EN - RAPTION 22 KW TRIO - Installation Manual

Fast Charge Station for
Electric Vehicles
INSTALLATION MANUAL
RAPTION 22 kW TRIO
RAPTION 22 kW TRIO - Installation Manual
This document is the property of Circontrol S.A. since 2016. All rights reserved.
Circontrol S.A. It reserves the right to make improvements to the products described in
this manual at any time without notice.
No part of this manual may be reproduced, copied, translated or transmitted in any

form or by any means without prior written permission from the original manufacturer.
The information provided in this manual is intended to be accurate and reliable.
However, the original manufacturer assumes no liability for its use or for any
infringement of the rights of third parties that may result from its use.
All other product names or trademarks are the property of their respective owners.
V1.0, January 2016 Edition

INSTALLATION MANUAL – RAPTION 22 kW TRIO
CONTENT
1 PREFACE ............................................................................................................................. 2
1.1 CERTIFICATIONS......................................................................................................... 2
1.2 SAFETY ......................................................................................................................... 2
1.3 IMPORTANT SAFETY INFORMATION ........................................................................ 4
2 OVERVIEW ........................................................................................................................... 6
3 DIMENSIONS ........................................................................................................................ 7
4 PRE-INSTALLATION CONSIDERATIONS .......................................................................... 8
4.1 MINIMUM DISTANCES ................................................................................................. 8

4.2 INSTALLATION REQUIREMENTS ............................................................................... 9
5 FIXING THE UNIT ............................................................................................................... 10
5.1 DIRECT MOUNTING................................................................................................... 11

5.2 FIXING BY CONCRETE BASE ................................................................................... 12
6 TRANSPORTATION, STORAGE AND INSTALLATION................................................... 13
6.1 UNIT INSTALLATION.................................................................................................. 14
7 ELECTRICAL INSTALLATION .......................................................................................... 19
7.1 ELECTRICAL WIRING CONSIDERATIONS .............................................................. 19

7.2 PROCEDURE.............................................................................................................. 20
8 SIM CARD ........................................................................................................................... 23
8.1 3G MODEM LOCATION ............................................................................................. 23

8.2 MODEM OVERVIEW .................................................................................................. 23
8.3 INSTALLATION ........................................................................................................... 24
8.4 CONFIGURATION ...................................................................................................... 24
9 VERIFICATION ................................................................................................................... 25
10 TECHNICAL DATA ............................................................................................................. 26
CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

Tel .: +34 937 362 940 - Fax: +34 937 362 941 1
Web: www.circontrol.com - E-mail: ps-support@circontrol.com
1 PREFACE
This manual provides information for installing the charge station, which has been
designed and tested to allow charging electric vehicles, as specified at IEC 61851,
there are different sections and step by step installation procedure.
Speaking about installation, it includes the transport and handling of the Charging
Station, the necessary concrete base to put the unit on, the minimum distances that
have to be respected between the unit and the wall and how to connect to the electrical
feeder line. The adaptation of the power line must be performed by qualified technical
personnel, trained in the art and always respecting the rules and laws that are
applicable in the country of installation.
In the case that your Charging Station is integrated under a general management
system, like a Back Office, also has to be done the communication installation.
1.1 CERTIFICATIONS
• Compliant with IEC 61851; Electric vehicle conductive charging system (IEC
61851-1, IEC 61851-22 and IEC 61851-23).
• Compliant with IEC 62196; Plugs, sockets-outlets, vehicle connectors and vehicles
inlets, Conductive charging of electric vehicles (IEC 62196-1 and IEC 62196-3).
• Compliant with CHAdeMO 1.1 certification.
• Meets the CCS specification.
• Directives: 2014/53/UE, Radio and Telecommunication Terminal equipment;
2014/30/UE, Electromagnetic Compatibility (EMC); 2014/35/UE, Low Voltage
directive.
1.2 SAFETY
It is mandatory to follow the basic security information supplied in this manual to ensure
safe and proper installation.
Failure to follow safety instructions may involve personal injury, equipment damage
and danger of death. CIRCONTROL is not responsible for events arising from such
breach.

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THESE SYMBOLS ARE USED FOR IMPORTANT SAFETY

INFORMATION IN THIS DOCUMENT
- This symbol indicates a potentially hazardous situation

which, if not avoided may result in a risk of fire, serious
injury or death.
- The unit must be disconnected from any power source

before performing any maintenance, repair or electrical
manipulation inside.
- Follow the instructions preceded by this symbol, if not

respect them or perform them correctly, may result in
minor or moderate injury to the user, damage to
equipment, damage to facilities or other property.
- Handling the equipment can cause injuries as result of

the dimension and weight. Persons handling the unit
must wear safety shoes and gloves.
WARNING
People who use electronic medical devices such as implanted
cardiac pacemaker or implantable cardio verterdefibrillator
(ICD) might be affected by electric wave from the quick charger.
Keep yourself away from the quick charger the minimum
security distance according with your device meantime the unit
is charging.

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1.3 IMPORTANT SAFETY INFORMATION
• Do not use the Charge Station for purposes that are not recharge electric vehicles.
• Read all the instructions before installing, using, or performing any maintenance of
the Charge Station.
• Do not use cables there are not in perfect conditions to do the Charge Station
installation.
• Installation, commissioning and maintenance of the Charge Station must be
carried out by competent technical personnel qualified and authorized, fully
responsible for the compliance of regulations concerning installation and charging
equipment for electric vehicles and to any local and nationally regulations for
electrical installations.
• When performing inspection or service work at the Charge Station, follow the
instruction to perform correct operation.
• Repair, conversion and/or modification of the Charge Station is prohibited, only the
manufacturer or expressly designated personnel can perform it. Failure to follow
this instruction, CIRCONTROL will reject all responsibility and the warranty is void.
• Do not make repairs or manipulations with the unit energised, when you need to
access the inside of the unit to perform maintenance or repairs, make sure that it
is disconnected from the main power source.
• Make sure that the maintenance staff is wearing personal protective equipment
when performing high voltage system operation in the unit according country rules.
• Cover with a roof all parts of the Charge Station to protect from the rain or snow
before to perform any maintenance task.
• Do not use the Charging Station if the enclosure or the EV connectors are broken,
cracked, open, worn, soiled or shows any other indication of damage. It has to be
checked that are in perfect condition, including cable and holder.
• Replace from service any item that has a fault that could be dangerous for users.
Use only CIRCONTROL supplied spare parts.
• As the Charge Station has high voltage, there is a risk of electric shock or electric
leakage if it is handled incorrectly.

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• The owner or manager of the Charge Station must ensure that it is always in
perfect working order and safety.
• In case of any fault, should not make any charging and communicate it to the
manager or maintenance team.
• Perform a visual inspection of the casing of the Charge Station and make sure it is
not damaged and that no access to the interior open.
• Do not remove any identification, such as safety signs, warning signs, nameplates
and signs of the power line.
• Do not throw blunt objects against the HMI Screen, as this can cause permanent
damage to it.
• If the Charge Station has not been used for a long period of time, perform a visual
inspection and check all the main functions and safety.

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2 OVERVIEW
16
2
15
3
14
17
13
18 12
11
4
10
6 8
1. Cover 2. CHAdeMO state beacon 3. CCS state beacon

4. CCS holder 5. CHAdeMO holder 6. Decorative front panel
7. Eyebolt nut 8. Decorative rear panel 9. Lower natural ventilation
10. Power module air inlet 11. Rotate handle 12. AC socket - Type 2
13. Emergency STOP 14. AC socket state beacon 15. Upper natural ventilation
16. 3G Antenna 17. HMI Screen 18. RFID reader

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3 DIMENSIONS
Units specified in milimeters

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4 PRE-INSTALLATION CONSIDERATIONS
4.1 MINIMUM DISTANCES

Respect the minimum space and minimum distances for installing the unit. The next
picture shows how it should be installed.
• Do not install near areas where water or fluids can penetrate into the unit.
• Do not install the unit in unstable terrain.
• (*) Respects the minimum lateral distance to allow proper circulation of air flow.
This unit has forced ventilation.
• (**) If Bollard Impact Protector has to be installed, keep 100 cm as a minimum
in order to open the unit door.
● Front space (for maintenance operations)  100 cm

● Back Space  5 cm
● Ventilation space on the left side  80 cm
● Ventilation space on the right side  80 cm

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4.2 INSTALLATION REQUIREMENTS

For safety reasons and facing the user, is recommended to install the unit under cover
(covering charger and vehicle), to avoid possible water contact between the connectors
of the charger and the electric vehicle.

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5 FIXING THE UNIT

The purpose of this chapter is the technical definition and basic requirements for
implement the base and fixing the unit.
- The unit can be installed both inside and outside.

- A mounting template is provided to ensure the distances between the threaded
rods.
- Is recommended to remove the template after practicing civil works.
Note: In the event of any doubt about the terrain regarding the installation of this unit,
due to the weight and dimensions, it will be necessary to define a final solution to install
the unit, It must be confirmed by a specific technical project made for an architectural
firm prior to its installation.

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5.1 DIRECT MOUNTING

This Installation will be done directly over the ground, mainly for indoor or locations
limited in depth. Using the template provided, fix the threaded rod with chemical
anchors.
It should be done a previous check in order to ensure the bearing capacity of the
ground to support the unit.
NOTE: Remember to remove the mounting template before installing the unit.

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5.2 FIXING BY CONCRETE BASE

If the unit has to be installed outside and there is no limitation of depth, is
recommended to install the unit over a concrete base.
The concrete base shall provide the passage of power cables, it must be done by
corrugated tube placed inside the foundation through the mounting template, as it can
be seen below:
NOTE: Remember to remove the mounting template before installing the unit.

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6 TRANSPORTATION, STORAGE AND INSTALLATION

This chapter provides the necessary information for proper transport, storage and
installation of the unit, for their correct use and to ensure a long lifespan.
SUPPLY
All the units pass their correspondent quality test and are properly packaged for safe
transportation ensuring thus their correct operation. The proper transport of the unit is
responsibility of the freight forwarder.
Upon receipt of the unit make a careful inspection to verify that there is no shipping
damage.
If any damage caused by the forwarder is not indicated in the delivery note during the
receipt of unit, CIRCONTROL will not be held responsible for the cost of
repair/replacement.
UNLOADING AND HANDLING

All processes of unloading and handling of the unit must be executed and monitored by
qualified personnel attending to the significant weight of the unit, complying with safety
rules and using the appropriate points of support. The unit has two lifting points.
STORAGE
Whenever possible, the unit must be unloaded in their place of installation and
operation. In case of unloaded to a temporary location for storage, it is convenient to
not remove the packaging and store them meeting the following minimum
requirements:
Safety: products must be protected against negative elements such as heat radiation,
direct solar radiation, mechanical damage, organic dissolvent impacts, etc.
Temperature: for temperatures below -20 ºC and over 60º C special attention must be
paid to the storage and handling.
Environment: products must be stored in a dry and dust-free location. The distance
from a heat source must be 1 m away. Outdoor storage of the unit has to be avoided.

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6.1 UNIT INSTALLATION

Notice:
- The delivery truck only unloads the pallet carrying the unit.
- The delivery truck does not have the lifting facilities to move the unit to its final
location.
- The placement of the unit to its final location is the responsibility of the
contractor.
Step Action
- Once you have unpacked the unit, locate inside a box with the accessories
required for installation, you will find:
1 • Installation manual.
• Three security keys.
• Two user cards.
• Mounting plate
• Two transportation eyebolts.
- Open the unit in order to remove the nuts that are keeping the unit on the
pallet.
1- When the door is locked, the handle is latched in the retracted position.
Insert door key and turn the key 180ᵒ clockwise, pull the handle outward and
after turn 90 degrees counter clockwise to open the door:

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2- At the bottom of the unit, we can find 4 x M20 nuts with washers, it has to
be removed so as to take off the unit from the pallet:
- Once the unit is free from the pallet, there are two options to move the unit to
the final location.
1- Move the unit with eyebolts.
a) Disconnect the 3G antenna connector and remove the unit cover

taking off the 6 x M5 nuts:
3
b) Fix de eyebolts provided on the top of the unit as you can see below:

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c) Hold the sling to the eyebolts, raise the unit and placed on the final
location:
d) Remove the eyebolts form the unit, replace the unit cover, connect the
3G antenna connector again and screw back the 4 x M20 nuts with
washers on the threaded rods:

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2- Move the unit with forklift truck.
a) Remove the decorative front panel:
- There are 4 x M5 screws, remove them:
- Pull the decorative front panel outward.

4
b) Remove the decorative rear panel:

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- There are 4 x M5 nuts in every side of the unit, remove them:
c) Once the decorative panels have been removed, it will be available

enough space to introduce the forklift truck:
d) Place the unit on the final location and Screw back the 4 x M20 nuts with
washers on the threaded rods:

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7 ELECTRICAL INSTALLATION
7.1 ELECTRICAL WIRING CONSIDERATIONS

The installation company will be responsible for dimensioning the wires size, protection
elements, in compliance with the current country regulations. The power supply for the
unit must be done by a specific line of supply, with a general switch and a unique
differential, installed according to the standards of local or state security.
Check that the power supply line has enough capacity to power the unit; length, cable
section, and the protection thereof (hose or cover) should be adequate for the unit.
Check using a multimeter that the supply voltage is stable within acceptable values.
Before starting wiring connection for the unit, have to be checked the following
important elements:
Minimum cross section of the AC input cables: 25 mm2
1 Make sure the main switch wiring (MCCB or fuses) of the AC power supply are
cutting the electricity supply during installation.
2 It is recommended to strictly follow the current regulations to determine the

appropriate section of the power cables to feed the unit and at any time as a
minimum comply with indicated in the box above.
3 After unpacking the unit, ensure that all electrical components are in good
condition.
4 After the installation, you must seal all holes inside the unit to prevent access of
dirt, foreign objects, animals, etc.

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7.2 PROCEDURE
The power supply for the unit must be done by a specific feeder line, there are two
options to enter in the unit:
1- Entering to the unit from bottom.

2- Entering to the unit through the decorative rear panel.
Step Action
1- Entering to the unit from bottom.
If the unit has been installed on a concrete base, entering from bottom is the
most common way.
2- Entering to the unit through the decorative rear panel.
If the unit has been installed directly on the floor, entering through the
decorative rear panel is the most common way.
Note: for entering to the unit through the decorative rear panel, the hole is not
done from factory, It has to be done through the adequate tool by the installer.

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Make sure that the main switch power from the feeder line, MCCB or
3
fuses, is set to the off position during installation.
- There are two ways to connect the Charge Station, regarding to the feeder
line cable, the ‘X0’ terminal block is ready for connecting 1 or 2 feeder line
cables, always depending of your installation.
Connecting only 1 feeder line cable
1 feeder line cable for DC / AC  Max. consumption current 64 A
- Connect the feeder line cable to the “DC Block” and after, connect to the
“AC Block” by cable links.

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Connecting 2 feeder line cables
1 feeder line cable for DC  Max. consumption current 32 A

1 feeder line cable for AC  Max. consumption current 32 A
- Connect the first feeder line cable to the “DC Block” and the second to the
“AC Block” independently.
Note: it is recommended to use end sleeves according with the wire

thickness.
a. Cut the wires of each power cable to the correct lengths to reach the ‘X0’
terminal block. Do not make the wire routing too tight, or too loose.
b. Use wire stripper pliers to remove 15 mm of the insulation from the ends
of the wires (black, brown, grey, blue and yellow-green).
c. Attach a wire end sleeve in every cable.
d. Loosen every bolt at terminal block.
e. Insert the wires into the ‘X0’ terminal block.
f. Tighten the bolts.

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8 SIM CARD
This section describes how to install the SIM card into the unit’s 3G modem.
8.1 3G MODEM LOCATION

The modem is installed inside the unit and the antenna is fixed outside, right on the
roof of the unit.
8.2 MODEM OVERVIEW

The 3G modem installed from factory in the unit is:
Sierra Wireless AirLink LS300
This device allows to the unit connects over 3G networks to remotely view or manage
the status (SIM card not provided with equipment).

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8.3 INSTALLATION
Before installing the SIM card into the modem, make sure you have unplugged the
power cord from the modem.
The following schematic explains in detail the proper installation of the SIM card:
8.4 CONFIGURATION
Plug again the power supply for the modem.
NOTE: After plugging back the modem, it can take until 5 minutes to respond.
3G modem configuration is performed using the Ethernet interface. Connect your

computer using an Ethernet cable as shown in the following image:
EXAMPLE
IP Address: 192.168.13.31
Netmask: 255.255.255.0
IP Address: 192.168.13.50
Netmask: 255.255.255.0

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1- Open a web browser in the computer and enter http://192.168.13.31:9191.

Wait until ACE manager login screen appears.
2- Default username is user and default password is 12345. Do not change the
default credentials; the charge point requires consulting information from the 3G
modem.
3- The ACE manager homepage appears. You can now configure each device
with ACE manager.
For more information about how to configure the 3G modem in detail, please visit
following website: http://www.sierrawireless.com
9 VERIFICATION
Once completed the entire installation procedure, check the following points:
1. Check that all the MCB and RCD are powered on before starting a charging
session.
2. Check that all beacons are illuminated in green.
3. Verify that each EV connector is in good condition.
4. Make sure the ventilation air flow is correct and there is not any obstruction at the
ventilation grill.
5. Check for abnormal noise while charging a vehicle.
6. Check that all safety labels are correctly placed.

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10 TECHNICAL DATA
RAPTION 22 kW TRIO
AC INPUT
AC Supply Voltage 400 VAC (3P + N + PE)
AC Voltage range + / - 10 %
Maximum input current 64 A
Apparent power 45 kVA
Power Factor > 0.98
Efficiency 94 % at nominal output power
Frequency 50 / 60 Hz
OUTPUT AC DC
Charging system Mode 3 Mode 4
Plug Type 2 Socket JEVS G105 Combo 2
Cable length -- 3 meters 3 meters
Maximum output current 32 A 56 ADC
Maximum power output 22 kW 22,5 kW (@400 VDC)
Output voltage range 400 VAC 150-550 VDC
ELECTRICAL PROTECTIONS
Overcurrent protection MCB (1 x AC + 1 x DC)
Safety protection RCD 30 mA; Type A (1 x AC + 1 x DC)
GENERAL
Compliance IEC 61851 / IEC 62196 / CE / CCS / CHAdeMO
Enclosure rating IP54 / IK10
Enclosure material Stainless steel
Operating temperature -5 °C to +45 °C
Ambient temperature storage -20 °C to +60 °C
Operating humidity 5 % to 90 % RH (non-condensing)
ISO / IEC14443A / B
RFID system MIFARE Classic, MIFARE DESFire, MIFARE DESFire EV1,
®
FeliCa , ISO 18092 / ECMA-340 (NFC) 13.56 MHz
Display 8 " TFT, anti-vandal touch screen
Sound level in operation < 55 dBA
Charger status indication RGB colors indicator
Integration Protocol OCPP / XML
Dimensions (D x W x H) 310* mm x 900 mm x 1700 mm
Weight 215 kg
Cooling system Air cooling fans
* 390 mm with connectors positioned.

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C / Innovació, 3
Pol. Ind. Can Mitjans
08232 - Viladecavalls
Barcelona - Spain
Tel: +34 937 362 940
Fax: +34 937 362 941
www.circontrol.com

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Fast Charge Station for

No part of this manual may be reproduced, copied, translated or transmitted in any

V1.0, January 2016 Edition

4 PRE-INSTALLATION CONSIDERATIONS .......................................................................... 8

4.1 MINIMUM DISTANCES ................................................................................................. 8

5 FIXING THE UNIT ............................................................................................................... 10

5.1 DIRECT MOUNTING................................................................................................... 11

6 TRANSPORTATION, STORAGE AND INSTALLATION................................................... 13

6.1 UNIT INSTALLATION.................................................................................................. 14

7 ELECTRICAL INSTALLATION .......................................................................................... 19

7.1 ELECTRICAL WIRING CONSIDERATIONS .............................................................. 19

8 SIM CARD ........................................................................................................................... 23

8.1 3G MODEM LOCATION ............................................................................................. 23

10 TECHNICAL DATA ............................................................................................................. 26

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

THESE SYMBOLS ARE USED FOR IMPORTANT SAFETY

- This symbol indicates a potentially hazardous situation

- The unit must be disconnected from any power source

- Follow the instructions preceded by this symbol, if not

- Handling the equipment can cause injuries as result of

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

1.3 IMPORTANT SAFETY INFORMATION

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

1. Cover 2. CHAdeMO state beacon 3. CCS state beacon

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

Units specified in milimeters

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

4.1 MINIMUM DISTANCES

● Front space (for maintenance operations)  100 cm

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

4.2 INSTALLATION REQUIREMENTS

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

5 FIXING THE UNIT

- The unit can be installed both inside and outside.

- Is recommended to remove the template after practicing civil works.

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

5.1 DIRECT MOUNTING

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

5.2 FIXING BY CONCRETE BASE

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

6 TRANSPORTATION, STORAGE AND INSTALLATION

UNLOADING AND HANDLING

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

6.1 UNIT INSTALLATION

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

1- Move the unit with eyebolts.

a) Disconnect the 3G antenna connector and remove the unit cover

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

2- Move the unit with forklift truck.

a) Remove the decorative front panel:

- There are 4 x M5 screws, remove them:

- Pull the decorative front panel outward.

b) Remove the decorative rear panel:

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

- There are 4 x M5 nuts in every side of the unit, remove them:

c) Once the decorative panels have been removed, it will be available

CIRCONTROL, S.A. - Innovació, 3 -08232 - Viladecavalls (Barcelona)

7.1 ELECTRICAL WIRING CONSIDERATIONS

Minimum cross section of the AC input cables: 25 mm2

2 It is recommended to strictly follow the current regulations to determine the