PRACHT NRG1006 5.5m Charging Cable User Manual

PRACHT NRG1006 5.5m Charging Cable User Manual

NOTES ON THIS DOCUMENT

Before installing and using the wallbox, the instructions must be read and understood in full by the installer and each user. Please keep the manual for the entire service life of the wallbox in order to be able to access it later.
Also observe the operating instructions for your electric vehicle.

SAFETY, INSTALLATION AND USE

The wallbox is only suitable for use in private and semi-public areas (e.g. company parking lots).
The wallbox must not be installed in areas with an explosive atmosphere (EX area) or where flammable liquids or objects are stored.
The wallbox is only suitable for stationary installation. Minimum distances of 50cm to all neighboring objects must be maintained. Installation in a closed box is not permitted. Likewise, the wallbox must not be installed in areas at risk of flooding.

The wallbox may only be installed and put into operation for the first

time by a trained electrician.

The electrical connection must be made in accordance with nationally applicable standards, as well as other national and international regulations regarding accident prevention and personal protection, as well as fire protection.
The wallbox may only be connected to and operated on TT, TN-C and TN-C-S networks. Operation on an IT network is not permitted.
Work on the wallbox may only be carried out when it is de-energized. There is a risk of fatal electric shock due to the components inside the box!
Modifications or conversions to the wallbox are not permitted and will result in the loss of any warranty and guarantee claims against the manufacturer.
The box and all associated components may only be used for their intended purpose. The manufacturer assumes no liability for personal injury or property damage resulting from improper use.
Defective or damaged wallboxes must not be put into operation. In this case, contact your installer. Check the function of the RCD switch regularly in accordance with national regulations.

OTHER USE INSTRUCTIONS

• Vessels containing liquids must not be placed on the charging station
• Kinking or running over of the charging cable must be avoided
• The charging cable must be wound up on the device provided for this purpose when the charging station is not in use
• Fix the charging coupler in the charging coupler receptacle provided when not in
• Before using the charging coupler, check it visually for damage or dirt on the
• The charging coupler must not be disconnected from the vehicle during the charging process
• The insertion of objects into the charging coupler is prohibited
• Do not wash the vehicle with a garden hose or high-pressure cleaner when the charging coupling is plugged in, in order to prevent water from entering the charging coupling or the connecting device of the
• The vehicle must be parked at a suitable distance from the charging station to ensure that the charging cable can be plugged in without tensile stress
• Avoid direct sunlight
• Do not open charging station mounted outdoors during rain or snowfall
• The charging cable must not be connected to extension cords or adapter cables
• Do not allow children to play unsupervised in the vicinity of the charging station
• The charging station must always be closed during operation
• The key for opening the charging station should be kept in a place to which unauthorized persons have no access
• For persons with a pacemaker or defibrillator, despite compliance with all European directives and standards on electromagnetic compatibility, no statement can be made regarding the suitability of use, maintenance or repair work of the charging Please contact the manufacturer of the defibrillator or pacemaker for further information.

Improper use can cause serious injury or death, as well as destroy the vehicle or the charging station

SCOPE OF DELIVERY

• Wallbox ALPHA DUO with RFID module and RS 485 interface

• Key

• Jumper, pre-assembled

• Instruction manual

• Drilling template

• Fastening material, consisting of:
  1x mounting lug left
  1x mounting bracket right
  8x self-tapping screws for mounting straps

• 2 pieces RFID card (more cards available – NRG9003) Check the scope of delivery for

TECHNICAL DATA

ALPHA – NRG1006

Charging power mode 3 [kW] per output

Charging power mode 3 [kW] total

| 3.7 (1-phase) / 11 (3-phase)

7.4 (1-phase) / 22 (3-phase)

Nominal voltage UN [V] 50Hz| 230 (1-phase) / 400 (3-phase)
max. line protection [A]| 20
Residual current

protection/disconnecting device

| 30
AC [mA]| 6
max. current consumption [A]

(adjustable)

| 10, 13, 16, 20
max. charging current [A] per vehicle| 16
Protection type| IP 65
Protection class| I
Impact resistance box| IK08
Number of charging ports| 2
Charging port/coupling| Typ 2
Charging cable length [m]| 5,5
Mounting location| Indoor, protected outdoor, no direct sunlight
Mounting type| Wall mounting, column mounting (optional)
Ambient temperature| -20°C to +40°C for connected load < 11kW

-25°C to +35°C with connected load > 11kW

Altitude| max. 2000m a.s.l.
Relative humidity [%]| max. 95 (non-condensing)
Dimensions [mm] (W x H x D)| 299 x 425 x 180 (without coupling)

299 x 425 x 380 (with coupling)

Material| ABS, Aluminum
Weight [kg]| 11

optionally available

| NRG9000 – Stand with roof

NRG9001 – Roof for mounting in unprotected outdoor area NRG9003 – RFID cards

NRG9004 – Wall cable holder

ASSEMBLY

REQUIREMENTS

The wallbox may only be installed by a trained electrician.

Before installation, the device must be thoroughly checked for damage. The wallbox is only suitable for vertical installation.
The box may be mounted indoors or in protected outdoor areas, such as under canopies. The ambient temperature at the installation site must be in the range of -20°C to +40°C. The wallbox must be mounted away from easily flammable parts. Sufficient ventilation must be ensured during operation. The mounting location must be selected so that the connected charging cables cannot come into contact with water. To prevent the ingress of water, the proper fit of the cover and the tight fit of the cable glands must be checked after installation.

WALL MOUNTING

1. The enclosed mounting plates (left/right) are to be mounted on the back of the wallbox with four self-tapping screws Make sure that the beveled tabs are oriented towards the center of the housing (cf. Figure 1).
2. The drilling distances for wall mounting are to be transferred to the wall with the aid of the enclosed drilling template.
3. Drill holes in the
4. Insert four dowels (not included in the scope of delivery) according to the wall
5. Screw the two lower screws into the dowels and place the wallbox on the screws using the screw
6. Screw the upper screws into the dowels, align the wallbox and finally fasten it using the total of four screws.

The next step is the electrical connection of the wallbox.

ELECTRICAL CONNECTION

The supply line of the wallbox must be disconnected from the power supply during installation work.

CONNECTION TO THE MAINS

The supply line must be correctly fused.

1. Pull the supply line into the box
2.  Connect the supply line as shown in Figure 2 and then relieve the strain and seal it using the cable
   

Check the electrical connection and voltages using a measuring device.
Also make sure that neutral (blue) and ground (PE, yellow/green) are connected correctly.
The sequence of L1, L2, L3, N may differ depending on the type. Please observe the imprint next to the connection terminals.

ATTENTION:

Switch off the RCD during insulation resistance tests (according to DIN VDE 0100-600) to avoid damage to the electronics!

WIRING OF THE RFID MODULE

When using RS485, a double line with a characteristic impedance of 120 Ohm must be used. Since this is a data bus, it must be terminated with a resistor at the end or beginning. This can be done with the resistor pre-mounted in the interface or with the termination functions of other Modbus accessories. When using our PCC, it must always be mounted at the beginning or end of the bus as it has an integrated termination resistor. The GND connection must be carried on a separate wire (or pair of wires) in the cable to avoid interference effects.

SETTING THE MAXIMUM CURRENT

It should be noted that the loading speed depends mainly on two factors:

1. amount of the maximum power output of the
2. maximum charging power of the electric vehicle Preferably, the wallbox should be connected with three

Before commissioning, the maximum current that the wallbox draws via the supply line must be set using the enclosed jumper on the control board.
When setting the maximum current, it must not be higher than the fuse or the cable cross-section and the length of the supply line allow.
The setting is made by plugging the jumper into the corresponding position on the control unit. The slots on the control unit can be found by means of the inscription “I max”. The assignment of the slots is shown in the following tables

By setting an additional jumper to FUNCTION 1, simultaneous loading of the vehicles is prevented. Loading now takes place one after the other. The vehicle that first makes the request to load is served first. The second vehicle can only be charged after the charging request has been dropped.

VALUES FOR ALPHA NRG1006 (MAX. 11KW PER VEHICLE)

Position connector (Jumper)| Current raiting| Min. cross section supply line| 1-PHASE LOADING| 2-PHASE LOADING| 3-PHASE LOADING
---|---|---|---|---|---
1 Car| 2 Car| 1 Car| 2 Car| 1 Car| 2 Car
(1Ph supply line, 1Ph car)| (1Ph supply line, 1Ph car)| (3Ph supply line, 2Ph car)| (3Ph supply line, 2Ph car)| (3Ph supply line, 3Ph car)| (3Ph supply line, 3Ph car)
1| 10 A| 1,5 mm²| 2,3 kW| 2,3 kW| 0,0 kW| 4,6 kW| 4,6 kW| 0,0 kW| 6,9 kW| 6,9 kW| 0,0 kW
2| 13 A| 1,5 mm²| 3,0 kW| 1,6 kW| 1,4 kW| 6,0 kW| 3,2 kW| 2,8 kW| 9,0 kW| 4,8 kW| 4,2 kW
3| 16 A| 2,5 mm²| 3,7 kW| 1,8 kW| 1,8 kW| 7,4 kW| 3,7 kW| 3,7 kW| 11,0 kW| 5,5 kW| 5,5 kW
4| 20 A| 4,0 mm²| 3,7 kW| 2,3 kW| 2,3 kW| 7,4 kW| 4,6 kW| 4,6 kW| 11,0 kW| 6,9 kW| 6,9 kW

After the end of the charging process, the power at the other connection point corresponds to the charging power with only one vehicle. Nominal values with tolerance +-10%
Before commissioning, check that the jumper is seated correctly.
No settings are required to divide the charging current between two vehicles. The charging current is regulated by the controller.
Due to increased cable length of the supply line, it may also be necessary to compensate for the resulting voltage drop by using a larger cable cross- section.

OPERATION

This charging station s suitable for electrically charging one or two vehicles with type 2 charging couplings.
By programming an RFID card (see “Programming RFID cards”), charging is only possible for authorized persons. If no RFID card is programmed, the wallbox is freely accessible.
Pay attention to your safety when operating inside the wallbox and do not touch any live components. Also abserve the operating instructions for your electricvehide.

LED DISPLAY

The wallbox is equipped with a separate LED indicator light for each charging cable, which shows the current status during
operation. From software V12 (see door inside)

 |
---|---
green| No vehicle connected, wallbox ready for operation
blue| Box unlocked via RFID module
yellow| Vehicle connected, waiting state, charging process completed
green, slowly flashing| Vehicle is charging (more than 16A available)
red, flashing| Charging cable has short circuit, plug very dirty
red, 2x flashing| CP signal not stable, connector dirty
red, 3x flashing| Diode in vehicle defective, plug dirty
3 seconds flashing pink| RFID card not known / all RFID cards successfully deleted
3 seconds white| RFID card was taught
yellow flashing| Total power of the box limited via digital interface
light blue flashing| Power of a charging point limited via digital interface
red luminous| DC fault current >6mA, fault current sensor error or

connection error (from V12 restart of ALPHA required)

red and yellow flashing (from V12)| Ventilation requested by the vehicle therefore no charging allowed

The LED indicator lights also show the preset current consumption every time the box is restarted.

TEACH-IN OF RFID CARDS

To use the RFID module, itis necessary to teach in at least one RFID card.
RFID cards are taught as follows:

1.  Open the wallbox with the key provided for this purpose.
2. Press and hold the Learn button on the RFID module and place the card to be learned on the right outside of thewallbox. (see Figure 4) Ataught-in RFID card is signaled by a white status LED of the wallbox. In this way, up to 100

RFID cards, possibly also from third-party suppliers, can be taught.

DELETING RFID CARDS

Note: It is not possible to delete individual RFID cards. The deletion process removes all previously taught-in cards.

1.  First open the wallbox with the key provided for this purpose.

2. . Startthe deletion process by pressing and holding the Clear and Learn buttons on the RFID module until the LEDindicator flashes pink. The memory has been successfully deleted. This process can take up to one minute. (see
   Figure 4)

3. . Lock the wallbox.

ACTIVATION OF THE WALLBOX

There are two ways {o start the charging process or to unlock the wallbox.

Option 1

1.  Place a taught-in RFID card on the right-hand outside of the wallbox.
   The wallbox signals the unlocking by a blue LED display.

2.  Establish the connection between the wallbox and the vehicle to be charged within 30 seconds.

Option 2

1. First connect the wallbox to the vehide to be charged.
2.  Then unlock the wallbox by placing the RFID card on the right-hand side of the wallbox. In this case, too, the blue LED  indicator signals that the wallbox has been successfully unlocked.

LOADING

Connect your vehicle to the wallbox.
As soon as the electric vehicle is ready for charging, the charging process starts automatically.
After successful charging, the vehicle ends the charging process automatically. Overcharging” is therefore not possible.
If two vehicles are charged at the same time, the wallbox regulates the available power. For example, the charging current is divided between the two vehicles. If the charging process of one of the two vehicles is completed, the charging power of the vehicle still charging is automatically increased.

SEQUENTIAL LOADING

Note: The time-delayed allocation of the charging current is not supported by all electric vehicles.
A charging current of at least 6A is required for each vehicle to be charged.
If the wallbox has been configured for a low charging current, this may mean that both vehicles cannot be charged at the same time. In this case, the two connected vehicles are charged one after the other (sequentially).
If the charging process of the second vehicle does not start automatically, it may be necessary to disconnect the vehicle from the system for a short time first. After reconnection, the charging process starts.
As a preventive measure, observe the connection sequence to the box. First connect the vehicle that does not support sequential charging. Only then connect the second vehicle (sequential charging is supported by this one).

RESTARTING THE BOX

To restart the box, first disconnect all vehicles from the system.
Switch off the internal I of the wallbox for 5 seconds.
After switching on the voltage, the microcontroller of the box restarts automatically.
Within 2 seconds, the box reports the preselected seting by white flashing of the LEDs, for example, 10 flashes signal a preset of 10amps.

INTERFACE RS 485

The RS 485 interface communicates with Modbus RTU, 9600 baud, 8 DATA bits, 1 stop bit, parity none, slave ID 1, unsigned integer 16bit (UINT16, internal values 8 bit). The timeout is less than 2000ms.
Register type 40XX read and write, register type 30XXX read only.

shutdown)
3| 40004| max. current KFZ1 limit| 255| in A (values below 6 A lead to shutdown)
4| 40005| max. current KFZ2 limit| 255| in A (values below 6 A lead to shutdown)
11| 30012| Allocated current KFZ1| 0| in A
12| 30013| Allocated current KFZ2| 0| in A
74| 30075| taught RFID cards (number)| 255|
100| 30101| Software version RFID and Modbus module| 255| Decimal value Software version

(D3 -> “3”)

101| 30102| Software version motherboard| 255| Decimal value Software version

(V3 -> “3”)

102| 40103| Release register charge points|  |  | 1| Share all|
2| Lock all|
11| Enable charging point 1|
21| Lock charging point 1|
12| Enable charging point 2|
22| Lock charging point 2|
Automatic locking takes place ~30 seconds after release!

(Register available from software D2)

103| 30104| Temperature in the box| 255| (value register -72)*0.4244= Temp in °C
106| 30107| Status KFZ1| 255| 0 no car, 1 car connected, 2 charging request, 3 charging request with fan, 4 short circuit
107| 30108| Status KFZ2| 255| 0 no car, 1 car connected, 2 charging request, 3 charging request with fan, 4 short circuit
114| 30115| Set charging current Supply line| 255| Value in A of the jumper position
115| 30116| Set charging current Supply line after corrections Temperature and setting| 255| Value in A that is available for all connected vehicles in total.
---|---|---|---|---
116| 30117| Lock status display| 0|  | 0 (0b00)| Box released|
1

(0b01)

| Charging point 1 locked|
2

(0b10)

| Charging point 2 locked|
3

(0b11)

| Both charging points locked|

Information about RFID cards can be requested depending on the software version at support@pracht.com.

MAINTENANCE AND CLEANING

In the event of a defect, please contact the manufacturer directly.
Before cleaning, the wallbox must be disconnected from the power supply for safety reasons.
Dirt can be removed with a damp cloth.
The use of harsh deaning agents is not permitted.
The wallbox must not be cleaned with a water jet or high-pressure cleaner.

ENVIRONMENT

Disposal of the packaging material is carried out via the collection containers for paper and plastics provided for your region.
The disposal of old devices and their accessories is carried outin accordance with the national and regjonal regulations for the disposal of electrical and electronic devices. Accordingly, these must not be disposed of with household or bulky waste.

TROUBLESHOOTING

 |
---|---
No function of the wallbox (LEDs extinguished).| ·        Check the fuses in the house distribution.

·        Check the residual current circuit breaker (FI) in the house distribution.

·        Check the internal fuses.

·        Check the internal residual current circuit breaker (FI).

Wallbox no longer responds.| ·        First disconnect all vehicles from the system. Then restart the wallbox.
The wallbox signals a fault (red LED display).| ·        Disconnect the connection to the vehicle.

·        Check the charging coupling and charging cable for possible damage.

·        In case of damage, disconnect the box from the power

supply and repair it.

·        Check the contacts of the charging coupler for dirt. To do this, disconnect the box from the power supply.

·        After repair or cleaning, the wallbox can be connected to the mains. Once the fault has been rectified, the box is ready for operation.

The vehicle suddenly charges with lower charging current or briefly interrupts the charging process.| ·        The wallbox is equipped with thermal overload protection.

·        From around 40°C outside temperature, the system gradually reduces the maximum charging current.

·        If the ambient temperature continues to rise, the wallbox may switch off the charging process.

·        As the outside temperature decreases, the wallbox

automatically continues the charging process.

The loading process was canceled.| ·        Restart the charging process. To do this, disconnect the connection between the wallbox and the vehicle for 10 seconds.

PRACHT Industry GmbH
Am Seerain 3, 35232 Dautphetal-Buchenau, Germany
Tel. +49 6466 9140-900 info@prachtenergy.com, www.prachtenergy.com

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References

• Wallbox Alpha - PRACHT Energy Solutions
• Wallbox Alpha - PRACHT Energy Solutions

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