. Nevertheless, during its use hazards to life and limb of the operator or third parties
may occur or the product and other material assets may be negatively affected. Intended use
includes observing the operating manual and compliance with the maintenance requirements.
Only use the product if it is in technically perfect condition.
Use the product as intended and in a safety-conscious manner. Have malfunctions or damage
that could impair safety remedied immediately by Schrack Technik GmbH or a certified i-
CHARGE Partner.
2.2 Reasonably foreseeable misuse
The charging station must be mounted on a wall or on the Schrack mounting post EMCIONS1
/ EMCIONS2and installed stationary. It is not allowed to operate the charging stationin a loose
state (not steadily mounted) –because this would not comply with the ratings.
•Unmounting, tampering with or deactivating the safety devices is forbidden.
•No technical changes may be made to the product without consulting Schrack
Technik or a certified i-CHARGE Partner.
•Furthermore, liability and warranty claims are excluded in case of non-compliance
with the intended use.
•The product may only be operated under the operating conditions specified in the
documentation.

Operating Manual Limits of use
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2.3 Operating conditions
Ambient temperature:
-30 °C to +50 °C at 16 A
-30 °C to +40 °C at 32 A
Installation site:
Indoors and outdoors (garages, underground car parks,
exterior walls, car repair shops, parking spaces on mounting
poles)
The wall must be able to support the device (for details, see
chapter 4.5)
Relative humidity:
5 to 95%
Use:
Possible daily if required
Table 9 Operating conditions
To ensure colour fastness, it is recommended to protect the charging station from direct UV
and sunlight. In extreme cases such exposure can lead to an increase in temperature inside
the station, which results in a power reduction or ultimately in an interruption of the charging
process.
If the charging station is positioned at locations fully exposed to the elements, very low
temperatures in combination with snow and ice may cause ice to accumulate on the
EMCIONxxCx with the charging cable in parking position. In that case, please put the
protective cap over the charging plug and roll up the charging cable over the top of the station
as described instead of putting it in the parking position.
2.4 Target group and prior knowledge
This documentation is addressed to qualified personnel for installation and initial operation as
well as to the user (layperson) for operation and maintenance of the product.
User (layperson)
Unattended operation of the product by laypersons is only allowed if they
•have read and understood this Operating and Maintenance Manual,
•have read and understood all the safety instructions.
Qualified personnel (electrical engineering specialist)
Only qualified personnel is allowed to perform initial operation, inspection and configuration
work. The qualified personnel must have read and understood this Operating and Maintenance
Manual. We recommend a corresponding certification as i-CHARGE Partner from Schrack
Technik GmbH.

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Qualified personnel (certified i-CHARGE Partners)
Only certified i-CHARGE Partners are allowed to perform initial operation, service, repair,
overhaul, inspection, configuration, andmaintenance work. The qualified personnel must have
read and understood this Operating and Maintenance Manual.
2.5 Principle
The product conforms with the state of the art andthe applicable safety and health regulations.
Nevertheless, the following dangers can be caused by incorrect operation or misuse:
•Hazards to life and limb of the user or third parties
•Perils to the product and other material assets of the operator
•Risks for the efficient use of the product

Operating Manual Safety
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3 Safety
This documentation is designed according to the applicable EU regulations and contains safety
instructions. The operator of the product must be handed over the necessary safety-relevant
information and read the documentation. Each individual is responsible for following the safety
instructions.
This chapter contains a general introduction to the safety instructions and the description of
the warnings and safety instructions depicted on the safety markings attached to the product.
Here you also find important notes on accident prevention.
3.1 Classification of document conventions
This document contains the following types of instructions:
•Warnings and safety instructions
•Instructions
•Information
3.1.1 Warnings and safety instructions
This document contains safety instructions which you have to comply with for your own safety
and to avoid damage to property. Warnings and safety instructions inform the user of hazards
which may result in light, severe physical injury or even death, or cause considerable damage
to property if the corresponding instructions are not followed.
In each chapter these warnings indicate the corresponding hazards. The structure of warnings
and safety instructions is identical. Safety instructions and warnings are highlighted by a
warning triangle icon; they must be strictly observed.

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3.1.2 Instructions
Instructions contain important information about a product, the handling of the product, or that
part of the documentation to whichthey draw attention. Thefailure to observe such information
can have disadvantageous effects which, however, only exceptionally and in rare cases can
lead to hazards for people or the product. In all cases instructions must always be carefully
read and observed in order to ensure correct operation and functioning.
3.1.3 Information
Information refers to additional comments or hints on a section of this manual or about the
product, the handling of the product, or that part of the documentation to which they draw
attention. They should be observed in order to obtain a potential benefit. All Information
sections should be carefully read and observed in the interest of optimal use and operation of
the product.
3.2 Signal words and safety instructions used
DANGER
Imminent danger.
Severe and permanent injury or death.
WARNING
Potentially dangerous situation.
Severe injury or death.
CAUTION
Potentially dangerous situation.
Light injuries or damage to the product.
INSTRUCTION
Potentially harmful situation.
Damage to the product or to its surroundings.
INFORMATION
Indicates usage tips and other highly helpful details of information
before the individual steps.

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3.3 Warning, mandatory and prohibitory signs used
3.3.1 Warning signs
Pictogram
Meaning
Designation
General warning sign
W001
Electrical voltage warning
W012
Table 10 Warning signs
3.3.2 Mandatory signs
Pictogram
Meaning
Designation
General mandatory sign
M001
Mind the manual
M002
Table 11 Mandatory signs
3.3.3 Prohibitory signs
Pictogram
Meaning
Designation
General prohibitory sign
P001
Do not lean
P041
Table 12 Prohibitory signs

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3.4 General safety instructions
Even though maximum care has been taken in the design and construction of the product and
all safety-relevant circumstances have been considered, residual hazardsmay still exist, which
have been evaluated by means of a risk assessment.
The following safety guidelines must be observed during all work on the charging
station:
•Disconnect
•Secure against reconnection
•Earth and short circuit
•Secure or insulate surrounding, live parts
Some BEVs require external ventilation, because when carried out indoors the charging
process may lead to noxious or explosive gases being generated. This option is available for
the i-CHARGE CION, please contact us for ordering.
3.5 General regulations
In general, the following safety regulations and obligations apply when handling the product:
•The product may only be operated in perfect condition.
•It is prohibited to remove, modify, bridge or bypass any protective, safety or
monitoring equipment.
•It is prohibited to reconfigure or modify the product.
•Faults or damage must be reported to the manufacturer immediately. They must be
remedied immediately with original spare parts.
•For any activity other than the intended use in the proximity of the product, it must
be disconnected from the power supply and secured against reconnection.
•The safety instructions and operating instructions from the documentation of the
components used must be observed in all cases.
•All protective, safety and monitoring equipment must be inspected and serviced
regularly by the operator.
•The maintenance work can be requested from Schrack Technik GmbH and must be
carried out by them or a certified i-CHARGE Partner.
•After maintenance or repair, the product may only be put into operation with all
protective devices installed.
•The national safety and accident prevention regulations apply to the operation of
the product.