Alphatec DB9.0043 AC Wallbox Power 22kW with key switch Instruction Manual

Alphatec DB9.0043 AC Wallbox Power 22kW with key switch

Important safety information

It is essential that you pay close attention to the safety instructions and precautions marked in this manual. Further safety and operating guidelines are displayed on and in the charging station.
The symbols used have the following meaning:

Installation and operation

The described charger for electric vehicles is a product that may only be connected by qualified electricians. Specialists should have familiarized themselves with the topic of electromobility and the associated standards.

Any damage to the outer casing or the charging cables or to insulation parts of the charging socket could possibly lead to fire or risk of injury to personnel. Regular checks and careful handling of these devices will prevent such risks. Please note that the prescribed residual current circuit breakers for personal protection must be installed in the pre-installation or in the supply line of each charging point.

With some versions of the charging point, one or more RCDs (RCD, 30mA or RCD 6mA) are also directly installed in the charging device. Even in such cases the supply line, which can then be a common line for two charging points, must be protected by miniature circuit breakers LS (MCB) or ideally FI and LS (RCD

• MCB).

Each charging point then also has its own FI (RCD, Type B or A+) within the pole.
It is very important that the equipment and the housing parts are well grounded. The earthing must be checked by a qualified electrician during installation. Depending on the installation site, the necessary measures for lightning protection must be evaluated If necessary, additional lightning protection devices must be installed in the buildings or the existing pre- installation.

Place of installation

Please be aware that the right place for Installation should be where the charging inlet to the choose car will be. It is recommended that the connected cable should not lead to stumbling.
Please also consider that exposure to direct sunlight will lead to reduced charging current when the internal heat decrease automatically the current as long as the charger cools down.

The product consists of flame-retardant plastic.
For installation on wooden walls or other fire prone or heat-sensitive surfaces, the use of a metal wall plate or the available pillar made of powder-coated special steel is recommended.

The charger is particularly suitable for private or semi-public use vandalism resistance is only limited (IK08). Depending on the equipment,
RCD (FI) type A are installed for each charging point, MID meters and residual current detectors are integrated.
Other equipment or other types and accessories can be found on our website.

This is an electrotechnical product which generates waste heat
when used. In the warm season and when operating under full load, the device can thus heat up. The integrated temperature measurement then reduces the possible charging power. To avoid this, it is strongly recommended to not install the charger in a place where it is exposed to extreme solar radiation.

Recommended tools for installation

• screwdriver for slotted screws
• screwdriver Torx TX20
• screwdriver PH1 and PH2
• socket wrench set
• e-mobility test simulator
• earth connection and RCB tripping test equipment
• in best case additional: thermal imaging camera to check low-loss connections of the supply lines

Drill pattern

Installation with a domestic outlet

Vorgeschriebene Leistungsschutzschalter und Fehlerstromschutzschalter in den Zuleitungen JEDES Ladepunktes.
Required MCB and RCB (FI) – RCB in the supply lines of Every charging point.

Block circuit diagram

Installation step by step

1. remove cover

   • Open 2 screws from the bottom side and 2 screws from the topside to remove the door

2. wall attachment

   • Use 4 screws to fix the box to the wall. Depending on the wall material use the enclosed screws and plastic dowels.

   • Connect the power source according to local standards and laws to the clamps. Ensure that the connections are tight and correct.

3. recloser

   • Position the cover on the top side off the basic part as shown in the picture and close it by pushing it down. Close the 4 screws after the lid is in position.
     

4. lid fixation

   • Fixation of the cover with 2 screws from the rear. The cover must be closed completely and without any visible distance to the base.
     

Information

• Screws are from rear to make it more difficult for unauthorized person to open the charger. For installation it is recommended to use an offset screwdriver or similar.

Initial inspection

• Open 2 screws from the bottom side and 2 screws from the topside to remove the door

1. visual inspection
   • Housing, base, foundation, the screw connection of the components as well as charging cables and charging sockets should not exhibit any visible signs of damage.
2. functional test
   • Use the adapter for vehicle simulation to check the faultless function. Run through all relevant charging sequences.
3. Measurement
   • Testing and measuring of the protective devices.
4. written report
   • Results of the inspection, functional tests and measurements are to be documented and filed in the product and installation file.

Key lock connection and access control

The key lock connection functions as an external switch to interrupt or release the state of operational readiness. By that it offers an effective way of access control.

External switch for interrupting or releasing of the charging device
Remove the bridge as shown in the picture below to use this function. Connect the switchable output of the relay or the key switch instead. When the concoct bridge is opened the charging device is active but not ready to start charging, because the communication with the vehicle is interrupted.

Eco-Mode and Power-Charging Switch /connection to master EVC

Information
This setting affects both charging points. The maximum current of 6A in ECO MODE is divided between the two charging points.

Connection of both EVC to master-slave configuration

l2C bus connection for local power sharing

reducing the maximum current
Additional reduction of the maximum current is possible through external control. An external relays is connected to the master of the connected charge controller.

Maximum current adjustment

• It is possible to set a current limit by using the on board rotary switch. This should only be performed by a qualified electrician or ordered with maximum setting. The maximum current affects the whole installation, power source and charging behavior. You shall not attempt any changes
  to the setting without your local electrician.

Maximum current setting

Step by step

1. Ensure that the power source is disconnected.
2. Turn the rotary switch with a small screwdriver to the correct position (see table).
3. Close the cover.
4. Enable the power source. The settings will be active after a reboot of the charger after a power-off.
5. Connect the charger to the test-simulator or a car which shows the current while charging.
6. Control the settings with the real current.

LED display of the settings during the boot sequence: The blue flashing sequence shows the tens place, the green flashing sequence shows the ones place of the current.

z. B.
32 ampere = 3 long blue blinks and 2 short green blinks
15A = 1 x blue / 5 x green

Connection to external control

Information

• Use the RS 485 / Modbus Bus connection for external control.

Information

• With the input from an external or internal Relay on K401, the charger can reduce its charring current to minimum e. g. 6A (eco-mode) for example when a Photovoltaic system cannot provide enough current.
  For more detailed information contact the manufacturer or your local electrician.

Bus connection and function

changing the Modbus ID

1. write new ID to address 6
2. read address 6 to check
3. write 1 to address 7 to save EEPROM
4. write 1 to address 8 to reboot

Information

•  For BUS monitoring and changing the settings it is possible
  to use standard programs like MoD Bus and USB to RS485 Converter. e.g. DSD TECH or Model SH-U10. It is also possible to use any other relevant program or converter. There are plenty of them on the market.
  For better understanding the basic structure of these kind of programs is shown in the following.

• Use the bus terminating resistor for groups of chargers that are connected to the BUS at the end of the connected group.
  

us connection and function

read parameters:   read   Holding   registers (0x0,3)

Address| parameters| description
0| EVSE status 1 ready,
2 connected, 3 charging|
1| actual Modbus ID, default 1|
2| installed Amps (ready for rotary switch)|
3| force unlock (always 0)|
4| 0 = charging station enabled; 1 = disabled|
5| throttled A| max Amperage
6| new Modbus ID|
7| write new ID to EPROM|
8| reboot unit (always 0)|
11| firmware version|
write parameters:   Write   Multiple   registers (0x10)

address| parameters| description
0| N/A (egad only)|
1| N/A (read only)|
2| N/A (read only)|
3| force unlock (always 0)| locking pin, socket version
4| 0 = charging station enabled; 1 = disabled|
5| set actual Amps, must be higher than 6A| lower than 6A goes into WAIT
6| new Modbus ID|
7| 0 = no action, 1 write parameter 6 to EPROM|
8| 0 = no action, 1 unit reboots|

Maintenance and cleaning

• According to DGUV V3, the operator of electrical equipment is legally obliged to check the systems to ensure that they are in proper condition with regard to functionality and safety.

maintenance times

• Through initial testing before commissioning
• Through periodic inspections conducted regularly
• After each modification or repair

Caution!

• Installation and maintenance should only be carried out by qualified electrical contractors. In the event of a breach of this requirement, the manufacturer’s warranty obligations shall expire with immediate effect.

technical data sheet

general

product line| DL22CSAC-S2S2_Dual-Port Basic WB, 1x22kW or max. 2x11kW
product number| DL22CSAC-S2S2
packaging| pallet, Euro pallet
| IEC 61851-1 :2012-01 ; VDE 0100-722
| 30/EU
standards| TS 61439-7
| IEC64/1846/CDV:2012 (DIN VDE 0100-722)
enclosure

structure| Wall box
 material and surface| plastic, front lacquered
surface protection and color *| single layer of varnish, front inlet grey
mounting| Screws
dimensions (h x w x d)| 400 mm x 500 mm x 135 mm

• Depending on the ordered quantity, customer specific color selection and the available color options.
  Anschluss / connection

  connection to the power supply| Domestic connection according to regional regulations
  nominal voltage| 400V
  rated current| 32A (can be limited to 16A)
  nominal frequency| 50Hz
  back-up-fuse| 32A per charging point (11kW version = 16A)
  supply line| at least 4 mm² (10mm²) per charging point
  communication network| network cable min Cat 6, CAN bus, depending on Type
  Interface| I²C, RS485, external relays
  remote diagnosis, software update| not in standard type
  vehicle interface

  charging point left| charging socket, type 2, IEC 62196-2
  charging point right| charging socket, type 2, IEC 62196-2
  output voltage| 230 / 400V
  maximum charge current| 3 x 32 A per charging point, 32A max. in total (power sharing)
  maximum charging

power

| 22kW each charging point, 22kW in total
IEC 61851-1| not in standard type
customer interface

back end| not in standard type
au then fifi cation| charging socket, type 2, IEC 62196-2
operation| 230 / 400V
consumption meters| not in standard type
safety and protective devices

current surge MCB per charging point| LS (MCB), 32A, 3 poling, C-characteristics integrated in pre-installation
residual current device per charging point*| FI (RCCB), type A, 30mA

integrated in pre-installation

energy meter and current monitoring| MID meter on request
lightning protection| May necessary if pole for installation or distance to the building requires extra lightning protection

• For maintenance purposes, RCD should be installed in the pre-installation. RCD TypA+ or TypA should be preferred (Also: RCBO, TypA) Also possible RCD TypB (not permitted in line with Typ A RCD´s !)

Information

• The installed electricity meters are approved for billing according to EU law (MID-compliant). Depending on country regulations, further approvals may be necessary. Approval on request.

operating conditions

protection class| 2 acceding to DIN EN 61140 / VDE0140-1
surge voltage category| 3
max. surrounding storage temperature| -30° bis +80°
max. ambient operation temperature| -30° bis +40° (+50°)
relative air humidity| 5 – 95%
(non condensing)
pollution degree| 3
housing protection class| IP44 / IK08

• Environmental temperature +50°C with simultaneous maximum charging current can lead to electronic reduction of the charging power.
  certification

  CE| DIN EN 61851-1 / IEC 61851-22|
  DIN IEC/TS 61439-7
  Emission according to EN55011 Class Conducted emission EN55011B Interference immunity EN61000-4-4, Burst: +/- 2,0kV
  EN61000-4-5: Surge: +/- 1kV LN, +/-2kV
  RoHS, WEEE
  compliant|
  accessories

  column for freestanding installation| on request
  customer log, adhesive sheeting| on request
  customized colors| on request
  charging cable type 1/type 2 or type 2/type 2| extended length or spiralized cables on request
  item number for original   accessories   from Aliphatic

  accessories item| item number
  stainless steel pillar| STV-Ape
  charging cable| K5eM
  concrete base stainless steel pillar| FF-ST-24-45

Dimensions packaging

Dimensions of product

Product type – product code

www.alphatec-systeme.de

Alphatec Schaltschrank systeme GmbH
Bibersbach 2a | 93179 Brennberg | Deutschland
Tel.: +49 (0)9484 951090 |
Fax: +49 (0)9484 951095 [email protected]

References

• Alphatec Schaltschranksysteme GmbH

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