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User Manual

Keywatt 50 Cube

www.ies-synergy.com

DUM1017795-EN_V001

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Summary of Contents for Keywatt 50 Cube

Page 1: ...User Manual Keywatt 50 Cube www ies synergy com DUM1017795 EN_V001 ...

Page 2: ... your own personal noncommercial use all or part of this document on any medium whatsoever without permission of IES Synergy given in writing You also agree not to establish any hypertext links to this document or its content IES Synergy does not grant any right or license for the per sonal and noncommercial use of the document or its content except for a non exclusive license to consult it on an ...

Page 3: ...pecification 12 Technical specification 12 6 Handling and storage instructions 14 Storage 14 Transport 14 7 Installation 15 Visual inspection 15 Upstream protection of charger power circuit 15 Electrical connection 15 Input harness connection 16 Battery harness installation 17 Connector and cable support installation 18 Installation of the plexiglass cover 19 8 Charger operation 20 Starting up 20 ...

Page 4: ...bol to avoid possible injury or death I I DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or seri ous injury I I WARNING WARNING indicates a potentially hazardous situation which if not avoided can result in death or seri ous injury I I CAUTION CAUTION indicates a potentially hazardous situation which if not avoided can result in minor or mod era...

Page 5: ...ormations needed for installation use and end of life of the Keywatt 50 Cube This guide must be read with other related documents This guide is intended for users of the charger Document scope This guide concerns the following charger P N PFCU1017795 Related documents Document title Reference User Manual DUM1017795 EN User comments We invite you to write to us to communicate any inaccuracies or om...

Page 6: ...www ies synergy com User manual DUM1017795 EN 6 Derating Derating curve in current according to the mains voltage Derating curve in power according to the temperature ...

Page 7: ... sure to mechanically lock the connectors before connecting the charger to the mains The vehicle cable must be disconnected from the vehicle before any intervention on the charger Do not attempt to open the unit or remove any of its components covers shutters doors etc except by qualified personnel Do not open the door at any time while input power is present Wait 15 minutes before opening the doo...

Page 8: ...tor its protocol cable can be changed in a few minutes in Combo CHAdeMO or GB Based on many years of experience IES mobile chargers provide a robust solution to facilitate the development of new vehicles by manufacturers Solid and reliable they are also used to charge the batteries of new vehicles at the end of the production line Easily connectable to the mains without resorting to a heavy instal...

Page 9: ...P button to stop the charge 3 Voltage presence indicator light 4 Charger ready 5 Failure indicator light 6 Auxiliary function indicator light 7 Charge indicator light 8 Emergency stop button 9 Control display 10 CAN bus connection on SUB D9 port 11 USB port 12 Ethernet network connection Note May change depending on version or technical modification ...

Page 10: ...ector 14 Charger disconnection device 15 Battery harness Harting connector Note May change depending on version or technical modification Battery harness harting connector Position Description 16 GND module 17 BAT module 18 BAT module 19 Signal 20 pins module Note May change depending on version or technical modification ...

Page 11: ...able resistance GND 11 Ground LOCK 3 Connector locking signal PROXY 4 Connector connection check GND 16 Ground CP 9 Control Pilot GND 13 Ground S S1 7 Start Stop charge 1 S S2 1 Start Stop charge 2 12V 2 12V P P 10 Charge permission prohibition GND 14 Ground CAN L 6 CAN_H CAN H 12 CAN_L 17 Internal use 18 Internal use 19 Not used 20 Not used ...

Page 12: ...protection Class Class II DC output Output voltage VDC 500 4 Max VDC 200 Min Output current IDC 125 A 1 2 Max IDC 5 A Min Max Output Power POUT 50kW Max Output connector Swapped vehicle cable Car Plug coupler COMBO1 COMBO2 CHAdeMO GB Output cable length 6 m Internal DC output protection Hardware and software short circuit protection Yes Over voltage protection VDC 550 Nom Overheating internal prot...

Page 13: ...ax Type of installation Trolley 4 wheels Protection type EN60529 IP IP21 Cooling systems Heatsink with forced air flow by fans IP54 without air filter Climatic Environment constraints Operating temperature with derating 20 C to 40 C 3 Storage temperature 40 C to 70 C Relative humidity without condensation RH 10 to 95 Installation altitude Alt 2 000m Max Pollution category 2 1 Max output current wi...

Page 14: ... the state of the charging station packaging regularly Do not store the charging station for more than a year without powering it up to avoid the deterioration of in active electronic components Transport During the entire transport phase take all necessary measures to maintain the stability of the transport crate NOTICE RISK OF DAMAGE TO THE CHARGING STATION Improper storage or handling may cause...

Page 15: ...on of the protective devices with the charger All external circuits connected to your product must be of the Very Low Voltage SELV type and be Limited Pow er Sources less than 15VA and meeting the requirements of Chapters 2 2 and 2 5 of the standards IEC60950 1 2005 A1 2010 A2 2013 and EN60950 1 2006 A11 2009 A1 2010 A12 2011 A2 2013 Electrical connection The charger is equipped with a power cable...

Page 16: ...connectors before connecting the charger to the mains or to the EV Input harness connection 1 Note Visual inspection of the circuit breaker status is possible through the transparent cover of the circuit breaker hatch If the circuit breaker is in the down position disabled you must reset it by following the steps below 1 Remove the screws x6 from the circuit breaker hatch on the right side of the ...

Page 17: ...efore connecting the charger to the mains Failure to follow these instructions can result in death or serious injury Ouput cables and connectors are described below IES ref Description Length Manufacturer Connector FLPLA018118 COMBO 1 CABLE 6m IES FLPLA018074 COMBO 2 CABLE 6m IES FLPLA018116 CHADEMO CABLE 6m IES The connection of the charging cable to the charger must be done at a standstill This ...

Page 18: ...ack the locking tabs under the Harting connec tor locking levers 8 Tighten the locking tabs nuts x4 I I WARNING RISK OF ELECTRIC SHOCK INJURY AND OR BURNING Be sure to mechanically lock the connectors before connecting the charger to the mains or to the EV Failure to follow these instructions can result in death or serious injury Connector and cable support installation 1 Place the supports MKBRN0...

Page 19: ...ation of the plexiglass cover 1 Place without tightening completely the screws FXVIS012307 x4 of the cover MKBRN018953 on the con nector and cable supports position 2 Place the cover position 3 Fix the cover tightening the screws G G Recommended torque 3 N m ...

Page 20: ...n result in death or serious injury Turn the disconnecting device to the position I ON to power up the charger The charger displays its name after a startup phase represented by XS50 Keywatt by IES Universal Charger Choose the charging mode with the RED button Combo 2 selected Confirm with the GREEN button Combo 1 selected Confirm with the GREEN button CHAdeMO selected Confirm with the GREEN butto...

Page 21: ...Y flashes Connect the vehicle and press the GREEN button to start 9 9 In the event of an error the charger will display one of the two messages below Pwr module failure 0 OK and 2 Fail or No power module Starting a charge in CHAdeMO Connect the charging cable to the vehicle secure firmly Press the START button The LED CHARGER READY flashes The charger starts to communicate with the vehicle STARTIN...

Page 22: ...r locks the charging plug and performs the insulation test INSULATION TEST INSUL TEST COMPLETED successfully 9 9 If there is an insulation failure Cancel charge INSULATION FAILURE If there is no failure the charge starts CHARGING 30min 23A 360V 40 The display indicates the time left the charging current and voltage and the current battery capacity The LED CHARGE flashes with a long pulse for 2 sec...

Page 23: ...NG CONNECTOR Disconnect the connector and press the RED button The charger performs the stop charge procedure Charging is stopped either by the BMS or by the operator pressing the STOP button The charge status indicator flashes slowly for 2 seconds Note The language can be configured via CCU Manager ...

Page 24: ...when unlocking the CHAdeMO connector discon press the RED button Error message End of charge displayed when an error occured during the charge Combo mode Once the Combo mode selected the charger performs an internal check and initialization Please wait for a few seconds Initialization The LED CHARGER READY flashes Connect vehicle to start charge 9 9 In the event of an error the charger will displa...

Page 25: ...on Communication in progress Communication has been established Then the charger performs the insulation test INSULATION TEST INSUL TEST COMPLETED successfully 9 9 If there is an insulation failure Cancel charge INSULATION FAILURE If there is no failure the charger launches a precharge phase this step depends on the EV PRECHARGING 1000 mA 320V Once the precharge level is reached and after receivin...

Page 26: ...maining time to full SOC 22 min Remaining time to Bulk SOC 10 min Full SOC 75 Bulk 80 Full 100 Voltage target 390 V Current target 50 A Full charge not complete Bulk charge not complete Pmax 20 000 W Vmax 420 V Imax 60 A When charging is complete STOPPING CHARGE EV welding detection in progress Charge ended Please disconnect EV The charger performs the stop charge procedure Charging is stopped eit...

Page 27: ...n the event of an error the charger will display one of the two messages below Pwr module failure 0 OK and 2 Fail or No power module Starting a charge in GB Connect the charging cable to the vehicle secure firmly The LED CHARGER READY flashes Vehicle connected and press the GREEN button Then the charger performs the insulation test INSULATION TEST INSUL TEST COMPLETED successfully 9 9 If there is ...

Page 28: ...he le temps depuis le début de la charge le courant de charge la tension et la capacité actuelle de la batterie L utilisateur peut afficher d autres paramètres et informations en appuyant sur START comme Voltage target 390 V Current target 50 A Pmax 20 000 W Vmax 420 V Imax 60 A When charging is complete STOPPING CHARGE Charge ended Please disconnect EV The charger performs the stop charge procedu...

Page 29: ...m User manual DUM1017795 EN 29 Emergency Stop messages The LED FAILURE flashes Emergency Stop Manual Emergency Stop Emergency Stop Software Emergency Stop Emergency Stop PSU connection lost Internal Fault Emergency Stop ...

Page 30: ...o incoherent state internal fault Connector_Lock CHAdeMO plug locking coil defect BatteryIncompatib Battery voltage range not suitable for the charger BatteryMalfunction Vehicle battery fault No CAN communication at charge start up Incorrect current or voltage data Abnormal voltage at charge start up ChargingStopCtl Charge start up denied CAN or physical i o line VehicleShiftPosition Gearshift is ...

Page 31: ...y power supervisor in ternal PSU Bad Vred Input voltage out of range detected by power supervi sor internal OverCurrent Output current exceeds the maximum value ERR EV Charge Status Not Ready The vehicle requests a charge but its status is not ready ERR Bad Pilot State during charge The pilot changes from status C during charging EV bad pilot state at start Pilot status is not A or B at start Erro...

Page 32: ... OR BURNING Only qualified trained and authorized people will repair replace or adjust this equipment Failure to follow these instructions can result in death or serious injury Fuse ref Location FUCRT011930 200A fuses x2 installed on the output bat tery side FUCRT015901 10A fuses x3 FU1 FU2 FU3 installed on the mains board CRAUX017939 ...

Page 33: ...fore any maintenance work to ensure that it is separated from the supply of AC mains Failure to do so may cause physical injury or damage to the electrical system and charging unit Maintenance of the charging station shall be conducted only by a qualified technician Wait 15 minutes before opening the door Residual voltage remains present after the power failure Failure to follow these instructions...

Page 34: ...nment End of Life Recycling This product has been optimized to reduce the amount of waste produced at the end of their useful life and for better recovery of component parts and materials when following customary processing procedures Products have been designed so that their components can be processed by conventional procedures decon tamination where this is recommended reuse and or dismantling ...

Page 35: ...www ies synergy com User manual DUM1017795 EN 35 Notes ...

Page 36: ...ne Bergfeldstr 11 34130 Saint Aunès 83607 Holzkirchen France Germany Tel 33 0 4 99 13 62 80 Tel 49 0 80244633980 Fax 33 0 4 99 13 62 81 IES Synergy Inc USA IES WANMA New Energy China 330 East Maple Rd Building No 4 Wellong Technology Park Unit U No 88 Jiang Lin Rd MI43084 Troy Binjiang Hangzhou USA Zhejiang 310051 Tel 1 586 206 4410 China Tel 8657189877710 www ies synergy com DUM1017795 EN_V001 Oc...

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