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Circutor Raption Series, Service Manual

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Circutor Raption Series Service Manual Download Page 57

Service Manual

57

                                                                         

Raption 

H

Contactors

This board closes when Charging Station is powered ON for a power modules detection 
procedure. This procedure may last around 5 minutes. If relays board remains closed for 
a longer period of time, it means that one or more power modules haven't been detect-
ed. Check if they are correctly supplied.

Relays board has to be open in standby.

It will close too when Charging Station is charging in the DC side. 

AC contactor closes when Charing Station is charging in the AC side.

DC Relays board:

AC Contactor:

DC Relays board

AC Contactor Raption 50

AC Contactor Raption 50 HV 

 

  

AC Contactor Raption 50 EVO
AC Contactor Raption 100   

Summary of Contents for Raption Series

Page 1: ...Raption Series SERVICE MANUAL M186C01 03 21B...

Page 2: ...I 7 A 7 D 7 E 7 G 8 10 10 21 M186C01 03 21B Changes in the following sections 2 C 4 A 4 C 4 E 4 G 5 F 7 G 10 Disclaimer CIRCUTOR SA reserves the right to make modifications to the device or the unit...

Page 3: ...f this manual can be reproduced copied translated or transmitted in any form or by any means without the prior written permission of the original manufacturer Information provided in this manual is in...

Page 4: ...Disconnector 36 B RCD 37 C MCBs 38 D RCBOs 40 E Backflow diode and Clixon 41 F Transient surge protector 43 G Isolation protection device 44 5 Other components 48 A Heater system 49 B Ventilation sys...

Page 5: ...ng the error 70 D Error code in remote 78 E Communication errors 80 F OCPP Errors 81 G Power modules errors 87 8 Maintenance 90 9 Annexes 94 10 Technical Data 96 A Raption 50 96 B Raption50HV Raption5...

Page 6: ...s not responsible for events arising from such breach ELECTRIC RISK This symbol indicates a potentially hazardous situation which if not avoided may result in a risk of fire serious injury or death Th...

Page 7: ...y strictly with electrical safety regulations according to your country Do not make repairs or manipulations with the unit energized Only trained and qualified personnel should have access to the elec...

Page 8: ...Raption 8 Service Manual 2 A Main features 1 3 2 5 6 7 16 8 4 9 10 11 12 13 14 15 18 19 20 17 21 22 23 24...

Page 9: ...Decorative rear panel 9 Handle 10 CHAdeMO holder 11 CCS holder 12 AC holder or socket 32A 1 13 CCS light beacon 14 CHAdeMO light beacon 15 Antenna 16 Air outlet 17 Exit DC cable 18 Touch screen Axial...

Page 10: ...Raption 10 Service Manual B Dimensions Units specified in millimeters...

Page 11: ...upper part there are the electronic boards the electrical protections and the electrical actuators In the medium part there are the power modules In the lower part there is the power input supply sect...

Page 12: ...Raption 12 Service Manual 1 A ELECTRONIC BOARDS ETC Raption 50...

Page 13: ...r 10A 230VAC GMR 4M 2a2b K13 3 10 Three phase MID energy meter P9 1 11 AC MCB Q9 1 12 Auxiliar contact 6A Q9 2 13 RCD protection T4 1 14 RCD protection T9 1 15 Panel thermostat NC 10A 250Vac B13 1 16...

Page 14: ...Service Manual 1 B ELECTRONIC BOARDS ETC Raption 50 HV Raption 50 EVO AND Raption 100 7 24 7 25 7 26 7 27 7 7 7 1 7 2 4 3 5 6 7 8 7 7 7 9 7 10 7 11 7 12 7 14 13 13 7 15 7 16 7 17 7 18 7 19 7 20 7 21...

Page 15: ...P12 1 11 AC MCB Q12 1 12 Auxiliar contact K12 2 13 RCD protection T5 1 14 RCD protection T12 1 15 Panel thermostat NC 10A 250Vac B16 1 16 Contactor 4 Poles KM13 1 17 Mode 4 Control Board N17 1 18 24Vd...

Page 16: ...Manual 2 POWER MODULES 1 7 2 3 4 6 5 13 8 9 12 11 10 Depending on the model of Raption chosen are assembled power modules of 12 5kW in Raption 50 and power modules of 25kW in Raption 50 HV Raption 50...

Page 17: ...W 1 A5 1 for Raption 50 8 Power module 25kW 1 U6 1 for Raption 50 HV Raption 50 EVO and Raption 100 3 9 Power module 12 5kW 2 A5 2 for Raption 50 9 Power module 25kW 2 U6 2 for Raption 100 10 Centrifu...

Page 18: ...h disconnector 3 poles neutral 160A F3 1 Main circuit breaker 3 Ground terminal block 4 Transient surge protector device optional component 5 Communications module for CEM energy meters T4 1 6 Three p...

Page 19: ...EVO AND Raption 100 2 1 1 Differential circuit breaker 16A 30mA Class A Q3 2 2 Switch disconnector 3 poles neutral 250A Q3 1 Main circuit breaker 3 Terminal block Note in order to find more details a...

Page 20: ...When using a unit with Mechanical connector locking accesory at DC holders is not possible to pull back the connectors from holders until user has shown RFID card and selected the connector he wants...

Page 21: ...ion 50 2 PC Screen A15 3 for Raption 50 HV Raption 50 EVO Raption 100 3 RFID card reader B12 1 for Raption 50 3 RFID card reader B15 2 for Raption 50 HV Raption 50 EVO Raption 100 1 3 2 Common for all...

Page 22: ...tion 22 Service Manual 4 5 6 7 4 RCBO 1P N 10A 30mA class A Q14 1 5 Service schuko E14 1 6 Communications module for CEM energy meters P4 2 7 Three phase MID energy meter Indirect measurement 5 10 A P...

Page 23: ...Service Manual 23 Raption 6 BLOCK DIAGRAM...

Page 24: ...ts communicating via TCP IP Ethernet and its respectives IPs As there are IPs already in use when connecting a service terminal laptop to the charging station use DHCP or work with static IP 192 168 1...

Page 25: ...Service Manual 25 Raption...

Page 26: ...esy lights connector The PC screen HMI and the RFID reader are located at the right door Normally at the RJ45 port it is connected the Ethernet cable coming from the router when it is installed Howeve...

Page 27: ...evices Electrical scheme Screen has two RS485 connectors In one of them there is the RFID reader and the other there is a bus of communications with many devices RS485 Connector 1 Mode 4 Mode 3 Meter...

Page 28: ...Raption 28 Service Manual Update Screen can be updated from the Setup Webpage Find the details of the procedure in the Instruction Manual Firmware file can be obtained from the Expert Area...

Page 29: ...4 J9 Inputs for Tacometer relay state CHA Precharge state CCS 5 J10 Inputs for Opto J and relays state of CCS 6 J23 Outputs PWM turbines control 7 J4 LEDs lock system Mode 4 Board B Mode 4 board is c...

Page 30: ...J7 RS485 1 M communications with isolation detector device 12 J8 RS485 2 S Communications with the screen 13 J5 CAN 1 communications with CHAdeMO cable 14 J6 CAN 2 communications with Expansion board...

Page 31: ...ally by the Screen So when Screen is updated both components are getting a new firmware version each one its corresponding Check in the previous point the procedure to update the Screen and find the n...

Page 32: ...d C This board is in charge of the communications of the CCS connector It works as a bridge between the EV and the Mode 4 translating the communications from PLC to CAN pro tocol This board has a defa...

Page 33: ...e steps described in the guide How to update CCS board IoTecha M2ievse which can be found in the Expert Area Additionally remote upgrade via Screen firmware update same as the Mode 4 board is expected...

Page 34: ...The device integrates an Ethernet port which does not allow connectivity to TCP IP networks It is used for internal use as digital inputs and outputs The default configuration modbus address is set at...

Page 35: ...eing charged Error LED red Proximity error or E status request CPU LED red Device powered ON RX TX yellow RS 485 communications working To update this component it is necessary an ICD3 device Updating...

Page 36: ...e charger These devices isolates the Charging Station from the grid The disconnector for Raption 50 HV 50 EVO and Raption 100 not only is a circuit breaker it also protects against overcurrents and sh...

Page 37: ...by a compact system that includes a current transformer and differential relay that activates when current leakage is detected There are two of them installed one in the AC circuit and another one in...

Page 38: ...ice Manual MCBs C There are few MCBs in the Raption protecting components from overcurrents and over temperatures in the cables AC Circuit Model for Raption 50 Model for Raption 50 HV Raption 50 EVO a...

Page 39: ...Service Manual 39 Raption Power Modules Model for Raption 50 Model for Raption 50 HV Raption 50 EVO and Raption 100 Note Q7 1 and Q7 2 not included in Raption 50 HV...

Page 40: ...Raption 40 Service Manual RCBOs D There are three RCBOs in the Raption protecting the Auxiliary branches From the left to the right Service Schuko Ventilation Heater Main supply...

Page 41: ...ither on the EV or in the Charging Station side In order to keep a safe temperature in this zone it is installed a radiator and a fan Additionally it is installed a Clixon This component will notify t...

Page 42: ...s located just after the power modules when positive and negative wire are collected and before the output contactors And in the next picture Fan managed by the Expansion board Clixon system that send...

Page 43: ...changeable cartridges based on varistor Also it is equipped with a visual indicator and a remote indicator Remote indicator is not integrated so make sure visually that the status of the cartridges is...

Page 44: ...power up It will be flashing if there is some connection error Alarm LED AL1 Lights when alarm value AL1 has activated or overvoltage alarm flashes during connection error Alarm LED AL2 Lights when al...

Page 45: ...this connector Bender device can be configured manually using its buttons or via software on RS485 communications Check the Annexes to find the configuration steps in case service staff has to do the...

Page 46: ...Raption 46 Service Manual Electrical scheme Raption 50 scheme Raption 50 HV Raption 50 EVO and Raption 100 scheme...

Page 47: ...Service Manual 47 Raption...

Page 48: ...Raption 48 Service Manual 5 Raption series is divided internally into 5 different circuits Main branches DC AC Auxiliar branches Supply of internal compo nents Heater Ventilation Service schuko...

Page 49: ...inimum values The objective is to keep the unit over 15 C So heater will be activated previously in order to avoid reaching this value Thermostat Additionally there is a protection system for the comm...

Page 50: ...1 Disconnects the supply of the internal components 2 Activates the heater So as a result when the Charging Station is powered and the environmental temper ature is lower than 15 C this system is acti...

Page 51: ...s of it There are 4 fans in the Charge Station 1 On the roof 2 On the Backflow diode 3 In the Power modules section 4 In the A8 screen this component was not originally installed Screen s s fan is wor...

Page 52: ...and the card RFID reader has a LED status indicator Looking at the LED status indicator colour Green LED RFID configured and ready to be used In this case there is no additional configuration require...

Page 53: ...n D AC meter The three phase electrical energy meter for AC side measures current and voltage that is supplied to the AC socket The meter has RS485 communications with the Screen A1 This meter is a CE...

Page 54: ...The three phase electrical energy meter for indirect measurement for the DC side measures current and voltage that supplies the DC sockets The meter has RS485 com munications with the Screen A1 This...

Page 55: ...supply Q11 1 triggers Depending on the model of Raption chosen it can be two different components In case of having a Raption 50 it is included a SuperCapacitors board and a Raption 50 HV Raption 50 E...

Page 56: ...n 56 Service Manual G Power supplies Power supply 24Vdc Power supply 12Vdc There is a power supply of 12Vdc and another one of 24Vdc supplying most of the inter nal components fans boards screen route...

Page 57: ...time it means that one or more power modules haven t been detect ed Check if they are correctly supplied Relays board has to be open in standby It will close too when Charging Station is charging in t...

Page 58: ...arge circuit Output contactors allow Welding detection function When one of the contactors is welded Mode 4 control board will receive this information and will identify which is the faulty contactor...

Page 59: ...a CSMS so Raption can be remotely managed It also allows remote access which is very useful for maintenance remote diagnosis and eventually to adjust the settings of the Charging Station such as tarif...

Page 60: ...LEGIC Prime ISO14443 A B compatible to part 4 MIFARE DESFireEV13 MIFARE Plus S X3 MIFARE Pro X3 MIFARE SmartMX3 SLE66Rxx my d move 3 SLE44R351 PayPass1 NTAG2xx4 ISO15693 EM4x353 Tag It3 SRF55Vxx my d...

Page 61: ...This RFID reader has two particular points It is supplied with 5Vdc so it is necessary a power supply device converting from 24Vdc to 5Vdc It communicates via RS232 protocol It is necessary to conver...

Page 62: ...ts with AC side that build Socket outlet instead of a cable it is possible to install shutter protection Socket outlet has electrical active parts which can be accessible Shutter solution pro tects pe...

Page 63: ...Service Manual 63 Raption...

Page 64: ...ors coming from different parts or devices When the Error screen appears the Information touch button has to be pressed in order to see the error message as can be seen below which needs to be decoded...

Page 65: ...It is essential to answer the questions exposed below to receive a proper support Answering these points will be helpful for customer too in order to understand the error and allow the maintenance st...

Page 66: ...harging session does not even start During initial checks Starting process Randomly during charging session Stopping process Permanent error 3 Does the error appear with a specific car model CIRCUTOR...

Page 67: ...sual inspection on the charger All devices powered Any external device physically damaged Any internal device damaged Any cable performing a bad contact Any device in fault status Service staff can pe...

Page 68: ...s storage even for a few days but this will vary depending on the activity of the EVSE To solve this problem it is possible to install a Micro SD card in the Screen Important events will be stored the...

Page 69: ...Service Manual 69 Raption http IP ADDRESS services cpi record xml Then to access to a specific register for example n 2 http IP ADDRESS services cpi record xml id 2...

Page 70: ...gine errors and also DC errors Errors from AC side are normally easier to identify Most of the times they can be fixed with the Engine error section Procedure for DC charging is more complex than AC F...

Page 71: ...ning of the code The correct order to check these levels is 1 Socket One plug may have more than one socket Error can affect one socket and the plug still being available 2 Plug Error affecting one pl...

Page 72: ...32 Power Supply dropped RCD 0X40 64 RCD dropped TEMPERATURE 0x80 128 Temperature out of range OTHER 0x100 256 Other error not defined above COMMUNICATION 0x200 512 One or more devices configured on t...

Page 73: ...ency button pressed TEMPERATURE 0x200 512 Temperature out of range EV_ COMMUNICATION_ DEVICE 0X400 1024 Communication between charge point and vehicle failed EV_CORD 0x800 2048 Proximity pin error Mod...

Page 74: ...Contactor failed METER 0x80 128 Meter failed EMERGENCY 0x100 256 Emergency button pressed TEMPERATURE 0x200 512 Temperature out of range EV_ COMMUNICATION_ DEVICE 0X400 1024 Communication between char...

Page 75: ...or the Connector error CCS2 or CHA and lines for the Converter power modules Both of them Connector and Converter provide information about the Error and the states of the machine M Est Finally there...

Page 76: ...al Identify if your Raption is Gen1 or Gen2 and select proper option in the tabs from the top Introduce the lines from the error code in the Connector faulted and Converter section Example about how t...

Page 77: ...oder tool will show indications regarding the issue the faulty component or the possible causes It is shown the current error or alarm and the historical In some cases historical is helpful in order t...

Page 78: ...0 0000 0000 0000 0020 Historical error flags 0000 0000 0000 0000 0000 0000 0000 0120 Predecessor errors 0 0 Status message flags 0000 0000 0000 0000 0000 0001 0000 0001 Historical status message flags...

Page 79: ...s messages 0 0 State machines 701 700 2080 80 1 0 701 700 1080 80 1203 Nov 8 09 39 18 raption user info pss 311 VECTOR OF ERROR FLAGS OBJECTS Error Flags Object Module Type 10 Name Converter Error fla...

Page 80: ...of errors can be generated by many reasons Device improperly powered Cables incorrectly fastened or bad contact Problems in the RS485 bus Faulty device The setup webpage allows service staff to identi...

Page 81: ...to the network Otherwise check modem parameters some celullar providers requires especial APN configuration If no modem Then ethernet IP address must be static using gateway and DNS from this network...

Page 82: ...n be solved adjusting the MTU to a lower value Default value is 1500 and a good solution would be to adjust it to 1000 or 1200 bytes In this way problem is solved as messages size is lower than the fi...

Page 83: ...valid public ID timeout Raption eVolve Master The password of the modem f e admin01 in Teltonika Rut240 has been changed It cannot be changed Check the list of Blocked IPs of the modem If IP of the ch...

Page 84: ...DNS protection parameter in Teltonika router Check if DHCP ON whithin Network section on web page from CP Reboot required Evolve WB Smart Check if embedded modem is connected to the network Otherwise...

Page 85: ...check modem parameters some celullar providers requires especial APN configuration If no modem Then ethernet IP address must be static using gateway and DNS from this network Do not use DHCP ON CS Con...

Page 86: ...l reason Invalid HTTP status Charger reaches the CS but it has rejected the charge point ID configured CS should check if charger is added in their side Check charge point ID whithin OCPP configuratio...

Page 87: ...wing table for further diagnosis Red Replace rectifier Meaning of colours in relation with LED status Colour LED Status System Status Green ON Correct operation OFF Not able to provide output power An...

Page 88: ...ghts placed in rectifier 1 LED named OK Green Yellow bi color 2 LED named RFA Red Meaning of colours in relation with service Colour System Status Green Everything ok No diagnostic or user interaction...

Page 89: ...0 2s ON 0 2s OFF Not in charging enable mode Firmware update green led and yellow led flash alter nately 1 pulse Communication out of time 2 pulse Input AC over voltage under voltage protection 3 puls...

Page 90: ...is absolutely necessary make sure to switch OFF all circuit breakers before starting to work The charger contains electric mechanical and consumable components that must be periodically checked in ord...

Page 91: ...4 years 16K cycles 5 years 20K cycles Estimated time hours for replacement General maintenance Preventive maintenance I I I I I I 1 5 Control devices Screen ensemble Raption I I I I R 0 3 Connectors a...

Page 92: ...important point to check is the torque of the components Here a list indicating the specific torque for those components Component Description Torque MCBs 2 Nm RCBOs 2 5 Nm Disconnector 13 Nm Backflow...

Page 93: ...Service Manual 93 Raption AC output contactor 2 5 Nm DC output contactors 6 5 Nm Hat top 3 5Nm Clamp for CHAde MO connector 7Nm Clamp for CCS connector 3Nm Clamp for AC connector 2 5Nm...

Page 94: ...has been created the next list All this material is available in CIRCUTOR s Expert Area where can be downloaded by being registered List of Annexes 1 CCS cable maintenance 2 CHA cable maintenance 3 W...

Page 95: ...e Manual 95 Raption Annexes Find all the documents from the List of Annexes in the Expert Area If you have any trouble ask sat circutor com for the requested file or document https expertarea circontr...

Page 96: ...eTX TCP IP Cellular Modem 4G GPRS GSM WiFi Hotspot 4 Interface protocol OCPP 1 5 or OCPP1 6J ENVIRONMENTAL CONDITIONS Operating temperature 30 C 45 C Storage temperature 40 C 60 C Operating humidity 5...

Page 97: ...ge range 400 V 10 Model for 480 V mains Voltage range III 480 277 V 10 Model for 480 V mains Power supply II P N Model for 480 V mains Voltage range II 208 240 V 10 Power factor 0 98 Efficiency 95 at...

Page 98: ...1643 1 class II Cable Length 5 5m all cables Anti vandal connector protection CHAdeMO CCS mechanical connector locking Type 2 Charging Socket Shutter Network hub Switch TCP ethernet 8 ports Switch TCP...

Page 99: ...50 kW 400Vdc DC 50 kW 400Vdc CCS1 T1C32 DC 50 kW 400Vdc AC 22 kW DC 50 kW 400Vdc AC 7 4 kW CCS2 T2C32 DC 50 kW 400Vdc AC 22 kW Output voltage range DC 50 500 Vdc DC 50 500 Vdc CCS1 T1C32 DC 50 500 Vd...

Page 100: ...CHA T1C32 DC 50 kW 400Vdc AC 22 kW DC 50 kW 400Vdc AC 43 kW DC 50 kW 400Vdc AC 7 4 kW CCS2 CHA T2C32 DC 50 kW 400Vdc AC 22 kW Output voltage range CCS1 CHA T1C32 DC 50 500 Vdc AC 400 V DC 50 500 Vdc...

Page 101: ...125 A DC 125 A AC 32 A Number of connectors 1 2 2 Connector type M B MODELS CCS1 T2S32 CCS1 CHA T1C32 CCS1 CHA T2S32 Maximum AC input current 63 A 480V 3F 35 A 208 240V F N 63 A 480V 3F 35 A 208 240V...

Page 102: ...HAdeMO 3 meters AC Cable length 3 meters Socket protection Locking System Weight 235 kg Dimensions D x W x H 355 x 940 x 1800 mm Without cable engaged STANDARDS IEC 61851 1 IEC 61851 23 IEC 61851 21 2...

Page 103: ...it control DC AC by software OPTIONAL DEVICES Wireless Comunication LATAM APAC 4G LTE GPRS GSM Surge protection Four pole transient surge protector IEC 61643 1 class II Cable Length 5 5m all cables An...

Page 104: ...rrent 76 A 76 A 108 A Required power supply capacity 53 kVA 53 kVA 75 kVA Maximum output power DC 50 kW 400Vdc DC 50 kW 400Vdc CCS1 T1C32 DC 50 kW 400Vdc AC 7 4 kW CCS2 T2C32 DC 50 kW 400Vdc AC 22 kW...

Page 105: ...er DC 50 kW 400Vdc AC 22 kW CCS1 CHA T1C32 DC 50 kW 400Vdc AC 22 kW DC 50 kW 400Vdc AC 7 4 kW CCS2 CHA T2C32 DC 50 kW 400Vdc AC 22 kW Output voltage range DC 150 920 Vdc AC 400 V CCS1 CHA T1C32 DC 150...

Page 106: ...dc DC 150 920 Vdc AC 208 240 V Maximum output current DC 125 A DC 125 A DC 125 A AC 32 A Number of connectors 1 2 2 Connector type M B MODELOS CCS1 T2S32 CCS1 CHA T1C32 CCS1 CHA T2S32 Maximum AC input...

Page 107: ...mum output power DC 100 kW 400Vdc DC 100 kW 400Vdc CCS1 T1C32 DC 100 kW 400Vdc AC 7 4 kW CCS2 T2C32 DC 100 kW 400Vdc AC 22 kW Output voltage range DC 150 920 Vdc DC 150 920 Vdc CCS1 T1C32 DC 150 920 V...

Page 108: ...kW CCS1 CHA T1C32 DC 100 kW 400Vdc AC 22 kW DC 100 kW 400Vdc AC 7 4 kW CCS2 CHA T2C32 DC 100 kW 400Vdc AC 22 kW Output voltage range DC 150 920 Vdc CA 400 V CCS1 CHA T1C32 DC 150 920 Vdc AC 400 V DC...

Page 109: ...0 A CCS AC 32 A Number of connectors 1 2 2 Connector type M B MODELS CCS1 T2S32 CCS1 CHA T1C32 CCS1 CHA T2S32 Maximum AC input current 132 A 480V 3F 35 A 208 240V F N 132 A 480V 3F 35 A 208 240V F N 1...

Page 110: ...Raption 110 Service Manual...

Page 111: ...es has been improperly used or the storage installation and maintenance instructions listed in this manual have not been followed Improper usage is defined as any operating or storage condition contra...

Page 112: ...CIRCUTOR SA Vial Sant Jordi s n 08232 Viladecavalls Barcelona Tel 34 93 745 29 00 Fax 34 93 745 29 14 www circutor com central circutor com...

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