Ratio ELECTRIC Solar Box Solar and Dynamic Charging User Manual

Ratio ELECTRIC Solar Box Solar and

 _ **Dynamic Charging User Manual**_

IMPORTANT SAFETY INSTRUCTIONS

Carefully read these instructions and the charging instructions in your vehicle owner’s handbook before charging your electrical vehicle. Take special note of all information marked with the following symbols:

Note: This means pay particular attention. Notes contain helpful suggestions

Caution: This symbol means be careful. You are capable of doing something that might result in damage to equipment.

Warning: This symbol means danger. You are in a situation that could cause bodily injury. Before you work on any electrical equipment, be aware of the hazards involved with electrical circuitry and standard practices for preventing accidents.

Safety Guidelines

⨳ Use this Solar Box to charge electric vehicles equipped with a conductive charge port only. See the vehicle’s owner’s handbook to determine if the vehicle is equipped with a conductive charge port.
⨳ Make certain the Solar Box’s supply cable is positioned so it will not be stepped on, tripped over, or otherwise subjected to damage or stress.
⨳ There are no user serviceable parts inside. Refer to the Customer Support section in this manual for service information. Do not attempt to repair or service the Solar Box yourself.
⨳ Do not operate your Solar Box if it or the supply cable or housing is visibly damaged. Switch off the MCB in the electrical cabinet and contact your Service Representative for service immediately. Refer to the Customer Support section in the manual for information on the Service Representative in your area.

SAFETY INFORMATION

Warning: When using electric products, basic precautions should always be followed, including the following: Read all the safety warnings and instructions before using the product. Failure to follow the warnings and the instructions may result in electric shock, fire and / or serious injury. This device should be supervised when used around children. Do not put fingers into the electric vehicle connector. Do not use this product if the flexible power cord or EV cable are frayed, have broken insulation, or any other signs of damage. Do not use this product if the enclosure or the EV connector are broken, cracked, open, or show any other indication of damage

Warning: If, at any time, you think the equipment is unsafe, switch off the MCB in your electrical cabinet and immediately contact Customer Support for service. Do not use your Home Box until the problem is identified and corrected.
Caution: Children should not be allowed to use this Home Box. Do not allow children to play in or around the Solar Box. Close supervision of children is necessary when the Solar Box is used.

Caution: Do not open the enclosure.
Note: This Solar Box is designed according the IEC61851 Mode 3 standard.
Note: This product must be grounded/protective earthed. If it should malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This product is equipped with a cord having an equipment grounding conductor and a grounding plug.

Warning: Improper connection of the equipment-grounding conductor is able to result in a risk of electric shock. Check with a qualified electrician or serviceman if you are in doubt as to whether the product is properly grounded.

DESCRIPTION

This charging station is used for charging electric vehicles (EV’s) and is compatible with the common IEC61851 standard. This unit includes a charging station, 1 (single phase) or 3 (3-phase) current clamps (CT’s) and a sensor box V2. The sensor box measures the current (direction) of the power in the electrical cabinet and transmits this information to the charging station. When other appliances are switched on, the power to the EV will automatically be reduced. It is also possible to charge the EV on pure solar power. The charging station uses the sensor box to try to sent all generated power from the solar panels to a charging EV.

INSTALLATION

1. The installation must be done by a qualified and licensed electrician according the local legislation.
2. The electrical installation must be free of power during the entire installation period.
3. Since this Charging Unit uses circuits that reference to ground, no Merging must be done after connecting to power.
4. Wiring and protection:

• For cable length up to 25m

PLEASE NOTE:
All charges include an AC ( > 30mA) and DC (> 6mA) residual-current- detection. Always place a type A RCD and the MCB (or combination unit) in the electrical cabinet.

5. Open bottom cover of the Charge Station (5 screws ­Fixed cable Outlet see picture). Carefully brake out required cable opening for incoming power cable and charge cable. Use supplied M25 cable gland to fix power cable from the bottom. Use supplied grommet to fix power cable from the back. Use supplied M25 cable gland to fix charge cable.

6. Use 4 wood screws M4,5x35mm to mount Charging Station on the wall. The Charging Station should be installed between 0,80m and 1,20m from bottom to the ground.

7. Connect in-coming power to the left terminal block.
Single Phase :
L1=Brown
N= Blue
Earth= Green/Yellow

3 Phase
L1=Brown
L2=Black
L3=Grey
N=Blue
Earth=Green/Yellow

8. Connection Sensor box V2 and CT’s The Sensor box V2 has three inputs for CT’s (current transformers) and a voltage input to determine the direction of the current. The connection to the charging station is via a 4-pole plug. With the Sensor box V2 it is possible to determine the direction of the current, this makes it possible to charge the EV with self-generated solar power.

The voltage input (220-240V) is not a power supply for the Sensor box, but serves to determine the direction of the measured current. The CT’s are placed just after the main fuse but before the connection of the solar panels. See page 9. This way it will be able to measure the total current per phase and send this information to the Smart Box. In order to measure the current, Current Transformers are used (type SCT013-000, one for each phase). Clip the CT’s around the phase wires.

Try to find out which wire is L1 and connect it to connection 1 of the Sensor box. Make sure that the orientation of the CT’s is in the same direction for all phases. (arrow on the CT in the same direction). From the same phase also a voltage connection must be made to the mains input of the Sensor box. Use the supplied mains cable fort his.

Attention : The voltage input (mains) must be connected to the same phase as the CT connected to terminal 1!
Then connect the CT’s of phase L2 (to 2) and L3 (to 3) (when used).

9. Connection of the Sensor Box to the Charging station The data cable on the Sensor box should be connected to terminals A (white), B (yellow), +12V (brown) and GND (green).

NOTE: The data cable between Sensor box and Smart Box is not supplied. You can use a standard UTP cable or 4 x 0,25 mm2 data cable.

Connect the data cable in the charging station with the supplied 4 pole connector. Master/Slave configuration: Connect the A, B and GND connection from the Master to the Slave(s). So A connects to A, B goes to B etc. Make sure that the +12V wire coming from the Sensor box is connected to the Master Smart Box only.

10. Close the bottom cover and carefully slide grey cover over the Charging Station.

IMPORTANT: OUTLET VERSION – before closing outlet cover, be
sure the outlet is unlocked!

Installation of Current Claps (CT’s)

CONFIGURING THE SOLAR BOX

The Solar Box has a display to show the charging status and push buttons to do the setup. After you have connected the Solar box to the power you will see in the display: Ready to charge.

Hold the center button for 2 seconds to enter the menu. You can now use the left and right buttons to go to the different menu options.

Pressing the center button, selects the option, and allows you change the value (for example change the charging current).

What is displayed depends on the options you have set.

If you enabled smart mode (MODE->SMART) then the MAINS and MIN option will be shown.

If you selected the CONFIG->FIXED option, a fixed cable is to be used,

The EXIT menu option stores the settings, if you don’t want to store the settings, wait 2 minutes (or disconnect the mains) and the setup menu will be exited without saving any settings.

After starting, the charger is always ready to charge with the previous settings. You can’t access the setup during the charging.

ALL MENU OPTIONS

LOAD BALANCING

It is possible to connect up to 4 Solar Box modules to each other and let them share one mains supply.

Software configuration
Configure the Solar Box units load balancing option (LOADBL) and set one module to MASTER, the others to SLAVE 1,2,3. Make sure there is only one Master, and the Slave numbers are unique. Example: for a two units Load Balancing setup, set the first module to Master and the second to Slave 1.

On the Master configure the following:
MODE – Set this Smart if a Sensor box with CT’s is used to measure the current draw on the mains supply. It will then dynamically change the charge current for all connected EV’s. If you are using a dedicated mains supply for the EV’s you can leave this set to Normal.

MAINS CIRCUIT – Set this to the capacity of the mains supply.  Set this to the maximum current of the circuit. This will be the maximum current all EV’s combined will use.

MAX – Set the maximum charging current for the EV connected to this Smart Box.

MIN – Set to the lowest allowable charging current for all connected EV’s.

On the Slave’s configure the following:
MAX – Set the maximum charging current for the EV connected to this Smart Box.

After setting the Slave’s load balancing option, there will be an error message on the display: “ERROR NO SERIAL COM” This indicates, that the Slave unit was not able to communicate to the Master. This message will disappear after the modules are correctly wired up.

Hardware connections
Connect the A, B and GND connections from the Master to the Slave(s). So A connects to A, B goes to B etc… If you are using the Sensor box, you should also connect the A, B and GND wires to the same screw terminals of the Smart Box. Make sure that the +12V wire coming from the Sensor box is connected to only one Smart Box. This wire will provide power to the Sensor box.

ERROR MESSAGES

If an error occurs, the Sensor Box will stop charging and display one of the following messages:

ERROR NO SERIAL COM
No signal from the Sensor box or other Home box (when load balancing is used) has been received for 10 seconds. Please check the wiring to the Sensor box or other Home Box.
ERROR NO CURRENT

There is not enough current available to start charging, or charging was interrupted because there was not enough current available to keep charging. The Home Box will try again in 60 seconds.

ERROR HIGH TEMP
The temperature inside the module has reached 65o Celsius. Charging is stopped. Once the temperature has dropped to 55o Celsius charging is started again.

TESTING AND CONFIGURING

Configure the Solar Box and make sure the option MODE is set to SOLAR. Also make sure the menu option MAINSMET is set to SENSORBOX. After exiting the menu, the measured currents should be visible on the display.

From top to bottom the display shows the measured values for L1, L2 and L3. A minus indicates that the power at that phase is delivered to the grid.

When using the CT’s, it’s possible that the measured currents are not displayed correctly. If there are negative values shown, while not feeding back to the grid, the voltage input plug (MAINS) on the Sensor box should be reversed.

In case of deviating values, check the order of the CT connections on the Sensor box. The value of L1 must be displayed correctly, if the voltage input is also connected to the same phase.

If necessary, swapping the CT’s on connection 2 and 3 should be sufficient to get everything right.

SPECIFICATIONS

MAINTENANCE

The Home Box requires no maintenance other than occasional cleaning.

Warning: Switch off your Homer Box before cleaning the unit.

Warning To reduce the risk of electrical shock or equipment damage, be cautious while cleaning the connectors and case.

Clean the Home Box using a soft cloth lightly moistened with mild detergent solution. Never use any type of abrasive pad, scouring powder, or flammable solvents such as alcohol or benzene.

FCC INFORMATION

This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) This device must accept any interference received, including interference that may cause undesired operation. This product has been designed to protect against Radio Frequency Interference (RFI). However there are some instances where high powered radio signals or nearby RF- producing equipment (such as digital phones, RF communications equipment, etc.) could affect operation.
If interference to your charge station is suspected, we suggest the following steps be taken before consulting your Service Representative for assistance:

1. Reorient or relocate nearby electrical appliances or equipment during charging.
2. Turn off nearby electrical appliances or equipment during charging.

Caution: Changes or modifications to this product by other than an authorized service facility may void FCC compliance.

WARRANTY INFORMATION

Ratio Electric B.V. warrants this product to be free from defects in material, manufacture and design for a period of three years after the date of purchase. If this product is defective in materials, manufacture or design during this warranty period, Ratio Electric B.V. will, at its option, repair or replace the product. Repair parts and/or replacement products may be either new or reconditioned at Ratio Electric B.V. discretion. This limited warranty does not include service to repair damage from improper installation, improper connections with peripherals, external electrical fault, accident, disaster, misuse, vandalism, unauthorized alteration or repair, abuse or modifications to the product not approved in writing by Ratio Electric B.V. Any evidence of an attempt to disassemble the Solar Box will void this warranty. Any service repair outside the scope of this limited warranty shall be at applicable rates and terms then in effect.

CONTACT / CUSTOMER SUPPORT

Ratio Electric B.V.
Ambachtsstraat 12
NL-3861 RH Nijkerk
The Netherlands
Tel. +31-33-2452360
info@ratio.nl
www.ratio.nl

References

• 📧info@ratio.nl
• Laadpalen, laadkabels, walstroom en PDU - Ratio Electric
• Ratio Electric | Ratio Electric

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