40KW DC Charging Pile Manual

Luoyang Grasen Power Technology Co.,Ltd.
Luoyang Grasen New Energy Technology Co.,Ltd.
40kW DC Charger Manual

June,2019
Preface:
In order to enable you to use 40kW EV DC charger safely, you can remove it in time
when you encounter a fault, please read the instructions carefully before use.
The charger is suitable for lithium-ion power batteries, providing energy output not
greater than the rated power, and maintaining high output voltage and current
accuracy; the display is the most important man-machine interface for the charger.
Display the state of charge, battery pack status, fault status, etc.
The charger strictly implements IEC 61851-1-2010 (Electric Vehicle Conductive
Charging System-Part 1: General Requirements) DIN SPEC 70121-2014-en (Electric
Vehicle-Hybrid Charging System, Electric Vehicle Charging Station for Controlling DC
Charging Digital communication with electric vehicles)
This manual is only applicable to 40kW series EV DC charger. The content of the
manual will be updated without any notice with the upgrade of control software and
display interface software.
Please keep the instruction manual for future reference.

Content
Operating Conditions and Safety Matters................................................................................................ 3
1. Overview............................................................................................................................................... 4
1.1 Function Description.......................................................................................................................4
1.2 Appearance Instruction.................................................................................................................. 4
1.2.1 Operational Zone..................................................................................................................... 4
1.2.2 Charging Connection Device....................................................................................................5
1.3 Main Technical Parameter..............................................................................................................5
2.Method of Application...........................................................................................................................6
2.1 Installation Instruction....................................................................................................................6
2.1.1 Structure Installation............................................................................................................... 6
2.1.2 Electrical Installation Instruction............................................................................................. 8
2.1.3 Outline Dimension Drawing.....................................................................................................9
2.2 Power-On Preparation..................................................................................................................10
2.2.1 Requirements for the Operators........................................................................................... 10
2.2.2 Inspection Matters before Use..............................................................................................10
3.Equipment Storage and Maintenance Instruction........................................................................10
3.1 Charger Storage.........................................................................................................................10
3.2 Charger Maintenance............................................................................................................... 11
4. Warranty............................................................................................................................................. 15
Operating Conditions and Safety Matters
(1) Operating Environment
Working temperature: -20℃～50℃;
Working Humidity: 5%～95%;
Atmospheric Pressure: 80kPa～110 kPa
(2) Safety Matters Instruction
1) Charger should be operated according to operation instruction provided by Luoyang
Grasen Power Technology Co.,Ltd.
2) Non professionals are forbidden to open charger cabinet and dismantle screen
touch without permission, sharp objects are forbidden to operate on the screen.
3) If there is stop halfway, first click “stop” button manually,then pull out charging
connector. Forbid inserting and pulling out charging connector directly during charging,
otherwise charging connector and charger will be burnt out and even the operators will get
burnt.
4) Any operation irrelevant to charging during the charging is forbidden.Other
operations should be done after clicking “stop” button on the charger and charging connector
disconnects with the vehicle.
5) Under urgent circumstances,press red emergency stop button on the charger and
cut down charger internal power supply.
6) Smoke and fire is forbidden around the charger and pay attention to ventilation.
7) The fuse must be replaced with the same type fuse and can’t be replaced by
copper and iron wire.
3
8) When there is high voltage or default, it should be repaired by professionals in risk
of danger.
9) Charger upper circuit breaker and power distribution cabinet should be
chosen,installed and operated by professional electricians;
10) It is recommended to turn off the power under severe weather such as
thunderstorm. If there is water accumulation in the charger, please contact the
manufacturer's personnel to deal with it before using it.
11) Charging cable unit weight is heavy,longer cable is easy to drag and under force,
adding the risk of cable twist,bump to and influence product service life. Therefore, pulling
hard and twisting charging cable is forbidden. Charging cable must not be twisted to make
charging socket under force when charging.
12) When inserting or pulling out charging connector, shaking the charging connector
is forbidden and it must insert or pull out with vertical force.
If the following conditions occur,please cut down the power in time and inform the
professionals for maintenance.
Abnormal sound inside the charger
 Abnormal sound inside the charger
 Abnormal smell or smoke inside the charger
 No indication or responsive in charger display screen
 An unrecoverable failure alarm in charger
Notice:Before power-on operation, please ensure good connection between device
shell and ground, otherwise there is danger of electric shock.
4
1.Overview
1.1 Function Description
This integrated DC charger can realize single connector fast charging, fast feed as well
as two connectors equal power charging at the same time.
1.2 Appearance Instruction
1.2.1 Operational Zone
Operation zone includes indicator, display screen, card reader zone and emergency
stop button. Indicator can show power supply, charging connector and fault status, display
screen is used for showing charging information, card reader zone is used for identifying
charging card and providing simple operation instruction, emergency stop button is used for
cutting off power supply under emergency situation to avoid accidents and normal outrage is
not suggested to use.
1-1 Charger Operational Zone Diagram
1.3 Main Technical Parameter
Serial Technical Index Technical Index

Remarks
No. Name Content
1 Input cable voltage 380V+15%
Input Voltage Type Three Phase AC Three phase five wire

2
system
5
3 AC Grid Frequency 50Hz±10%Hz
4 Output Voltage 200—750V Continuous adjustable

Above 600V, constant
5 Output Current 0—66.6A power, continuous
adjustable, stable output
Above 600V,meet
6 Rated Output Power 40kW
constant power output
7 Output Voltage Error ≤0.5％ Full output range
Output current≥30A:≤±1％
8 Output Current Error Full output range
Output current＜30A:≤±0.3A
Stabilized voltage
9 ≤0.5％ Full output range
precision
Stabilized current
10 ≤0.5％ Full output range
precision
11 Ripple factor ≤0.5％ Full output range
12 Average efficiency ≥94% Load at 50% and above
13 Power factor ≥0.99 Load at 50% and above
14 Leakage current ≤10mA

Power frequency 1 min no insulation
15 2500VAC
withstand voltage breakdown and flashover
16 Insulation resistance ≥20MΩ Test voltage 1000VDC
17 Noise ≤60dB
18 Protection IP54
19 Cooling Method Air Cooling
2. Method of Application
2.1 Installation instruction
2.1.1 Structure installation
(1)Foundation drawing
40kW charger adopts ground installation and the installation should be reliable and
fastened, the following foundation is suggested:
6
Back
inlet hole
Embedded 4-M12 bolts,
installation size 475x230(mm)
Left Right
Charging pile operation face(front)
2-1 Foundation Drawing
（1） Dismantle Instruction

(2) When installing, dismantle the cabinet wooden box pallet, remove the protection
plate,use the forklift to move the charger cabinet to the ground , then fasten the cabinet on
the abutment with bolt washer and nut, then put the protection plate back to the original
location.
M12 nut
Ø12 washer
M12 bolt
Waterproof cover
Protection
plate 2
Protection
plate 1
2-2 Dismantling Instruction
7
Installation Notes:
Drainage measures should be made at charger installation location to avoid charger
immersion to affect normal usage.
When installation,it should guarantee charger left and right side within 2 meters
without obstacles to ensure the charger heat dissipation and there should be enough
distance for easy operation in front of charger.
After fastening cabinet on the foundation, its installation vertical inclination should be
less than 5%, when fastening, nut tightening torque suggested is 28.5N·m.
Operation site should avoid direct sunshine and outside shade(rain-proof) shed
should be added.
2.1.2 Electrical Installation Instruction
DC charger electrical installation must be done by the professional technician

and the charger input adopts three phase five wire system AC power supply,
maximum input current：77A, the cable and inlet terminal specification is as below:
Cable
Inlet Terminal
Specification
YJV-3*16+2*10 SC16-6×3+SC10-6×2
Copper cable in accordance with GB 50217 and GB/T 12706.1 is recommended, adopting
terminal compression which matches with cable section, the exposed part of terminal joint
adopts heat shrinkable sleeve or insulation tape for insulation protection.
Requirement for tensile strength of compression terminals of every size is as below:

Conductor Size Pressure Tensile Conductor Size Pressure Tensile
（mm2） Strength（N）（mm2） Strength（N）
0.13 (AWG#26) 13 30 2300
0.2 (AWG#24) 22 38 2500
8
0.3 (AWG#22) 36 50 2900

0.5 (AWG#20) 58 60 3200
0.75 (AWG#18) 89 80 3500
1.25 200 100 3900
2 290 125 4000
3.5 540 150 4100
5.5 780 200 4400
8 980 250 4600
14 1400 325 4800
22 1800
If the conductor size used is not included in the table, it can choose appropriate
size corresponding tensile strength for test.
AC inlet is from charger bottom into charger, to AC input terminal and ground
terminal inside the charger. AC input must be connected according to inlet notes, the
zero line and phase can’t be connected reversely, otherwise leading to charger
unrecoverable fault.Charger upper breaker and distribution panel is chosen and
operated by professional electricians, torque 24N· m is suggested by electrician for
installation.
Inlet ground screw
Insulation heat shrinkable

sleeve
2-3 Electrical Wiring Diagram
Notice:First dismantle the terminal baffle when connecting the wire, then tighten the
terminal screw with socket wrench, it is forbidden to use screwdriver for operation
2.1.3 Outline Dimension Drawing
9
2.2 Power-on Preparation
2.2.1 Operator Requirements
Operator must receive the DC charger operation training and related certificates.During
working,wear uniform and insulation shoes as regulated. Staff with long hair should wear safety
helmet.
2.2.2 Inspection Matters Before Operating
The first power operation steps：
1) According to the standards of electrician operation, check the inside of the cabinet to see
whether there is electrical damage and loose parts and ensure that the crimping of all
connection terminals is tight and there is no damage and burning
2) Open the front gate of the cabinet, switch the breaker to ON, and control the air switch of
control circuit to conduct the on-off test to ensure that there is not short circuit.
10
3)Switch the breaker to OFF, the breaker is off, turn off the air switch of control circuit and
connect AC inlet well.
4) After the AC incoming line is powered on, please make sure that the emergency stop
button is off, then turn on the breaker and air switch and make a test with a multi-meter to
ensure the power-on.
5)Before charging, check charging connector, charging socket insulator, pin and pin hole
whether there is foreign matter, if yes, clean according to 8th of this instruction 3.2 .
2.4 Charging System Introduction
2.4.1Charging Method Introduction
After the charger is powered on, the system will check itself. Then the screen enters
the system main interface, as shown in Figure 2-4. The charger charges according to BMS
instructions. There are 7 charging mode,including automatic charging, time charging, energy
charging, SOC charging, The user can choose different modes to charge the vehicle based
on different modes among them.
2-4 Main Page 2-5 Connector Position Choice Page
(1) Automatic charging: click “automatic charging” button, enter connector position
choice page,shown as 2-5. Choose charging connector, click “continue” charger
enter charging parameter choice page, shown as 2-6.
It can check charging voltage, current, power, electricity, current SOC and charging time on
the screen.When the vehicle is fully charged, the system give a hint, shown as 2-7.
11
2-6 Charging page 2-7 Charging completion page
After confirmation of charging information,complete the charging, shown as 2-8.
2-8 Swipe the card to complete the charging
Money charging:operator can choose money charging on the main page, enter
charging amount setting page, shown as 2-9. Set charging amount, click “continue”
button, enter connector position choice and charging parameter choice operation
page, charger calculates charging amount according to tip and peak, flat, cereal
period rate set by the operator during charging process. When charging amount
reaches setting amount, charger stop charging automatically.
Energy charger: the operator can choose “energy charging” on the main page, enter
electricity setting page, shown as 2-10. Setting charging electricity, click “continue”
button, enter connector position choice, charging parameter choice operation page,
when charger output electricity reaches setting electricity during charging process,
charger stop charging automatically.
12
2-9 Money Charging Setting Page 2-10 Energy Charging Setting Page
Reservation charging: when time charging is off,operator can choose “reservation

charging” on the main page, enter reservation charging page, shown as 2-11.Set
reservation charging parameter, including start time and duration time, click
“continue” button, enter connector position choice, charging parameter choice.
Charger starts charging according to start time set by the operator, when charging
time reaches operator setting time during charging process, charger stop charging
automatically. When time charging is on, reservation charging can’t be used,shown
as 2-12.
2-11 Book Setting Page 2-12 Book Setting Page
SOC charging, operator can choose “SOC” charging on the main page, enter SOC
charging setting page, shown as 2-13, set vehicle battery SOC when charging is over,
click “ continue” button, enter connector position choice and charging function choice
page.When vehicle battery SOC reaches setting SOC, charger stop charging
automatically.
13
2-13 SOC Charging Setting Page
2.4.2 System Function Introduction
Click “system” on the main page and enter system setting page, shown as 2-
14,including password setting, position orientation,electricity bill setting, date setting,
function setting, communication parameter, fault record, charging record, screen
luminance 9 functions.
2-14 System Setting Page
Click “electricity bill setting” input initial password “******”and enter setting page,shown as 2-
15,customer can set electricity price during tip and peak, flat, cereal period within 24 hours.
14
2-15 Electricity Setting Page
2.4.3 Charging Mode Introduction
Two connector alternate charging: each connector output as per rated

power.When connector A is charging, after connecting charging connection device
reliably, finish charging operation and wait A to finish charging, system will charge for
connector B automatically. During waiting, charging page should display shown as 2-
16 and 2-17.Click white arrow on the page to display.
2-16 Connector A charging page 2-17 Connector B waiting to charge page
2.4.4 Calibration interface operation instructions
According to the market usage, the charger interface should be calibrated

regularly to solve the user's operating experience. In order to prevent the resistive
screen from being calibrated for a long time, the screen will shift as a whole. It is
recommended that the charger screen be calibrated once a month; frequent users
should reasonably shorten the calibration cycle, and it is recommended to have it
once every two weeks to ensure that customers have a good operating experience
(in the case of frequent and inappropriate use groups, users can Reduce the
calibration time as appropriate).
15
Because there is a hidden interface for the configuration of the charger, the
specific operation method is divided into two types of customer operations and after-
sales maintenance operations:
1. Customer operation: Click any interface on the screen to enter the screen
calibration interface as shown in the “ Calibration Interface ” in the figure below.
Click to perform the calibration. After the calibration is complete, the charging
operation can be performed.
Calibration interface
2. After-sales personnel maintenance operation: Click "System" to enter the "System

Interface"
Charging Page System Page

Click the "Hide Button" and enter the password "******" to enter the "hidden interface", click
"screen brightness" to enter the "screen adjustment interface", and click "calibrate screen" to
enter the calibration interface.
16
Hidden page Screen adjustment page
Click for adjustment and start charging operation after calibration is completed.
Calibration page
3. Equipment Storage and Maintenance Instruction
3.1 Charger Storage
Well packed equipment should be stored under good ventilation, temperature between -
35℃~ 55℃, monthly average relative humidity less than 90%.
Storage places should be free of corrosive and explosive gases, and should not be
exposed to rain, exposure, condensation and frost during storage.
Storage period:
Category I
Category II Category III
Environment
Equipment Environment Environment
Limited Remarks
Name Limited storage Limited storage
storage
period(Year) period(Year)
period(Year)
Charger 1 0.8 0.5
17
Storage ambient condition corresponding relations
Storage
environment
Temperature ℃ Relative Humidity % Remarks
condition
classification
I 15 ~ 25 ℃ ≤65 %
II -5 ~ 30 ℃ ≤75 %
III -35~ 55 ℃ ≤90 %
The corrosive products are forbidden to store at the same place!
3.2 Maintenance of Charger
User daily maintenance can guarantee that the charger is under good condition, main
works includes:
(1)Check regularly if there is dust inside the cabinet and clean regularly to prevent inner
insulation property decreasing;
3-1 Open the front door to observe the dust 3-2 Open the side door to clean wind inlet and
outlet dust
(2) Check regularly that the ground wire is reliably grounded.
18
3-3 Check grounding bolts and nuts are fastened
(3)Check regularly whether the cooling fan is working normally. If it is damaged, replace the
fan of the same model in time
3-4 Check whether the fan is working normally
(4) Check cabinet ventilation condition regularly,in order to ensure the ventilation of
the cabinet in good condition, it is necessary to clean the dust screen of the side door
regularly.It is suggested to clean the inner of cabinet every three months, if there is
severe environment, customer can shorten clean time gap depending on the
detailed situation. The dismantling and cleaning steps are as follows:
Open the left side door, remove the black filter, take ventilating shutter and metal
dust screen, and clean them with water;
Open the right side door,remove the thumbscrew fastening fan, open fan parts and
take black filter,ventilating shutter and metal dust screen, and clean them with water;
19
After metal dust screen and black filter dry,install the metal dust screen, ventilating
shutter and black filter, then lock with screw tightly.
3-5 Ventilation shutter detail picture 3-6 Take the inner side dust screen
(5) Check regularly charging connection cable and winding pile,if there is aging,corrosion,
it needs to change in time to guarantee safe application. If charging joint is loose, fasten
it in time.
3-7 Check charging connection cable and winding pile aging and corrosion
Maintenance operation should be done very month, if there is severe environment, it can
shorten the maintenance time according to actual situation.
(6) Daily maintenance of surge protector
Check regularly inlet and outlet cable of surge protector loose or not, to prevent line fault
because of aging of surge protector and cable line.
20
3.8 Check aging and corrosion of surge protector and cable line
(7) Daily maintenance of Dust
Check regularly cabinet dust and clean the dust inside the cabinet and spare parts
regularly. After cutting off the power, adopting vacuum clean or air compressor to clean
cabinet bottom, side door and spare parts.
3-9 Check dust regularly inside the cabinet
(8) Daily Maintenance of Charging Connector and Cable
When the charging connector is idle,it should be covered with a dust cover or inserted
into the socket of charger to forbid foreign matter. Use high pressure air gun, brush to clean
charging connector and socket every week, if there is no condition, use non dust cloth or
swab to clean. If there is accident(the charging connector is abandoned or falling on the
ground), it should be cleaned following the above methods.
21
3-10 Cleaning Charging Connector or Socket
Notes: Non professionals are not allowed to dismantle equipment assembly!
5.Warranty：
5.1.The quality of the products caused by the correct use method will be repaired by
the company during the warranty period from the date of purchase;
5.2.During the installation and use of the charger, due to not operate according to the
operation manual of the charger and the requirements of this specification, resulting
in various quality problems of the product, which are not covered by the warranty
5.2.1 Install the charger in a natural environment without protection, and use it in
extreme weather conditions such as heavy rain, hail, and blizzard, and cause all
product problems;
5.2.2 During the normal operation of the charger, all the product problems caused by
directly removing the charging gun without first stopping the charging;
5.2.3 Privately disassemble and modify the charger without communicating with our
company or without permission, resulting in all product problems.
22

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Luoyang Grasen Power Technology Co.,Ltd.

Luoyang Grasen New Energy Technology Co.,Ltd.

40kW DC Charger Manual

Luoyang Grasen Power Technology Co.,Ltd.

The charger strictly implements IEC 61851-1-2010 (Electric Vehicle Conductive

Charging System-Part 1: General Requirements) DIN SPEC 70121-2014-en (Electric

Vehicle-Hybrid Charging System, Electric Vehicle Charging Station for Controlling DC

Charging Digital communication with electric vehicles)

display interface software.

Please keep the instruction manual for future reference.

1.1 Function Description.......................................................................................................................4

1.2 Appearance Instruction.................................................................................................................. 4

1.2.1 Operational Zone..................................................................................................................... 4

1.2.2 Charging Connection Device....................................................................................................5

1.3 Main Technical Parameter..............................................................................................................5

2.1 Installation Instruction....................................................................................................................6

2.1.1 Structure Installation............................................................................................................... 6

2.1.2 Electrical Installation Instruction............................................................................................. 8

2.1.3 Outline Dimension Drawing.....................................................................................................9

2.2 Power-On Preparation..................................................................................................................10

2.2.1 Requirements for the Operators........................................................................................... 10

2.2.2 Inspection Matters before Use..............................................................................................10

3.Equipment Storage and Maintenance Instruction........................................................................10

3.1 Charger Storage.........................................................................................................................10

3.2 Charger Maintenance............................................................................................................... 11

Operating Conditions and Safety Matters

(1) Operating Environment

Working temperature: -20℃～50℃;

Working Humidity: 5%～95%;

Atmospheric Pressure: 80kPa～110 kPa

(2) Safety Matters Instruction

1) Charger should be operated according to operation instruction provided by Luoyang

Grasen Power Technology Co.,Ltd.

4) Any operation irrelevant to charging during the charging is forbidden.Other

disconnects with the vehicle.

cut down charger internal power supply.

copper and iron wire.

8) When there is high voltage or default, it should be repaired by professionals in risk

9) Charger upper circuit breaker and power distribution cabinet should be

chosen,installed and operated by professional electricians;

thunderstorm. If there is water accumulation in the charger, please contact the

manufacturer's personnel to deal with it before using it.

charging socket under force when charging.

is forbidden and it must insert or pull out with vertical force.

Abnormal sound inside the charger

 Abnormal sound inside the charger

 Abnormal smell or smoke inside the charger

 No indication or responsive in charger display screen

 An unrecoverable failure alarm in charger

Notice:Before power-on operation, please ensure good connection between device

shell and ground, otherwise there is danger of electric shock.

1.1 Function Description

1.2 Appearance Instruction

1.2.1 Operational Zone

1-1 Charger Operational Zone Diagram

1.3 Main Technical Parameter

Serial Technical Index Technical Index

1 Input cable voltage 380V+15%

Input Voltage Type Three Phase AC Three phase five wire

3 AC Grid Frequency 50Hz±10%Hz

4 Output Voltage 200—750V Continuous adjustable

12 Average efficiency ≥94% Load at 50% and above

13 Power factor ≥0.99 Load at 50% and above

14 Leakage current ≤10mA