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4

Installation

4.1 Installation Preparations

Checking Before Installation

●

Before unpacking the charging module, check the outer packing materials for

damage, such as holes and cracks, and check the model of the charging

module. If any damage is found or the model is not what you required, do not

unpack the charging module but contact the dealer as soon as possible.

●

After unpacking the charging module, check whether the deliverables are

intact and complete. If any item is missing or damaged, contact your dealer.

Tools

Figure 4-1 Tools

R100020G1 Charging Module

User Manual

4 Installation

Issue 05 (2021-11-16) Copyright © Huawei Digital Power Technologies Co., Ltd.

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Summary of Contents for R100020G1

Page 1: ...R100020G1 Charging Module User Manual Issue 05 Date 2021 11 16 HUAWEI DIGITAL POWER TECHNOLOGIES CO LTD ...

Page 2: ... features described in this document may not be within the purchase scope or the usage scope Unless otherwise specified in the contract all statements information and recommendations in this document are provided AS IS without warranties guarantees or representations of any kind either express or implied The information in this document is subject to change without notice Every effort has been mad...

Page 3: ...igh level of risk which if not avoided will result in death or serious injury Indicates a hazard with a medium level of risk which if not avoided could result in death or serious injury Indicates a hazard with a low level of risk which if not avoided could result in minor or moderate injury Indicates a potentially hazardous situation which if not avoided could result in equipment damage data loss ...

Page 4: ...nces in the figure showing the installation clearances Issue 04 2021 08 06 Optimized the illustration about the input connector directions Issue 03 2021 01 18 Updated the technical specifications button operations and power cable temperature resistance Issue 02 2020 09 03 Updated the technical specifications and installation requirements Issue 01 2020 06 30 This issue is the first official release...

Page 5: ... and Storage 21 4 Installation 22 4 1 Installation Preparations 22 4 2 Installation Requirements 24 4 3 Installing a Charging Module 25 4 4 Connecting Cables 27 4 4 1 Connecting DC Output Power Cables 27 4 4 2 Connecting AC Input Power Cables 29 5 Powering On the Charging Module and Setting Parameters 30 6 Maintenance 31 6 1 Routine Maintenance 31 6 2 Troubleshooting 31 6 3 Replacement 37 7 Techni...

Page 6: ...ironment 42 7 3 Input 43 7 4 Output 43 7 5 Protection 44 A Acronyms and Abbreviations 47 R100020G1 Charging Module User Manual Contents Issue 05 2021 11 16 Copyright Huawei Digital Power Technologies Co Ltd v ...

Page 7: ...y Follow all the safety precautions and instructions provided by the company The safety precautions given in this document do not cover all safety precautions The company will not be liable for any consequence caused by violation of the safety operation regulations and design production and usage standards Declaration The company will not be liable for any consequences in any of the following circ...

Page 8: ... able to correctly perform all operations Follow local laws and regulations when installing operating or maintaining the equipment The safety instructions in this document are only supplements to local laws and regulations If there is a probability of personal injury or equipment damage during installation immediately stop the operations report the case to the project owner and take feasible prote...

Page 9: ...e devices Pay attention to the warnings cautions and precautionary measures in this document and on the nameplates Promptly replace warning labels that have worn out Keep irrelevant people far away from the equipment Use insulated tools or tools with insulated handles Personnel Requirements Personnel who plan to install operate or maintain the equipment need to receive thorough training understand...

Page 10: ...quipment is permanently connected install an easily accessible disconnector at the exterior of the equipment Before making electrical connections switch off the disconnector on the upstream equipment to cut the power supply if people may contact energized components If a high electricity leakage tag is attached on the power terminal of the equipment you must ground the protective ground terminal o...

Page 11: ...ry powder extinguisher instead of a fluid fire extinguisher to put out the electrical fire otherwise electric shocks may occur Do not re enter the building or affected area until it has been deemed safe by qualified professionals Do not stop protective devices Pay attention to the warnings cautions and precautionary measures in this document and on the nameplates Promptly replace warning labels th...

Page 12: ...e system monitoring module over the CAN protocol You can set the output voltage mode of the charging module on the system monitoring module and perform voltage adjustment current limiting and startup or shutdown for the charging module Figure 2 1 Model number Model number description No Meaning Description 1 Module series name Rectifier 2 Maximum output voltage 1000 V DC 3 Rated output current 20 ...

Page 13: ...matic switching based on the module output port voltage factory default 2 Automatic switching based on the preset voltage 3 Automatic switching based on the battery voltage reported by the monitoring module Manual switching is also supported You can manually switch to the low voltage or high voltage mode on the system monitoring module Low voltage mode The output voltage ranges from 150 V DC to 50...

Page 14: ...cally allocated to the charging modules in a group to facilitate module identification Note that the software address may be different from the slot number of the charging pile The hardware address of a charging module can be set to stay consistent with the slot number of the charging pile The charging module saves the hardware address upon power off NOTE The software address will be reallocated a...

Page 15: ...rouping Control of modules in different groups on the bus by the system monitoring module Storage of group numbers and hardware addresses upon power off 2 3 Appearance NOTICE Do not remove the warranty label or barcode Otherwise the product warranty will be forfeited Figure 2 2 Charging module 1 Display panel 2 DC output and signal ports 3 AC input ports 2 4 Display Panel 2 4 1 Display Panel Figur...

Page 16: ...ndicators Indicator Status Description Power indicator green Steady on Normal The charging module has AC input Off The charging module has no AC input Blinking at 4 Hz Querying in progress Blinking at 0 5 Hz Module hibernation standby Alarm indicator yellow Off Normal The charging module does not generate any protection alarms R100020G1 Charging Module User Manual 2 Overview Issue 05 2021 11 16 Co...

Page 17: ...utput short circuit Communication failure between the primary side and the secondary side Abnormal discharge circuit of the output capacitance Unrecoverable no output breakdown NOTE If the charging module has no output due to mains failure no AC input the indicators are off Indicators are not mutually exclusive The three indicators can turn on at the same time if conditions are met During software...

Page 18: ...are address 127 decimal can be restored After the hardware address is modified the group number is restored to the default value Parameters can be set using buttons and the settings are saved upon power failure Group number GrP is displayed by default Hold down the button to enter the group number display screen static The group number is displayed in decimal format Parameters can be set only unde...

Page 19: ...set using buttons Table 2 5 Status code mapping Status Code Status Description H00 Default status H01 Silent mode H02 Input derating H03 Temperature derating H04 Air filter blocked H05 Manual switching mode H06 250 kbps baud rate H07 Customer version configuration mode 2 4 4 Button Operations The buttons allow you to set the output voltage output current hardware address and group number and to st...

Page 20: ...ton to switch to the mode display state Auo static 2 Hold down the left or right button to enter the setting state Auo blinking 3 Press the right button to switch to the dEG mode dEG blinking 4 Hold down the left or right button to enter the display state dEG static 5 Press the left or right button to switch to the output voltage display state Current output voltage static 6 Hold down the left or ...

Page 21: ...value Adjusted hardware address high middle or low order nixie tube blinking 5 Hold down the left or right button to save the settings Hardware address static Then the voltage display screen is displayed Setting the Group Number To set the group number you do not need to switch to the dEG mode The group number settings of the charging module are saved upon power failure only for the company protoc...

Page 22: ...2 4 DC output and signal ports Table 2 9 Output port definition Pin Item Function 1 2 1000 V DC Negative output pins 1 and 2 must be connected in parallel 3 4 1000 V DC Positive output pins 3 and 4 must be connected in parallel 5 CANBH CAN high level signal 6 CANBL CAN low level signal 7 CANBH CAN high level signal 8 CANBL CAN low level signal 9 CAN_GND Signal ground 10 LINK_CHECK_OK Insertion and...

Page 23: ... input power cables is Huafeng DY98 02Z01 You need to check the connector dimensions and prepare it by yourself Install the connector based on the requirements of the manufacturer NOTICE Before connecting a cable pay attention to the direction of the connector especially the silkscreen on the front and the chamfer on the rear of the connector to ensure that the cable is correctly connected R100020...

Page 24: ...cables can be connected in either of the following ways Output connector with welded board on signal pins The connector model is Huafeng DY98 01Z03 Install the external adapter board provided by the customer on the signal terminal weld and secure the board and then connect the communications cable R100020G1 Charging Module User Manual 2 Overview Issue 05 2021 11 16 Copyright Huawei Digital Power T...

Page 25: ...imped cables on signal pins Table 2 12 Output connector definition Pin Item Function 1 2 1000 V DC Negative output pins 1 and 2 must be connected in parallel 3 4 1000 V DC Positive output pins 3 and 4 must be connected in parallel 5 CANBH CAN high level signal 6 CANBL CAN low level signal 7 CANBH CAN high level signal 8 CANBL CAN low level signal 9 CAN_GND Signal ground 10 LINK_CHECK_OK Insertion ...

Page 26: ...10 of the DC output connector must be short circuited Otherwise the charging module cannot be started R100020G1 Charging Module User Manual 2 Overview Issue 05 2021 11 16 Copyright Huawei Digital Power Technologies Co Ltd 20 ...

Page 27: ...otected against rains snows and mechanical impact during transportation Storage Unused products should be stored in packing cases and placed in a dry well ventilated warehouse where the temperature ranges from 10 C to 40 C the relative humidity is not greater than 80 and no corrosive gas exists The product can be stored up to one year R100020G1 Charging Module User Manual 3 Transportation and Stor...

Page 28: ...ny damage is found or the model is not what you required do not unpack the charging module but contact the dealer as soon as possible After unpacking the charging module check whether the deliverables are intact and complete If any item is missing or damaged contact your dealer Tools Figure 4 1 Tools R100020G1 Charging Module User Manual 4 Installation Issue 05 2021 11 16 Copyright Huawei Digital ...

Page 29: ...able with withstand voltage 1000 V DC temperature resistance 105 C and conductor cross sectional area of AWG 6 for example UL 10269 AWG 6 Two positive cables and two negative cables If the cable surface temperature is higher than 90 C use high temperature cables AC input power cable Recommendation 1 flame retardant cable with withstand voltage 600 V AC temperature resistance 105 C and conductor cr...

Page 30: ...re not covered under the warranty Pollution sources refer to the following areas Areas within 0 5 km of salt water such as the sea Areas within 3 km of serious pollution sources such as metallurgic plants coal mines and heat and power plants Areas within 2 km of medium pollution sources such as chemical factories rubber plants and electroplating factories Areas within 1 km of light pollution sourc...

Page 31: ...llation Procedure CAUTION Do not keep the installed charging module in the standby or power off state for an extended period NOTE Ensure that all the mounting holes on the panel are secured by screws Ensure that the nixie tubes are on the left side of the charging module during horizontal mounting Ensure that the nixie tubes are on the upper side of the charging module during side mounting The cha...

Page 32: ...de mounting Step 2 Tighten the screws in the middle of the panel and install and tighten the screws on the upper and lower parts of the panel and the screws on the mounting ear R100020G1 Charging Module User Manual 4 Installation Issue 05 2021 11 16 Copyright Huawei Digital Power Technologies Co Ltd 26 ...

Page 33: ... metal socket is reliably crimped The minimum pull out force is 500 N for 6 AWG cables or cables with a cross sectional area of 16 mm2 The front end of the heat shrink tubing should not exceed the scale on the metal socket The outer diameter of the metal wire covered with the heat shrink tubing is less than or equal to 9 1 mm R100020G1 Charging Module User Manual 4 Installation Issue 05 2021 11 16...

Page 34: ...ith welded board on signal pins Install the external adapter board prepared by the customer on the signal terminal weld and secure the board and then connect the communications cable Output connector with crimped cables on signal pins Crimp the communications cable prepared by the customer connect the cable to the metal socket and then insert the cable into the corresponding pin of the output conn...

Page 35: ...ce is 400 N for 8 AWG cables or cables with a cross sectional area of 10 mm2 The front end of the heat shrink tubing should not exceed the scale on the metal socket The outer diameter of the metal socket covered with the heat shrink tubing is less than or equal to 7 5 mm Figure 4 9 Connecting AC input power cables R100020G1 Charging Module User Manual 4 Installation Issue 05 2021 11 16 Copyright H...

Page 36: ...ge 150 500 V DC in low voltage mode and 150 1000 V DC in high voltage mode Check that the power indicator on the charging module is steady on and the voltage displayed on the nixie tubes is the same as that measured by the multimeter Set the hardware address of the charging module if grouping is required R100020G1 Charging Module User Manual 5 Powering On the Charging Module and Setting Parameters...

Page 37: ...ed regularly to avoid dust buildup at the air inlet as dust can cause overheating inside the charging module 6 2 Troubleshooting If the charging module is faulty you can locate the fault based on the error code displayed on the nixie tubes If no error code is displayed locate the fault based on the indicator status Table 6 1 List of error codes Error Code Symptom Measure E00 No fault N A R100020G1...

Page 38: ... and circuit breakers of the charging module are normal If not rectify the fault 3 Exchange the slot of the faulty module with that of a normal module If the fault occurs only in the original slot the slot is abnormal and needs to be handled 4 Exchange the slot of the faulty module with that of a normal module If the fault occurs again after the slot exchange replace the faulty module or contact t...

Page 39: ...e with that of a normal module If the fault occurs only in the original slot the slot is abnormal and needs to be handled 3 Exchange the slot of the faulty module with that of a normal module If the fault occurs again after the slot exchange replace the faulty module or contact the technical support E06 Output overvoltage 1 Exchange the slot of the faulty module with that of a normal module If the...

Page 40: ...lot of the faulty module with that of a normal module If the fault occurs only in the original slot the slot is abnormal and needs to be handled 3 Exchange the slot of the faulty module with that of a normal module If the fault occurs again after the slot exchange replace the faulty module or contact the technical support E09 Poor connection 1 Check whether the charging module is properly connecte...

Page 41: ... fault 5 Check whether the charging module is properly connected If not rectify the fault 6 Check whether the fan of the charging module is stuck by foreign objects If yes rectify the fault 7 Exchange the slot of the faulty module with that of a normal module If the fault occurs only in the original slot the slot is abnormal and needs to be handled 8 Exchange the slot of the faulty module with tha...

Page 42: ...ut due to output overvoltage 1 Check whether the air channel of the charging module is seriously blocked If yes rectify the fault 2 Check whether the output of the charging module is short circuited If yes rectify the fault 3 Exchange the slot of the faulty module with that of a normal module If the fault occurs only in the original slot the slot is abnormal and needs to be handled 4 Exchange the ...

Page 43: ... and put on the ESD wrist strap and ESD gloves Step 2 Take out the charging module DANGER Do not touch the terminals at the rear of the charging module Avoid scalding due to module overheating 1 Loosen the screws on the left side of the panel and the screws in the mounting ear on the right Figure 6 1 Loosening screws horizontal mounting R100020G1 Charging Module User Manual 6 Maintenance Issue 05 ...

Page 44: ...he screws in the middle of the panel and remove the charging module Figure 6 3 Removing the charging module horizontal mounting R100020G1 Charging Module User Manual 6 Maintenance Issue 05 2021 11 16 Copyright Huawei Digital Power Technologies Co Ltd 38 ...

Page 45: ...nstall the new charging module 1 Slowly push the charging module into the slot Figure 6 5 Installing a charging module horizontal mounting R100020G1 Charging Module User Manual 6 Maintenance Issue 05 2021 11 16 Copyright Huawei Digital Power Technologies Co Ltd 39 ...

Page 46: ...nel and install and tighten the screws on the upper and lower parts of the panel and the screws on the mounting ear Figure 6 7 Securing a charging module horizontal mounting R100020G1 Charging Module User Manual 6 Maintenance Issue 05 2021 11 16 Copyright Huawei Digital Power Technologies Co Ltd 40 ...

Page 47: ... system monitoring module sends a startup command to the charging module Check that the green indicator on the charging module turns on to ensure normal running Step 6 Set the hardware address of the charging module if grouping is required as described in Button Operations End R100020G1 Charging Module User Manual 6 Maintenance Issue 05 2021 11 16 Copyright Huawei Digital Power Technologies Co Ltd...

Page 48: ...Specifications Dimensions H x W x D 84 mm x 218 mm x 518 mm without packaging 135 mm x 360 mm x 660 mm with packaging Weight 16 kg without packaging 18 kg with packaging IP rating IP20 7 2 Environment Table 7 2 Environment Item Specifications Operating temperature 35 C to 75 C The output power is derated when the temperature is higher than 55 C Relative humidity 5 95 RH non condensing R100020G1 Ch...

Page 49: ... 4 Output Table 7 4 Output Item Specifications Rated output voltage 1000 V DC Rated output current 20 A Output power Rated power 20 kW When the voltage ranges from the power conversion point to 260 V AC the output is linearly derated from full load to half load When the voltage ranges from the power conversion point to 528 V AC the charging module outputs at full load Power conversion point range ...

Page 50: ...to 0 5 A Current sharing imbalance 5 x 20 A 40 A Soft start time 3 8s Hibernation function Supported Standby power consumption during hibernation 10 W tested average power consumption under 400 V AC rated input voltage at 25 C Hot swapping Supported Communications bus protocol CAN The default CAN communication baud rate is 250 kbps The CAN communication baud rate can be changed to 125 kbps Ripple ...

Page 51: ...nabled in case of a short circuit Lockout if three or more short circuits occur within 1 minute Overtemperature protection Normal mode The module shuts down for protection when the ambient temperature exceeds 78 5 C and does not automatically recover after the temperature becomes normal Silent mode The module shuts down for protection when the ambient temperature exceeds 65 5 C and does not automa...

Page 52: ...re 7 2 Output characteristic curve Figure 7 3 Output derating curve R100020G1 Charging Module User Manual 7 Technical Specifications Issue 05 2021 11 16 Copyright Huawei Digital Power Technologies Co Ltd 46 ...

Page 53: ...AAcronyms and Abbreviations C CAN Controller Area Network R100020G1 Charging Module User Manual A Acronyms and Abbreviations Issue 05 2021 11 16 Copyright Huawei Digital Power Technologies Co Ltd 47 ...

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