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Autel MaxiCharger, Manual

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Autel MaxiCharger Manual Download Page 43

39 

 

4. 

Disconnect the EV charging cable from the EV. 

WARNING 

Hazardous  voltage.  Do  not  unplug  the  connector  suddenly  during  charging.  This 
may  cause  severe  damage  to  the  MaxiCharger  and/or  severe  personal  injury  or 
death. 

  Finish Charging 

Return the connector to the holster on the MaxiCharger. 

  Charging Errors 

This  section  depicts  several  common  problems  that  may  arise  during  your  charging 
session, along with possible causes/solutions to help you resolve those problems. If the 
problem persists, contact your local dealer or Autel Technical Support. 

  Connector Connection Error 

If the connector is not properly connected to your EV, then the Connector Not Connected 
screen  will  appear.  Insert  the  connector  into  your  EV’s  charge  port  and  check  the 
connection. 

  Authorization Failure 

If an error occurs when you start the authorization process but without starting charging, 
the  Authorization  Failure  screen  will  appear.  The  cause  and  possible  solution(s)  will 
display  on  the  screen.  Follow  the  on-screen  instructions  to  resolve  the  problem,  or 
contact your local dealer or Autel technical support. 

Summary of Contents for MaxiCharger

Page 1: ...ble at the time of printing Autel reserves the right to make changes at any time without notice While information of this manual has been carefully checked for accuracy no guarantee is given for the completeness and correctness of the contents including but not limited to the product specifications functions and illustrations Autel will not be liable for any direct special incidental indirect dama...

Page 2: ...GE INSTRUCTIONS 3 SYMBOLS ON THE MAXICHARGER 3 DISPOSAL INSTRUCTIONS 4 CYBER SECURITY 4 GENERAL INTRODUCTION 5 PRODUCT OVERVIEW 6 SPECIFICATIONS 9 LOCAL SERVICE PORTAL 12 CLOUD SERVICE PORTAL 13 PREPARATION 14 BEFORE YOU BEGIN 14 LOCATION REQUIREMENTS 14 PACKING LIST 16 INSTALLATION TOOLS 18 INSTALLATION 19 UNPACKING 19 MOVING THE MAXICHARGER 20 MOUNTING THE MAXICHARGER 21 ...

Page 3: ...35 BEFORE USE 35 CHARGING PROCEDURE 36 Standby Mode 36 Authorization 36 Start Charging 37 Charging 37 Stop Charging 38 Finish Charging 39 CHARGING ERRORS 39 Connector Connection Error 39 Authorization Failure 39 Charging Start Failure 40 Charging Failure 40 ENERGIZING THE MAXICHARGER 40 DE ENERGIZING THE MAXICHARGER 40 Measuring the AC Voltage 40 Measuring the DC Voltage 41 REMOVING CONDENSATION 4...

Page 4: ...INTENANCE 44 ROUTINE MAINTENANCE 44 Cleaning the MaxiCharger 44 Cleaning and Replacing the Filter 45 INSPECTION AND MAINTENANCE 46 REMOTE MAINTENANCE 46 MAINTENANCE SCHEDULE 47 TROUBLESHOOTING AND SERVICE 48 TROUBLESHOOTING 48 SERVICE 50 ...

Page 5: ...neer Qualifications Conventions Bold Text Bold text is used to highlight selectable items such as buttons and menu options Notes NOTE provides helpful information such as additional explanations tips and comments IMPORTANT indicates a situation that if not avoided may result in damage to the test equipment or vehicle DANGER indicates an imminently hazardous situation which if not avoided will resu...

Page 6: ...ng when you perform maintenance on the cabinet Keep the cabinet away from all water source Protect the MaxiCharger with safety devices and measures as specified by local rules Wear proper personal protective equipment such as protective clothing safety gloves safety shoes and safety glasses when necessary Owner Responsibilities The MaxiCharger owner runs the MaxiCharger for commercial or business ...

Page 7: ...he specifications of the MaxiCharger Installation Engineer Qualifications The installation engineers must Be qualified in accordance with all applicable local rules to do the work Be completely familiar with the MaxiCharger and its safe installation Obey all local rules and the instructions in the installation manual Usage Instructions Do not use the MaxiCharger and immediately contact the manufac...

Page 8: ...i connections The MaxiCharger can use a network interface for connection and information and data communication The owner bears the responsibility of providing a secure connection between the MaxiCharger and the owner s network or any other networks Appropriate measures shall be taken by the owner to shield the MaxiCharger the network the system and the interface from any security breaches unautho...

Page 9: ...ed for both indoor and outdoor use in fleets highway rest stops commercial parking garages and other locations DANGER If you use the MaxiCharger in any way other than described in its documentation you can cause death injury and property damage Use the MaxiCharger only as intended NOTE The images and illustrations depicted in this manual may differ slightly from the actual product This manual will...

Page 10: ...6 Product Overview 1 Light Sensor 2 Touchscreen 3 RFID Card Reader 4 EV Charging Cable 5 Ethernet Cable Port 6 AC Inlet Hole 7 Vent Front View Right View Left View ...

Page 11: ...7 8 Slot 9 Groove 10 Bezel 11 Lifting Handle Back View Bottom View ...

Page 12: ... B Electronic Control Unit C Inertial Measurement Unit 2 D Energy Meter PJ1 E Energy Meter PJ2 F 48 V Auxiliary Power G 24 V Auxiliary Power H AC Contactor KM2 I AC Contactor KM1 J Surge Protection Device K Fuse L Intermediate Relay ...

Page 13: ...ly CCS2 CCS2 charging for 2 EVs concurrently CCS2 Rated Max Input AC Current 87 A 96 A Input Voltage Range 400 VAC 10 10 50Hz Network Type TN S TN C TN C S TT Requires external RCD AC Input Connection 3P N PE DC Output Voltage CCS2 150 950 VDC CHAdeMO 150 500 VDC Cable Length 4 m 5 m Protection Overcurrent overvoltage under voltage ground fault over temperature short circuit insulation monitor sur...

Page 14: ...acteristics Enclosure Type Stainless steel 430 Operating Altitude 2000 m 2000 m 3000 m with power de rating Operating Temperature Range 30 C to 55 C 45 C to 55 C with linear power de rating Storage Temperature Range 40 C to 70 C Mounting Free standing cabinet User Interface Status Indication LED APP User Interface Autel Charge APP Autel Charge Cloud Connectivity Bluetooth Wi Fi Ethernet CAN ...

Page 15: ... portal Certification and Standards Charging System IEC 61851 1 IEC 61851 23 IEC 61851 21 2 Communication to the EV ISO 15118 PnC DIN 70121 CHAdeMO 1 2 EMC Compliance CCS 200 A CCS boost 300 A peak 400 A CHAdeMO 125 A 200 A Certification CE UKCA TR25 Design Life 10 year Warranty Base warranty 24 months after site acceptance test or 30 months after factory delivery Warranty extensions available ...

Page 16: ...es see Local Service Portal Operations Parameter Example indicates variables Charger ID DG1120B1 OCPP IP OCPP URL address Port number OCPP encryption method Country code UK Network selection auto wifi 4g Supplier Autel Control board SN C06G120 MAC address ba 9f aa 8c Password 000000 Connection ID 0 Connectors 1 and 2 initialization Charger configuration model 120 120kW MGR IP MGR URL MGR PORT MGR ...

Page 17: ... 5 QR code and credit card 6 NFC module and credit card 7 All Http test switch 1 Production environment Device Model Maxi CN DC Rated Power 120kW Rated Voltage 1000V Maximum current 200A Set Current 200A Max Power 120kW Cloud Service Portal Autel provides a set of cloud based tools to commission monitor and troubleshoot the MaxiCharger For more information contact your Autel e Mobility representat...

Page 18: ...ignal detection device to ensure the signal is above 90 dBm If the signal is below 90 dBm install repeaters to boost the strength of the cellular signal Repeaters are often required when installing the MaxiCharger in underground environments such as in an underground garage or enclosed parking space There is enough space available around the installation site to use a forklift or other lifting equ...

Page 19: ...ing port with the chosen cable length The standard charging cable length is 4 m and a 5 meter cable is also available For mounting on a pedestal To safely mount a MaxiCharger the concrete must be at least 80 mm thick The concrete surface must be perfectly flat and level Ensure the charging connector of the MaxiCharger can sufficiently reach the vehicle s charging port with the chosen cable length ...

Page 20: ... corresponding items can be found in the package For Mounting on a Wall MaxiCharger Wall Dock Holster Front Cover Holster Rear Cover M12 Lifting Eye Bolt 4 PCS M12 x 80 Expansion Bolt 4 PCS M6 x 60 Expansion Bolt 8 PCS Hex Key 6 mm Torx Screwdriver T25 ...

Page 21: ...17 For Mounting on a Pedestal MaxiCharger Pedestal M12 Lifting Eye Bolt 4 PCS M12 x 80 Expansion Bolt 4 PCS M12 x 30 Bolt 2 PCS Hex Key 6 mm Torx Screwdriver T25 ...

Page 22: ...et wrench 10 mm 19 mm Drill 16 mm 10 mm Cleaning tool Wire stripper Cable lug Voltage tester Digital multimeter NOTE The tools mentioned above are not provided Be sure to have all the tools prepared prior to the installation This tool list does not necessarily include all the tools you may need ...

Page 23: ... power supply before opening the MaxiCharger Do not touch the inside components of the MaxiCharger while it is powered on Ensure no voltage is applied while checking the MaxiCharger Operate the MaxiCharger only when its door is closed and locked Unpacking 1 Remove the outside packing and interior using appropriate tools 2 Inspect the MaxiCharger and the parts for installation for damage If damage ...

Page 24: ...pment crane straps and so on 1 Remove the packaging 2 Remove the four screws on top of the charger using a flathead screwdriver 3 Install and tighten the four M12 lifting eye bolts into the four holes 4 Connect the cables of the hoisting equipment to the eye bolts lifting loops 5 Move the MaxiCharger to the installation site ...

Page 25: ...el 2 Mark the four holes on the wall and set the wall dock aside NOTE There are three types of mounting holes on the wall dock the outer the middle and the inner Choose the most appropriate type based on the wall width For instance a narrow wall can use the inner mounting holes 3 Drill the four holes at the marked location measuring 16 mm in diameter and 80 mm in depth ...

Page 26: ...B spring washers C and flat washers D when the expansion sleeves A are stuck Set them aside 5 Attach the wall dock to the mounting location 6 Reinsert the flat washers spring washers and threaded bolts in order and tighten them using a 19 mm socket wrench to the torque 45 55 N m to secure the wall dock ...

Page 27: ...e wall dock and the groove D on the back of the charger will be fitted as well Ensure the charger is securely attached 8 Remove the four lifting eyebolts and reinstall the top screws Step 2 Mounting the Holsters 1 Place the holster rear covers against the wall 1040 mm above the ground and 300 mm from the MaxiCharger 2 Mark the eight mounting holes on the wall Remove the holster rear covers tempora...

Page 28: ...meter and 60 mm in depth 4 Attach the holster rear covers to the drilled location by screwing the eight M6 x 60 expansion bolts into the holes Tighten the screws to 3 N m using a 10 mm socket wrench 5 Position the holster front covers and press forcefully down to be secured ...

Page 29: ...ibed here are the minimum requirements Ensure that the installation complied with all applicable codes Step 1 Preparing a conduit 1 Trench and excavate a cable tunnel to accommodate the conduit 2 The conduit stub up should be minimum 100 mm 3 Pull the conduit and wire up through the exit opening leaving 600 mm flexible length for installation activities ...

Page 30: ... using a marker Remove the drilling template 3 Drill the four holes at the marked positions measuring 16 mm in diameter and 80 mm in depth 4 Clean the dust ashes Step 3 Mounting a pedestal 1 Tap the four M12 x 80 expansion bolts into the four drilled holes Remove the threaded bolts B spring washers C and flat washers D when the expansion sleeves A are stuck Set them aside ...

Page 31: ...al using a T25 Torx screwdriver to remove the front cover from the pedestal Set them aside 3 Place the pedestal onto the mounting location 4 Reinsert the flat washers spring washers and threaded bolts in order and tighten them using a 19 mm socket wrench to 45 55 N m ...

Page 32: ...e back of the charger to fit the protrusion A of the pedestal as shown below Ensure the charger is securely attached 2 Insert and fasten the included two M12 x 30 screws to the bottom holes A of the charger using a 19 mm socket wrench to secure the charger 3 Remove the four lifting eyebolts and reinstall the top screws ...

Page 33: ...MaxiCharger must be grounded to true earth An insulated grounding conductor must be installed as part of the branch circuit that supplies the MaxiCharger The grounding conductor should be grounded to earth at the service equipment or when supplied by a separately derived system at the supply transformer All connections must comply with all local codes and ordinances Use 25 mm2 wires Connecting to ...

Page 34: ...30 2 Loosen the two M8 hex screws A using the hex key and open the front door 3 Loosen the three M6 nuts to remove the insulating barrier A and set them aside ...

Page 35: ...ighten it to 20 5 2 5 N m Connecting to AC Input Wire 1 Use a wire stripper to remove 20 mm of the insulation from the end of the wires Ensure the stripped length is compatible with cable lugs 2 Use the crimping tool to attach the cable lugs to the end of the wires 3 Loosen the four M8 fasteners to attach the wires to the connectors L1 wire to the connector A L2 wire to the connector B L3 wire to ...

Page 36: ... Put the Ethernet cable through the Ethernet cable port at the bottom of the MaxiCharger 3 Plug the Ethernet cable into the RJ45 port 4 Tighten the cable gland A Installing the SIM Card 1 Locate the SIM card tray above the fan 2 Slide the SIM card in from the right ...

Page 37: ... For Mounting on a Pedestal 1 Close the front door by reinstalling the two M8 hex screws using the hex key and tightening the screws to 2 N m 2 Reinstall the side cover by inserting and tightening the six M5 security screws to 2 N m using the T25 Torx screwdriver 3 Organize the charging cables as described below a Remove the two brackets A by unscrewing the four M4 screws on both sides of the pede...

Page 38: ... Ensure the charging cables are allowed to remain its bending tolerance d Drape the cables over the cable holders on both sides of the pedestal and plug the connectors into the holsters 4 Reinstall the pedestal s front cover by screwing the four M5 security screws and tighten them to 2 N m ...

Page 39: ...nside Prevent the electronic components from being damaged by dust or particles 3 Use the multimeter to check the circuit connections among L1 L2 L3 N and PE If short circuit occurs contact Autel technical support otherwise reinstall the insulating barrier 4 Make sure that the RCCB and MCCB stay in the OFF position 5 Contact Customer Technical Support to turn on the upstream breaker then measure t...

Page 40: ...appear Manually select the appropriate connector on the touchscreen Authorization IMPORTANT Observe the screen for any abnormalities such as an error messages before starting a charge session Check the surroundings and the MaxiCharger for any abnormalities or damage as well If the screen displays an error message DO NOT use the MaxiCharger Contact Autel Technical Support When the Authorization Scr...

Page 41: ...wing the safety tests the charge session will start automatically Charging You will be informed of the progress during charging Information about the charging duration volume cost and power will appear on the Charging Screen Tap the right arrow button on the right to view more information about the charging status including SoC State of Charge current and voltage ...

Page 42: ... stops automatically 2 Normally you have to authorize again to finish charging using the same authentication method as was used to start QR code Scan the QR code by the Autel Charge app and tap the Stop button on the Charging Screen of the Autel Charge app RFID card Put the RFID card on the card reader again to finish charging Credit card Finish charging directly 3 When charging is finished your o...

Page 43: ...ou resolve those problems If the problem persists contact your local dealer or Autel Technical Support Connector Connection Error If the connector is not properly connected to your EV then the Connector Not Connected screen will appear Insert the connector into your EV s charge port and check the connection Authorization Failure If an error occurs when you start the authorization process but witho...

Page 44: ...hat provides power to the MaxiCharger to ON 2 The MaxiCharger will start and be ready for operation De energizing the MaxiCharger To de energize the MaxiCharger 1 Set the upstream breaker which provides the power to the MaxiCharger to OFF and lock it Make sure that this breaker stays in the OFF position during the procedure 2 Open the front door 3 Measure the AC voltage by referring to Measuring t...

Page 45: ... DC voltage between the output terminals make sure that all the measured voltages are 0 volts Power module group output 1 A to power module group output 1 B Power module group output 2 C to power module group output 2 D EV charging cable 1 output E to EV charging cable 1 output F EV charging cable 2 output G to EV charging cable 2 output H ...

Page 46: ...F position 3 Energize the MaxiCharger 4 Close the front door Wait 2 hours The internal heater of the MaxiCharger will heat inside and the condensation will evaporate 5 Open the front door 6 Set the main breakers from the OFF position to the ON position 7 Close the front door Local Service Portal Operations Setting the OCPP Parameters NOTE The OCPP parameter setting should be performed by an instal...

Page 47: ...s can take a few seconds 4 Set the following parameters Running environment current running environment OCPP IP IP address of the OCPP OCPP URL URL of the OCPP OCPP PORT port number of the OCPP MGR IP IP address of the management platform MGR URL URL of the management platform MGR PORT port number of the operational management platform NOTE Make sure that you type the URL or ID correctly and witho...

Page 48: ... If you remove the safety devices for maintenance reinstall them after completing the work Cleaning the MaxiCharger The MaxiCharger is powder coated The coating must be kept in good condition When the MaxiCharger is in a corrosion sensitive environment superficial rust may appear on welding points Visible rust has no risk to the integrity of the MaxiCharger To remove rust 1 Stop any charging proce...

Page 49: ...he inside of the MaxiCharger is dry during cleaning Do not use caustic solvents sprays solvents or abrasives The MaxiCharger is equipped with a filter with a large mesh area to prevent the electronic components from being damaged by dust Clean the filter every 3 months not to exceed 6 months Replace the filter annually To clean or replace the filter 1 Before cleaning and replacing be sure to stop ...

Page 50: ...ections are needed for safe use Check if the MaxiCharger was struck by lightning Check if the MaxiCharger was damaged due to an accident or fire Check the MaxiCharger installation site has been flooded WARNING Stop any charging processes and do not connect the power to the MaxiCharger until all the inspections are complete Remote Maintenance The MaxiCharger has the function of connecting to cloud ...

Page 51: ...y Actions Connector Every 3 months Check for cracks or ruptures on the connector Input Cable Every 3 months Check for cracks or ruptures on the cable Filter Annually Replace the filter MaxiCharger Every 6 months Clean and check for damage ...

Page 52: ...mer Technical Support Autel Technical Support The touchscreen displays a message Unable to lock the connector The connector is not connected correctly to the EV Plug the connector into the EV charging port correctly and retry Try another MaxiCharger to charge the EV Customer Technical Support Autel Technical Support The touchscreen displays a message Insulation error detected There is an insulatio...

Page 53: ...l Support Internet failure See QR Code Scanning Failure solutions above Customer Technical Support Autel Technical Support Charging Failure The connector is not properly connected Check the connector connection and reconnect it Try another MaxiCharger to charge the EV Customer Technical Support Autel Technical Support EV error Try another MaxiCharger to charge the EV Contact your EV manufacturer f...

Page 54: ...port Service If you cannot find solutions to your problems with the aid from the table above please contact Autel Technical Support AUTEL Europe Phone 49 0 89 540299608 Monday Friday 9 00 AM 6 00 PM Berlin Time Email evsales eu autel com evsupport eu autel com Address Landsberger Str 408 4 OG 81241 Munich Germany ...

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