Rolec Services SEC 80kW Series DC Fast Charger User Manual

Rolec Services SEC 80kW Series DC Fast Charger

FAQ

• Q: What should I do if there is a malfunction with the charger?
  • A: Refer to the troubleshooting section in the user manual for guidance on identifying and resolving common issues.
• Q: How often should maintenance checks be performed?
  • A: Regular maintenance checks should be carried out as per the after-sales service guidelines provided in the manual to ensure optimal performance of the charger.

Disclaimer

Manufacturer shall not be liable for any consequence caused by any of the following events:

• Out of warranty coverage.
• Not installed and used in accordance with the requirements of the manual, resulting in damage or failure of the product.
• Failure to implement relevant local codes and standards, resulting in product damage or failure.
• Incorrect transportation, removal, storage, installation, or use.
• Natural wear and tear or galvanic corrosion resulting from the operation of the equipment.
• Unauthorized changes to the original design of the product, resulting in damage or failure of the product.
• Intentional or negligent damage or failure of the product.
• Device damage due to force majeure (such as lightning, earthquakes, fire, and storms)
• Unauthorized modifications to the product nameplate or serial number or product appearance.
• Damage or malfunction of the product caused by improperly moving the device position.
• The customer, after receiving the contract equipment, ensure that it is placed reasonably, safely and without damage, and ensure that the location, environment and temperature are in line with the installation and storage conditions of the contract equipment, and that the storage time of the unpowered equipment should not exceed six months, otherwise it needs to be returned to the factory for a fee to detect aging.
• Customer caused by poor heat dissipation of equipment (such as improper customer installation location, not timely dust removal, etc.), equipment damage is not covered by our warranty.

Notice

Before connecting the power supply, ensure that electrical connections are correct. Do not connect or disconnect power cables with power on.
Personnel who will operate the equipment, including operators, trained personnel, and professionals, should possess the local national required qualifications in special operations such as high-voltage operations, working at heights, and operations of special equipment.

Foreword

Reader Object

This document (this guide) is primarily intended for the following engineers：

• Technical Support Engineer
• Maintenance Engineer
• Engineering installation team

Symbol Conventions

The following symbols may appear in this document and their description are as follows.

Safety Precautions

Special symbols for warnings and dangers

Safety instructions for use

• The SEC products are a series of integrated/distributed equipment that you can use to supply power to electric vehicles whether indoors or outdoors.
• The SEC products are high power and high voltage level equipment. Only qualified workers are allowed to conduct construction and maintenance.
• Please follow local laws and regulations when installing, operating and maintaining the equipment.
• Please follow the guidance of installation, operation and maintenance provided by the manufacturer.
• Please follow related safety standards on R&D, production, inspection, certification and filing locally if needed.
• To ensure personal and equipment safety, please pay attention to safety symbols on the equipment and safety instructions in this document. Otherwise, the device may encounter hidden dangers or malfunctions, or user’s body may be harmed.
• If any problems or faults occur during use, please contact manufacturer after-sales service team or distributor. Manufacturer will not be liable for any issue caused by maintenance by unauthorized third party, even under warranty.
• Please make sure the equipment keeps enough distance from fire and other hazard operating condition.
• Please make sure the minimum distance between the equipment and the block is satisfied.

Safety instructions for operation

• Please read this document carefully before first use. Make sure the equipment is correctly installed and commissioned according to the instruction in the installation manual.
• Do not modify the product without authorization. Manufacturer will not be liable for any consequences caused by the violation of the safety operation regulations and usage standards.
• Do not touch the EV charging connector, keep it dry and clean.
• Do not use this product if the power cable or connector has any worn-out, copper wire exposure or any other signs of being damaged.
• In case of any emergent situation, press the emergency button immediately, which will shut down the whole equipment to ensure safety. The system operator should be informed if the emergency button is pressed. The charging station shall not be restarted until operation technician resets the system.
• Please make sure no foreign matters are stuck in the EV charging connector.
• Please do not connect or disconnect the power cable when powered on. Disconnect the circuit breaker switch and set up a warning area when performing maintenance.
• Pay attention:  The copper wire carries dangerous voltage from the equipment even after all circuit breakers of the charger have been disconnected.
• Please prepare lighting sources when conducing maintenance since no power source is available from the charger.
• Connect protective earth wire (PE) before connecting neutral line and phase wire.
• After installation or maintenance, ensure that door are locked correctly.
• Please do not use any adaptors, conversion adapters or extension cords.

Product Overview

Brief description

The SEC is an integrated DC fast charger featuring high efficiency and flexible configure solution. It supports CCS2 & CHAdeMO dual connector to charge at the same time with an optional Type 2 charging socket. Used in centralized fast charging station, the product adopts 20kW charging power module, satisfying the capacity demand as well as flexibility demand on the market.

SEC series products model

Product types description

Specification

| Power distribution| Maximum current
---|---|---
Connector

A

| Connector

AC

| Connector

B

| ****

Connector A

| ****

Connector AC

| ****

Connector B

SEC1000/40Y-C-PA| 40kW| /| /| 134A| /| /

SEC1000/40Y-CJ-PA

| 20kW or

40kW

| ****

/

| 20kW or

40kW

| ****

134A

| ****

/

| ****

125A

SEC1000/40Y-CC-PA

| 20kW or 40kW| ****

/

| 20kW or 40kW| ****

134A

| ****

/

| ****

134A

SEC1000/40Y-CS-PA| 40kW| 22kW| /| 134A| 32A| /

SEC1000/40Y-CSJ-PA

| 20kW or 40kW| ****

22kW

| 20kW or 40kW| ****

134A

| ****

32A

| ****

125A

SEC1000/40Y-CSC-PA

| 20kW or

40kW

| ****

22kW

| 20kW or

40kW

| ****

134A

| ****

32A

| ****

134A

SEC1000/60Y-C-PA| 60kW| /| /| 200A| /| /

SEC1000/60Y-CJ-PA

| 40kW or 60kW| ****

/

| 20kW or 60kW| ****

200A

| ****

/

| ****

125A

SEC1000/60Y-CC-PA

| 40kW or 60kW| ****

/

| 20kW or 60kW| ****

200A

| ****

/

| ****

200A

SEC1000/60Y-CS-PA| 60kW| 22kW| /| 200A| 32A| /

SEC1000/60Y-CSJ-PA

| 40kW or

60kW

| ****

22kW

| 20kW or

60kW

| ****

200A

| ****

32A

| ****

125A

SEC1000/60Y-CSC-PA

| 40kW or 60kW| ****

22kW

| 20kW or 60kW| ****

200A

| ****

32A

| ****

200A

SEC1000/80Y-C-PA| 80kW| /| /| 200A| /| /

SEC1000/80Y-CJ-PA

| 40kW or 80kW| ****

/

| 40kW or 62.5kW| ****

200A

| ****

/

| ****

125A

SEC1000/80Y-CC-PA

| 40kW or 80kW| ****

/

| 40kW or 80kW| ****

200A

| ****

/

| ****

200A

SEC1000/80Y-CS-PA| 80kW| 22kW| /| 200A| 32A| /

SEC1000/80Y-CSJ-PA

| 40kW or 80kW| ****

22kW

| 40kW or 62.5kW| ****

200A

| ****

32A

| ****

125A

SEC1000/80Y-CSC-PA

| 40kW or 80kW| ****

22kW

| 40kW or 80kW| ****

200A

| ****

32A

| ****

200A

For -PA and -RA products, the parameters are the same except for the certification

Product views

Outside view of the SEC series DC fast charger

Inside view of the SEC series DC fast charger

socket

Product characteristics

• A variety of power configurations from 40kW to 80kW can meet the customized requirements of customers. And more flexible power distribution, the model with dual DC connectors can automatically switch the power according to the vehicle demand, which can meet the rapid charging of two vehicles at the same time.
• The charging system is built in the form of DC and AC to meet the charging demand of fast charging and slow charging, thus multiple charging points can be provided to support charging at the same time. Among them, the AC connector power and DC connector power are output separately, which do not affect each other and improve the charging experience.
• The constant current and constant power charging methods have the advantages of high charging efficiency, simple operation and reliable performance.
• Ultra wide output voltage range, with the highest output voltage can reach DC1000V. It can not only meet the low-voltage charging of small cars, but also meet the charging requirements of buses and high-voltage vehicles.
• With overload, short circuit, leakage, lightning protection, overcharge, over voltage, under voltage, reverse connection, over temperature and other multiple protection functions.
• Multiple supporting functions integrated: standard connector homing detection function; and supports optional functions such as flooding detection, smoke detection, tilt detection, etc. provides protection for the installation and use of charger; also supports optional heaters to support the use of charger installed in cold areas.
• The intelligent standby mode can effectively reduce the operation cost of customers in the whole project life cycle, and improve the return rate of station charging.
• The cabinet shell is made of stainless steel with protection grade of IP55, which can be applied to various outdoor environments. At the same time, the overall new design of the cabinet is smaller and more compact, which can save floor space, thus more  suitable for the arrangement of charger in operating stations.

Parameter table of product specifications

Specification

Category| Item| Parameter

Input Characteristic

| Input| 3P+N+PE
Input Voltage| AC 380~400V
Frequency| 50/60Hz
Power Factor| 0.99
THDi| <5%

Output Characteristic

| ****

Output Voltage

| CCS2 : 200-1000 Vdc CHA : 200-500Vdc

Type2 AC socket: AC 380~400V

Rated power

| 40-80kW (DC connector output power)

22kW (Type2 AC socket output power)

Max Current

| CCS2 : 200A CHA : 125A

Type2 AC socket:32A

Peak Efficiency| 96% @ peak efficiency
Connector Type| IEC 62196

Standards

| ****

System Standards

| ****

IEC 61851

Others

| Energy meter| High precision meter
---|---|---

Number of connectors

| 1  connector: CCS 2；

2  connectors: CCS 2 + CHA or CCS 2 + CCS 2

1  connector+socket: CCS 2 +Type 2 AC Socket

2  connector+socket: CCS 2+ Type 2 AC Socket+CHA or CCS 2+ Type 2 AC Socket + CCS2

Network Interface| 4G/LAN
Size| W850D500H2030 mm
Protection level| IP55/IK10
Weight| 390kg
Cable length| 5m ( Exposed cable length is 4.5m )
Communication

protocol

|

OCPP1.6J

Display Screen| 15 inches
Method of payment| QR Code/RFID/NFC/Bank card ( Optional )
Language| English

Environmental conditions

| Cooling method| Forced air cooling
Full power

operating temperature

|

-25 ~ 65 ℃( Derating operation over 50℃ )

Humidity| 5%~95%
Altitude| ≤2000m
Protection|  | DC Over current protection
Surge Protection Device
Emergency Stop Protection
Overload protection
Short circuit protection
Electric leakage protection
Overcharge protection
Over voltage protection
Under voltage protection
Reverse connect protection
Over temperature protection

Protection device parameters

current type**
80kW| 180A| 50kA| 30mA| Type A
60kW| 140A| 50kA| 30mA| Type A
40kW| 100A| 50kA| 30mA| Type A

capacity**
For 200A connector| 315A| 1000V| 50kA

Installation Instructions

Equipment dimensions

1. The figure and dimension of the charger are shown in Figure 3.1-A.
2. The hole size of charger base is shown in Figure 3.1-B.

Equipment installation requirements

1. Open the charger package box and put the charger to its right place, make sure the connectors can be used normally from any side. Installation space should be reserved. See Figure 3.2-A .
2. Install on a channel steel or concrete base. The cable shall be buried in the middle in advance. The reserved length of the ethernet cable should be no less than 4000mm, the reserved length of the control signal cable should be no less than 1500mm, the reserved length of the power cable should be 700 mm ± 20 mm, and the drilling diameter of the base through which 5 wires go through shall be less than 30 mm, as shown in Figure 3.2- B;
3. The height of the installation foundation is recommended to be 200 mm ± 20 mm, and the vertical inclination of the installation shall not exceed 5 °. See Figure 3.2-B for details.
4. Install 4 stainless steel M12 * 80mm expansion bolts between the base and the cabinet.
   • Note that the bolts need to be equipped with M12 stainless steel flat gasket.

Construction of distribution cables

Layout requirements of distribution cables

1. The input cable of the system is introduced from the inlet hole at the bottom of the charger, and the cable shall be laid through the cable trench.
2. The AC cable adopts copper core wire, and the cross-sectional area of the cable shall adapt to the load.
3. The outdoor power cable shall be laid according to the power specification. The power cable and the signal cable must be separated, and the signal cable should be put through the tube separately to avoid the pressure loss and interference of the communication signal.
4. The cable shall not be laid in the area easily damaged by mechanical damage, corrosive medium emission, humidity, strong magnetic field and strong electrostatic field interference. If necessary, please take corresponding protection or shielding measures.
5. The AC input cable starts from the user’s distribution switch and connects to the copper bar of the charger’s inlet cable switch. Protection devices shall be provided at the user’s power distribution.

Process requirements of distribution cables

1. Cable laying shall be free from external force, distortion and damage of insulation layer.
2. It is strictly forbidden to twist, flatten, break the protective layer and wear the protective layer seriously.
3. The protective pipe shall be cleaned before the cable passes through the pipe, and the wire shall not be damaged.
4. The cable arrangement shall be tidy. The binding should be neat and should not be crossed.
5. Sufficient allowance (no less than 600mm) shall be reserved for each wire of the cable, and the bending degree shall be consistent.
6. Crimp the terminal of the cable head, and there should be no gap on the penetration surface of the terminal after crimping.
7. When pressing the lug of inlet cable, the heat shrinkable tube should be set between the cable and the lug, and the inside and outside of the tube should be smooth without damage and crack. Before setting the heat shrinkable tube, the sundries on the cable shall be removed, and there shall be no burr and iron filings on the surface to prevent damage to the tube. The color of the tube shall be in accordance with the phase sequence. When the tube is heat shrinkable, the flame should be avoided to spray on the inside of the cabinet to prevent burning the internal components and cables of the cabinet. The appearance of heat shrinkable casing should be flat, smooth, uniform shrinkage, no dust and crack.
8. Attention should be paid to the wiring sequence when pressing RJ45 connector for Ethernet cable. Check whether the pressing is qualified after pressing.

Cable specifications for AC input (Recommended)

Capacity (kW)| Cable specification| Capacity of superior distribution switch| Screw specification (diameter: mm)
---|---|---|---
40kW| Copper：
425mm²+16mm²
Aluminium：
435mm²+25mm²| 125A| L1/L2/L3/ N：M10
PE:M8
40kW+22kW| Copper：
435mm²+25mm²
Aluminium：
450mm²+25mm²| 160A| L1/L2/L3/ N：M10
PE:M8
60kW| Copper：
435mm²+25mm²
Aluminium：
450mm²+25mm²| 160A| L1/L2/L3/ N：M10
PE:M8
60kW+22kW| Copper：
450mm²+25mm²
Aluminium：
470mm²+35mm²| 200A| L1/L2/L3/ N：M10
PE:M8
80kW| Copper：
450mm²+25mm²
Aluminium：
470mm²+35mm²| 200A| L1/L2/L3/ N：M10
PE:M8
80kW+22kW| Copper：
470mm²+35mm²
Aluminium：
495mm²+50mm²| 225A| L1/L2/L3/ N：M10
PE:M8

Internal wiring diagram of equipment

• The internal input cables are N, L1, L2, L3, Eth, PE from left to right. The ‘Eth’ indicates a Ethernet cable.
• The cabinet grounding is divided into two parts, one is the grounding bar inside the cabinet, and the other is the grounding of cabinet shell, as shown in Figure 3.4-A.

Installation steps of charging equipment

Tools required

Unpacking the outer package of the cabinet

Tools required: herringbone ladder, claw hammer, art knife, protective gloves

• With the help of the herringbone ladder, straighten the metal card on the top of the packing material with a claw hammer, and remove the upper cover plate. As shown in Figure 3.4.1-A.
• Straighten all metal cards with a claw hammer, remove the surrounding wood boards, cut the PE bags wrapped around the cabinet with the art knife, and remove the PE bags and foam. As shown in Figure 3.4.1-B.
• Use a wrench to remove the four M12 bolts around the base, as shown in Figure 3.4.1-C.

Foundation drilling

Tools required: electric drill, φ16mm drill bit, protective gloves

• The hole size is shown in Figure 3.4.2-A.
• Drill four mounting holes with a diameter of φ16 mm and a depth of 80-85 mm on the cement mounting base with an electric drill corresponding to the hole position.
• Knock four M12 * 80 expansion bolts into the holes with a claw hammer, and then screw out the screw part, so that the expansion bolt casing is embedded in the base mounting hole. As shown in Figure 3.4.2-B.

Placing charger

• Use forklift to transport the cabinet to the installation base, and use the crane to lift the cabinet. It is shown in Figure 3.4.3-A.
• Suspend the cabinet above the cement base, open the front door of the cabinet, and extend the embedded cable from the bottom of the cabinet through the inlet hole (the rubber film of the inlet hole needs to be punctured). At this time, slowly lower the cabinet and pull the remaining cables out from the front door until the cabinet is completely placed on the base. As shown in Figure 3.4.3-B.

Note:

1. it is necessary to match the mounting hole of the cabinet base with the hole on the cement base;

2. The inlet cable sealing plate of the cabinet can be removed, advise to remove the sealing plate, pull the reserved cables into the cabinet through the cable inlet hole, install the sealing plate to make the cables pass through the cable gland, and secure the sealing plate to ensure airtightness.The inlet cable sealing plate is shown in Figure 3.4.3-C- (1).

3. During operation, please pay attention not to damage the cable and charging connector wire. As shown in Figure 3.4.3-C-(2).

4. The inlet cable sealing plate is removable (2) Do not press the charging connector cable Figure 3.4.3-C

   • Remove the left and right sealing plates as shown in Figure Figure 3.4.3-D.
   • Install M12 * 80 (4 pcs)expansion bolts on the drilled installation holes around the base, and tighten the bolts to ensure the cabinet is fixed reliably, as shown in Figure 3.4.3-E.
   • Install the left and right sealing plates as shown in Figure 3.4.3-F.

Inspection after installation

Tightness

• According to the requirements of design and protection level, the junction between the inlet sealing plate and the inlet cable at the bottom of the cabinet must be sealed with fireproof mud to prevent insects or dirt from entering the cabinet.

Stability

• After the pile is installed, shake the cabinet from different directions, and there should be no obvious loosening and shaking.

Clean up

• Dispose of all transportation and packaging materials in accordance with local regulations.
• Clean up the sundries inside and around the cabinet, such as small section of cable, binding tape, screw / nut, desiccant, etc. Do not leave installation tools on site or in the cabinet (record the type and quantity of tools to prevent omission).
• Wipe the insulation with anti-static cloth. Do not use any corrosive solvent.

Inspection

• Check whether the base is fixed and sealed.
• Check whether the internal components of the equipment are tight and reliable.
• Check whether the electrical connection and wiring are correct and complete, whether the connection is reliable, and whether the grounding is reliable.
• Check whether the cable terminal is loose, and calibrate the screw fixing the terminal.
• Check whether the cable is broken, damaged and scratched.
• Check whether the protection level of the equipment meets the requirements, especially the cable entrance at the bottom of the pile.
• Check appearance, marking, integrity, cleanliness.
• Check the installation of the equipment according to the foundation installation drawing.

Special version

• Need to place the charging connector on the storage device after charging is complete. As shown in Figure3.6.

Operation Interface

Charging process

Note: when the charger is in standby mode, the screen is in energy-saving mode. Before operation, touch the screen with your finger to light up the screen. After that it can be used for advertising below the operation interface.

Standby interface

Tip:

1. Select CCS connector or CHA connector according to the socket type of the car. The following is the process of selecting CCS, and the CHA steps are consistent with CCS.
2. Click “language” in any interface to switch the language mode of the UI. At present, Chinese, English and Korean are supported.

Waiting for connector insertion interface

Tip

• Connecting the connector to the car will jump to the connector insertion interface.

Select charging mode interface

Notice:

1. If you want to pay by QR -code, please directly scan the QR-code and start charging
2. lf you want to pay by RFID card, please directly swipe card and go on.
3. lf you use App to start charging, please directly click the APP to start.

Code scanning charging interface process

Tip

• After charging, click back. If the other charging connector is in charging state, it will jump to the charging interface of the other charging connector, otherwise it will jump to the main interface.

RIFID card charging interface process

Interface process of pay by card charging

Password charging interface process

Tip: click the input box to pop up a small keyboard. Enter the complete password through the keyboard and click OK to verify the password. After passing the verification, it will jump to the password start charging interface (password setting: administrator > Settings > MCU > function > offline charging password).

EVCCID charging interface process

Simple troubleshooting

Analysis and treatment of common faults

Refer to the maintenance manual for detailed treatment

7

| ****

Lightning protection failure

| l   Check the status of the lightning arrest device. A red visual window of lightning protection indicates damage. Please replace it.

1

| ****

Emergency stop fault

| l   Please check whether the emergency stop button is pressed and not reset. If so, rotate and reset the button.

11

| ****

Over temperature protection of air outlet

| l   Please check whether the air outlet of the system is blocked and whether too much dust accumulates on dustproof cotton.

l   Please check the status of the air outlet fan. Replace it if

anyone of them fails.

32

| ****

Access protection

| l   Please make sure the cabinet door is completely closed.

l   If the alarm still exists, please check the status of the micro switch. Replace it if it is damaged.

20

| ****

Charging module failure

| l   Check the module front panel, confirm the fault and find fault cause.

l   Pull out the faulted module and replace with a new one.

l   Check whether the alarm light of RCD device is on. If so, it indicates that the system has leakage fault.

3

| ****

RCD action

| l   It is necessary to check whether there is insulation fault in the circuit at the back end of RCD.

l   Check whether the casing is reliably grounded.

Notice: To prevent electric shock, all switches of the equipment and front-end power distribution switch of the equipment shall be disconnected during fault detection and treatment, and protective measures shall be taken.

After-sales service

If you have any questions or problems, please contact the equipment supplier. Before contacting the equipment supplier:

• Please check the troubleshooting measures in the chapter “5. Simple troubleshooting”.
• Please record the model and serial number of the equipment (name plate of the equipment) and the failure time.

© Copyright 2024 Manufacturer. All rights reserve

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>