ccl-cp1e/b electric vehicle charging system in mode3 system
Contents
1. 9 4 4 ELECTRICAL INSTALLATION GENERAL CONSIDERATIONS cececcecececececcecececceacececcecsacecsacecsacecsacaceceeceueecs 10 5 USER GUIDE c X 11 5 1 NORMAL CHARGE EN E REEF r an EEU iia 11 5 1 1 Charge operation for Models with RFID reader and display CCL CP1E 11 Id SNO sd 13 5 1 3 End of charge cycle Normal end 13 5144 ENO OP CVGIGe e de CNG alaba 13 5 1 5 End of charge cycle missing charge end VV 14 5 2 RETRIEVE CREDIT OPERATIVE 5 1 ode re SUE OM Rae o E UU Need FE ROPl RU DEREN S tousse 14 5 2 1 Previous cycle interrupted card 14 5 3 MISSING CREDIT OPERATIVE icis oreste ka ica 15 SAn OS VE ERE 15 532 Display IG COONS 15 5 4 CHARGE OPERATION FOR MODEL WITHOUT RFID READER CCL CP1EB 15 6 NR 16 6 1 GENERAL DESCRIPTION MEER 16 6 2 DISASSEMBLY 17 6 3 ASS EVEN 18 6 4 PREVENTIVE MAINTENANCE2. essere esses esee 19 AE aa ae ao nn a oo ne ea da D ee qi ee 19 D MED PU Tee II II ee IA 19 6 5 CORRECTIVE MAINTENANCE oscura aaa SE ERere 20 6 5 1 Problems Causes 0 5 20 6 6 SPARED PARTS AND RECOMMENDED TOOLS ccececcecccccccceccsceccececccceacececcsceacecenceceaeecenceeeeseeeceeeceaeecs 21 6 7 AUTO DIAGNOSTIC DISPLAY CODE 22 6 8 ade M I cM 23 6 9 CONNECTION CONFIGURATION cia 25 7 TECHNICAL DATA c REN 27 8 APPENDIX 28 8 1 RECOMMENDED SECTION CABLE een ehe Ule A 28 XM 2558 ta ad io ha de 29 circontrol circontrol com C CIRCONTROL 1 OVERVIEW This user manual provides basic information about the electric vehicle charging unit the CCL CP1E B MOD3 according to EN 61851 1 Important instructions will be shown inside a box In some cases these will include special symbols Their meaning is explained next IMPORTANT INSTRUCTION WARNING DANGER ELECTRICAL RISK circontrol circontrol com C CIRCONTROL 2 SYSTEM DESCRIPTION The CCL CP1E B MOD3 charge units provide to electric vehicles a plug base according to EN 61851 1 Comparing with a simple plug CCL CP1E B MOD3 offers the following
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4. d a pa aos Lites ERHI ATr 4 24 circontrol circontrol com X CIRCONTROL 6 9 Connection configuration 1 Connect the input connection in monophasic or Threefasic configuration to contactor please be careful with phases L1 L2 L3 neutral as show the figure PHASES L1 L2 L3 NEUTRAL Figure 1 Threephase connection detail for CCL CP1EB MOD3 25 circontrol circontrol com 6 CIRCONTROL X2 MODE3 cards for MODE3 Topographic distribution LIRCARLIFE Xe 2 dp p Y Cp p 4p 0 PT TT T 0 0 0 0 0 0 Oo CIRCARLIFE EXPANSION gt lt Pu JUMPER UN CHANNELS JUMPER CCP 26 circontrol circontrol com AS CIRCONTROL 7 TECHNICAL DATA Rate input frequency Output Voltage Power meter RFID Reader Range Temperature Protection Envelope Input Voltage Maximun current Maximun consumption Mode3 connector Dimensions Weight circontrol 50 60 Hz Input voltage Internal meter ISO 14443A 10 60 C IP65 ABS 230V 400Vc a L N PE 10 96 32A 7 2kW Type 2 320mm 225mm 125mm 3Kg 27 circontrol com AS CIRCONTROL 8 APPENDIX 8 1 Recommended section cable Tabla 1 intensidades admisibles A al aire 40 C N de conductores con carga y naturaleza del aislamiento Conductores aislados en tubos empotrados en paredes aislantes Cables multiconductores en tubos empotrados en pared
5. Safe collection of energy for the installations operator Prevents fraud and misuse Reliable measurement system for the user since only the energy consumed is paid with an accurate reading of the energy consumed Protects end user against electrical risks Current is only present in a non interrupted charging cycle The system is not powered during all other cycles Current theft prevention function The operation is interrupted if the socked is removed during the charging process so that no more energy will be supplied to the base until the user is identified again Ensure the power supply is stopped before the physical disconnection of the connector Intelligent charging process off peak hours distribution of power available etc when complemented with the PC and in hourly discrimination periods Let not exceed the maximum permissible current of the cable Insurance for the car does not have an overload by recognizing of type of car that is connected MODE3 Dosing of the power available through a Duty Cycle Allowing a power control that recharge point can supply depending of the contracted power line MODES Reports the need for vehicle ventilation Allows determining the battery type of the car connected to the charging point and depending on this and the location of the site knowing the type of load acceptable by the vehicle MODES The system is complemented with Pre paid cards Available without cr
6. charging The speed of the rotation indicates the amount of load En Socket 2 O flashing indicates the charging unit has reached the preset time allowed for a Socket 2 A segment fixed in one position indicates there is no load When the segment is rotating it indicates charging The speed of the rotation indicates the amount of load The information that appears briefly in the card reader display shows the firmware version number i e 29 is version 2 9 Errors E1 E2 E4 have automatic recovery circontrol circontrol com 22 CIRCONTROL 6 8 Electrical wiring X2 Card Topographic distribution TOROIDAL CIRCARLIFE X2 MODULO DE ID 0 1 toma JUMPER CONFIGURACI N 122 tomas LED 1 ELECTRO LED LED DISPLAY O pilona 1 caja mural Ossin det proximidad 1 con detector Reset Par metros de comunicaci n Solo tras PowerUp Rs 485 twisted cable connection Terminal A brown Terminal B white Rs 485 TACHNICAL CHARACTERISTICS 5 600bps Default address 98 Default n of nodes Stop bit The number of nodes must be changed when it is integrated into a network by factory default is set at 98 the same goes for the direction of the Rs 485 23 circontrol circontrol com CIRCONTROL m 5 ES a 29 3 E 3 a ri A EE Pall m ct m a a E T T gt m r A un Im uns uH 2
7. CCL CP1E B ELECTRIC VEHICLE CHARGING SYSTEM IN MODE3 SYSTEM INSTALLATION AND USER MANUAL C CIRCONTROL CCL CP1E B MODE 3 This document is copyrighted 2010 2012 by Circontrol S A All rights are reserved Circontrol S A reserves the right to make improvements to the products described in this manual at any time without notice No part of this manual may be reproduced copied translated or transmitted in any form or by any means without the prior written permission of the original manufacturer Information provided in this manual is intended to be accurate and reliable However the original manufacturer assumes no responsibility for its use or for any infringements upon the rights of third parties that may result from its use All other product names or trademarks are properties of their respective owners V1 0 Edition JAN 2012 circontrol circontrol com AS CIRCONTROL CONTENTS INSTALLATION AND USER MANUAL cccccccccccccccccssccccccccsccsscosccssscsceccescocscosccsscssceccessoeccececssscseescersoes 1 1 OVERVIEW fe 4 2 SYSIEM DESCRIPTIONS 5 3 SAFETY INFORMATION iaa dai aiii 7 4 INSTALLATION sind ini diia di 8 4 1 PREVIOUS VERIFICATION cia 8 4 2 ANCHORING AND DIMENSIONS E pex DP Cv URN LUE N ES FP eR UNE DP 8 4 3 DIMENSIONS FOR CCL CP1E B
8. DISCONNECTION PROCESS Press the test button This test will show if the RCCB works correctly sensibility ls recommended to do in each intervention lf the RCCB has not jumped stop until the fault has been repaired by trained personnel Remember that the test button does not work if the residual circuit breaker is not powered Remember that the RCCB input terminals can be powered so it has to be careful to avoid manipulation closer it Do not do any operation if there are faulty cables insulation damage or vulnerability of any party liable to be powered 4 Disconnect the ground cable 17 circontrol circontrol com C CIRCONTROL 6 3 Assembling 1 Carry out the same steps in reverse order of removal 2 DO NOT FORGET THE GROUND CABLE RECONNECTION 3 To proceed to testing RCCB should be reconnected again 4 ATTENTION WITH THE RCCB CONNECTION PROCESS If the power supply was cut upstream supply the devices to test the If it is not possible to supply it just raise the handle to rearm the RCCB If long time passed between the disconnection operations RCCB should do the sensitivity test again as indicated in the previous section Proceed to press the test button If keeps not running treat the incident as a failure with the protocol established by those 5 Replace the lid and set it correctly 18 circontrol circontrol com 6 4 Preventive maintenance CIRCONTROL The recommended preventiv
9. charged if these systems are not installed This unit has been designed for outdoor use It has an IP65 protection degree in accordance with ANSI IEC 60529 2004 circontrol circontrol com X CIRCONTROL 3 SAFETY INFORMATION Do not use connection cables that are not in perfect working order Do not use the CCL CP1E B MOD3for other uses that have not been specified in its design i e for any application that is unrelated to charging electric vehicles Do not modify the CCL CP1E B MOD3 unit In case the unit is modified the warranty will be void and CIRCONTROL shall not be liable for any future malfunction Strictly follow the current safety regulations Do not repair or install elements while the unit is powered Only authorised and trained personnel can access the elements powered with voltages inside the unit Check the operation of the earth leakage relay periodically at least once a month and always after maintenance operations The installation must be checked once a year by qualified personnel Any unit with defects or faults that could represent a risk to the user must be removed from service broken plugs lids that do not close etc Do not use spare parts that are not original of CIRCONTROL circontrol circontrol com X CIRCONTROL 4 INSTALLATION 4 1 Previous verification e Make sure that the materials have not been damaged during transport e Make sure that the voltage used on the board
10. ct other side to Electrical Vehicle EA CIRCONTROL 1 Unit will start with safety communications between car and unit 2 CHARGE indicator lights charge starts Stop charge mode unplugging Type 2 connector from the unit 15 circontrol circontrol com 6 CIRCONTROL MANTENANCE 6 1 General Description The vehicles charge system CCL CP1E B MOD3 is an electrical and mechanical set able to offer charge service safely both indoors and public places and hold a continuous use recharge service CCL CP1E B MOD3 one type 2 output parking box with communication Ims A gt 16 circontrol circontrol com 6 CIRCONTROL 6 2 Disassembly To get access inside the CCL CP1E B charger is necessary to open the back lid depending on model with Allen screws NOTE Must use Allen wrench to screw supplied appliances for proper maintenance and do not cause premature degradation Once CCL CP2 is opened the electrical devices are able to be manipulated and the guidance system hat To continue with the removal follow the following sequence 1 Disconnect the power supply before disconnect electrical intervention Only trained personnel are authorized and with the precautions and appropriate personal protective equipment 2 If it s not possibly to take the whole power supply for example because there are others posts on charge disconnect the power supply from local area through de RCCB 3 ATENTION WITH THE
11. e maintenance and his frequency is the following 6 4 1 6 4 2 MONTHLY Sensibility test Make sure that the RCCB works correctly We recommend test it causing a current leakage in one plug is not necessary to test it on both YEARLY REMEMBER TO REMOVE POWER Do the monthly RCCB preventive maintenance Check the electrical wiring is correctly there are no obvious faults in the insulation or defects on the components Check the proper tightening of the screws the power components especially the if it s provided and circuit breakers to which access is provided Use the right tool on each case General cleaning on the electrical components area and the lower hat area Remove with a brush the dust Clean inside the card reader with the brush or o tissue Check the connection state base is correct 19 circontrol circontrol com 6 CIRCONTROL 6 5 Corrective maintenance 6 5 1 Problems Causes Solutions e METERING CURRENT PROBLEMS o If no credits discounts despite consumption hen the toroidal transformer is probably assembled incorrectly Solution Check and correct if necessary It could be problems with the corresponding card energy control the main or auxiliary If it is appropriate replace it remember that it must also replace the corresponding toroidal transformer Attention to assembling the toroidal transformer because it has polarity The ground wire must pass the toroidal bro
12. edit to recharge later and pre charged with 5 20 50 or 99 units of credit Pre paid card writer There are three models available Integral model capable of accepting credit cards and notes CCL Cash o Compact CCL Term software version with USB peripheral CCL Soft The CCL CP1E B MOD3 complies with the CE requirements and the current European Union directives for this type of equipments The main standards that have been taken into account during the design phase are as follows UNE EN 62196 1 Bases sockets vehicle coupling devices and vehicle access points Electric vehicle conductive charging Part 1 Charging electrical vehicles of up to 250A in alternating current and 400A in direct current circontrol circontrol com C CIRCONTROL UNE EN 61851 1 Electric Vehicle Conductive Charging System Part 1 General requirements UNE 61851 21 Electric Vehicle Conductive Charging System Part 21 Requirements of the electric vehicle for its conductive connection to the main in A C and D C UNE 61851 22 Electric Vehicle Conductive Charging System Part 22 A C charging station for electric vehicles Other Standards IEC61000 IEC60364 4 41 IEC60884 1 IEC61010 UNE EN5501 1 ISO14443A In accordance with these Standards the MULTIPOINT SYSTEM has been designed for MODE1 charging system as described in the 61851 Standard system with 30MA sensitivity is obligated for these systems Vehicles cannot be
13. es aislantes Conductores aislados en tubos en montaje superficial o empotrados en obra Cables multiconductores en tubos en montaje superficial o empotrados en obra Cables multiconductores directamente sobre la pared Cables multiconductores al aire libre Distancia a la pared no inferior a 0 3 D Cables unipolares en contacto mutuo Distancia la pared no inferior a D Cables unipolares separado minimo D lw lu Go hi o O Fo n 2325238 partir de 25 mm2 de secci n Incluyendo canales para instalaciones canaletas y conductos de secci n no circular en bandeja no perforada 4 en bandeja perforada D es el di metro del cable circontrol circontrol com C CIRCONTROL 9 ASOCIATIONS Our group belongs to and is actively involved in various committees on the Electric Vehicle CHAdeMO Association International Association works for the standardization of charging stations for electric vehicles Certified members e ASESGA Spanish Association of Car Parks and Garages Technology Committee AFME Association of Electrical Manufacturers Electric Vehicle Working Group e CEEC Cluster Energy Efficiency Catalunya Electric Mobility Group e AMEC URBIS Spanish Association of Urban Equipment and Traffic Electric Vehicle Commission Forever Spanish Forum Electric Vehicle AEDIVE Association of Business Innovative Electric Vehicle Infrastructure
14. is suitable for the place country where it will be operating e Make sure that the connection bases are suitable for the place country where the unit will be operating 4 2 Anchoring and dimensions The CCL CP1E B MOD3 is designed to be anchored to the wall and is expected to 4 points for attachment Not providing the anchor material as this will depend on the material where it will be anchored the box The anchoring operation is the same as in any electrical panel in common use To open the box lid it has to be used the type key of screw that it was delivered to its proper maintenance and so does not cause premature degradation circontrol circontrol com C CIRCONTROL 4 3 Dimensions for CCL CP1E B MOD3 LP P 4 Status indicators RFiD Receiver RI B MODES Indicators ao Type 2 connector circontrol circontrol com AS CIRCONTROL 4 4 Electrical installation General considerations Qualified professionals must undertake all activities related to the electrical installation regardless of whether a project is needed or not depending on the power installed This unit has been designed for its use in a single phase 230Va c and three phase 400Va c with a 10 tolerance In any case the end user must be protected against indirect contact with a residual voltage relay DDR or differences with a sensitivity of 30mA The device already includes 30mA differential protection
15. nstaller that designs and makes Depending on the model the device is able to communicate by Rs 485 compatible devices so it will be able to send and receive commands or information The Rs 485 network installation must follow the requirements that the standard prescript among others the linear topology end of line resistor shielding equipotential mass Such communication can be enhanced by connecting to R 440 module or multipoint system data can then be stored and accessed via Ethernet 10 circontrol circontrol com X CIRCONTROL 5 USER GUIDE 5 1 Normal charge operative MODE 3 charging station have three diferent leds indicators GREEN ORANGE and RED for indicate estate of equipment e Ready Indicates system is ready for charge e Charge Indicates system is charging Fault Indicates system has found one problem 5 1 1 Charge operation for Models with RFID reader and display CCL CP1E MOD3 1 Once unit get Power supply verify unit is ready ciRCONTROL 1 Green indicator lights in the marker Unit is ready for charging 2 Connect the electric vehicle with Type 2 connector to the unit 3 Approach RFID TAG to the unit for charge START 1 Display will indicates remaining credits inside Tag 2 CHARGE indicator lights and LCD display starts to roll RFID TAG Do not unplug connector from Vehicle till not stop the charge approaching TAG to the unit 4 Show RFID Tag to the unit f
16. om AS CIRCONTROL 6 7 Auto diagnostic Display code Software version is displayed for 1 second after unit is connected to the electrical supply Indicates credit avalible when the RFID card is presented to the card reader Example 88 When the credit number is flashing 99 this indicates that the credit value is greater than 99 Socket 1 Allows charging regardless of avaliable credit This option only works with a suitably formatted card and the correct software upgrade in the charging equipment Socket 2 Allows charging regardless of avaliable credit This option only works with a suitably formatted card and the correct software upgrade in the charging equipment Socket 1 H indicates that the charging unit has reached the preset time limit This feature can be enabled or disabled by the factory using the charging equipment software Socket 2 H indicates that the charging unit has reached the preset time limit This feature can be enabled or disabled by the factory using the charging equipment software Socket 1 O flashing indicates the charging unit has reached the preset time allowed for a minimum charge Sal Se SE minimum charge EB It draws a card of the channel 1 properly updated or insert a card that is not correct EB It draws a card of the channel 2 properly updated or insert a card that is not correct Socket 1 A segment fixed in one position indicates there is no load When the segment is rotating it indicates
17. or STOP charge 5 Now you can unplug electric vehicle 11 circontrol circontrol com 6 CIRCONTROL 5 1 2 End of charge cycle Normal end 1 Present the RFID card to the reader 2 Cycle is interrupted 3 Disconnect the charge 4 The credit not consumed is retrieved to the card 00 5 Displays the credit OO 6 Remove the card 5 1 3 End of charge cycle end of credit 1 If it s displayed stopped indicate cycle Digit 1 channel one NO active Digit 2 channel two NO active 2 Present the RFID card to the reader 3 Disconnect the charge 4 The credit is retrieved to the card xx 5 Displays the credit xx 6 Remove the card The following explanation refers to loans used but as a symbol In countries where the currency has a similar magnitude to the EURO can be considered as 1 or 1 credit In countries where the currency is very different order of magnitude to the EURO a conversion can be easily calculated which for example is 1 credit 1000 local units In that case speaking of credit makes more sense 12 circontrol circontrol com 6 CIRCONTROL 5 1 2 Start of charge cycle 1 2 Present the RFID card to the reader After a while displays the credit value If the claim is correct a deposit is deducted from the card and transferred to the charge Select the charging shocked Connect the charge Remove the card The system connect
18. recover the debt it is available whether or not in use the unit for another client the following operations 5 2 1 Previous cycle interrupted card 1 Present the RFID card to the reader 2 system looks for the target on to the TAG code buffer 3 Once found retrieves the value of credit that user had before the cycle was interrupted 4 Once you update the card the display shows rC 5 Remove the card 6 The reader unsubscribes in the buffer the TAG code of the card Once retrieved the credit the card is ready for a new charge cycle 14 circontrol circontrol com AS CIRCONTROL 5 3 Missing credit operative 5 3 1 Start of charge cycle 1 Present the RFID card to the reader 2 After a while it displays the credit value Ifthe credit is not correct the display show 0076 during 2s and doesn t start any new cycle 4 Remove the card 5 3 2 Display indications rC Credit retrieve Ex Error x Channel indication that it is on resting time During this time there is no reading card for this channel O The output is on charge cycle if oscillates vertically Stationary cycle while standing 5 4 Charge operation for Model without RFID reader CCL CP1EB MOD3 1 Once unit is powered please verify unit is ready to work r ciRCONTROL 1 Green indicator lights in the marker Unit is ready for charging 2 Plug connector Type 2 to the unit and conne
19. required so if it s necessary to protect upstream 4 must be selective or time sensitivity The choice must be made by responsible for the design of the facility so that REBT is met and to ensure maximum system availability This device can not be installed in places where there is a risk of explosion explosive atmosphere The minimum breaking power of the automatic header switch circuit breaker must be 4500A The following layouts show the outline of the installation in blocks They are shown for information purposes only The installation company will be responsible for dimensioning the section protection elements and lengths in compliance with the current regulations Esta informacion es unicamente a titulo informativo no aceptandose responsabilidad alguna por cualquier posible da o o perjuicio que la instalaci n pueda provocar Es el instalador final quien deber elegir bajo su responsabilidad la forma de instalaci n en funci n de las variables citadas especialmente las legalmente exigibles en su pa s There is a ground terminal that must be properly wired to the conductor with the minimum section of 6mm IT IS VERY IMPORTANT ITS RIGHT CONNECTION AND ITS DIMENSIONS The minimum section of the conductors must be 6mm but that will be in function of the installation conditions length ducts may be higher Consult REBT or the appendices The responsibility for the installation corresponds to the authorized i
20. res and there is a rC on the display it is not a real problem The charge does not start because the card is recovering the credit That credit was saved because the previous load that card ended incidents 6 6 Spared parts and recommended tools The required tools to perform proper preventive or corrective maintenance are the normal installation electrician The PPE Personal Protective Equipment are also common and should be designed by the Prevention Service employee responsible who makes the assistance The following mentioned tools are the only not commonly used e Flat brush with long hair The amount and type of recommended spare parts are described in the following list o Main card control If this card is replaced also replace the toroidal The spare card brings its own toroidal We recommend having 1 unit per 10 CCL CP1E B Auxiliary card If it is replaced also replace his toroidal The spare card brings its own toroidal We recommend having 1 unit per 10 CCL CP1E B Auxiliary MODES card We recommend having 1 unit per 10 CCL CP1E B Plug bases We recommend having 2 units per 10 CCL CP1E B RBC Check the sensibility of the RCCB is 30mA 0 030A We recommend having 1 unit per 10 CCL CP1E B Power relay We recommend having 2 units per 10 CCL CP1E B Overcurrent protector We recommend having 2 units per 10 CCL CP1E B Allen screws of the lid We recommend having 30 units per 10 CCL CP1E B 21 circontrol circontrol c
21. s the power and starts the control of credit as the energy consumed The display shows a segment simulating a twisting motion with a speed proportional to power output End of charge cycle Normal end Present the RFID card to the reader Cycle is interrupted Disconnect the charge The credit not consumed is retrieved to the card Displays the credit xx Remove the card End of charge cycle end of credit If its displayed stopped indicate that the system has stopped the charging cycle Digit 1 channel one NO active Digit 2 channel two NO active Present the RFID card to the reader Disconnect the charge The credit is retrieved to the 007 Displays the credit 00 Remove the card 13 circontrol circontrol com 6 CIRCONTROL 5 1 5 End of charge cycle missing charge end 1 In display 0 indicates system has stop charging system Digit 1 channel one NOT active Digit two channel two NOT active Present RFID to reader Unplug connectors for charge Remnant credit of the unit is returned to the card Display shows cr dit Remove tag This Stop mode only can happens after one minute from charge start if power consumption has occurred 5 2 Retrieve credit operative Following Interruption of the charging cycle through no fault of the user After the interruption outside the client when it returns to
22. wn side It is also important whatever the type of electronic card to replace to verify that the original bridges have inserted and reproduce in the spare card Do not replace any card under supply or with a different type o If there is no reaction when the card is inserted probably it not recognizes the card or it is empty e COMUNICATION PROBLEMS COM The communication follows always the same order X2 communicates with R 440 R 440 communicates with modem Modem communicates with the network Obviously the posts which don t have R 440 or modem do not apply to them what is said o Behind a communication interruption check as the following order depending with the material that the CCL CP2 incorporates The COM led of the X2 card Works correctly see on electrical wirings peg The communication with R 440 works when is flashing When the R 440 communicates with the X2 the led Tx and Rx are flashing case that doesnt work check the twisted cable Rs 485 has reliability and is will connected Terminal A Terminal B Check the R 440 configuration is charged correctly It is necessary to know the PowerStudio and connect by modem or Ethernet cable inverted 20 circontrol circontrol com 6 CIRCONTROL e OTHER PROBLEMS o If there is nothing displayed when a valid card is introduced probably there is no voltage The REC2 jumped or the power supply has been interrupted upstream o When charge is requi
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