V7 240~400kW

Outdoor Integrated DC Charger

User Manual

1
 Foreword
The guidance is mainly for the reference of:
Technical support engineers;
Maintenance Engineers;
Construction Engineers;
Symbol Reference:
Explanations of symbols that maybe used in this manual are as follows.
Symbol Explanation
“WARNING” means Danger.

Careful the operation steps and methods, wrong activity may cause
body hurt or death etc. The operations behind the “WARNING” symbol
only can be executed after fully understanding and satisfying all of
requirements.
“CAUTION” means Danger.

Careful the operation steps and methods, wrong activity may cause the
product gets damage or destroy etc. The operations behind the
“CAUTION” symbol only can be executed after fully understanding
and satisfy all of requirements.

“HINT” means skills & useful information

All of use skill & useful information are marked by “HINT” symbol.
However, the information of function which include warning danger
and hazard are not be included in it.

The symbol marks on the product, manual or package, it means the

Electrical and electronic equipment and their accessories should be
disposed separately with ordinary daily refuse.

The material can be recycled depend on the mark. According to the

recycle of used component, material or other styles, you can make a
great contribution to the environment.

2
 Catalog
1. Safety Instructions ................................................................................................. 5
1.1 How to Use the Product................................................................................5
1.2 Safety Operations ........................................................................................ 6
2. Brief Product Instruction.........................................................................................6
2.1 Basic Model Parameters .............................................................................. 7
2.2 Detailed Performance Parameters ............................................................... 8
2.3 Function Introduction .................................................................................. 9
3. Installation Instruction ............................................................................................9
3.1 Product Dimension ...................................................................................... 9
3.2 Installation ................................................................................................. 10
3.2.1 Installation Requirement ................................................................. 10
3.2.2 Installation Steps..............................................................................11
3.3 Power Cable Installation ........................................................................... 11
3.3.1 Configure the Requirements of Power Distribution Cable ............. 11
3.3.2 Recommended AC Input Cable Specifications(Copper Core Wire) 12
3.3.3 Schematic Diagram of Charger Connection ................................... 12
3.3.4 Wiring Diagram inside the Cabinet ................................................ 13
3.4 After-Installation Check ............................................................................ 13
3.4.1 Tightness ..........................................................................................13
3.4.2 Stability ........................................................................................... 13
3.4.3 Clean Up ......................................................................................... 13
3.4.4 Checking list ................................................................................... 14
4. Debugging Instructions ........................................................................................ 14
4.1 Configure the local network ...................................................................... 14
4.2 Configure the server information .............................................................. 15
4.2.1 Connect to the server using IP ........................................................ 15
4.2.2 Connect to the server using domain name ...................................... 15
4.2.3 Connect to municipal platform ....................................................... 15
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 4.3 Configure Charger Number and Service Hotline ...................................... 16
5. Instructions............................................................................................................16
5.1 Charging Precautions..................................................................................16
5.2 Charge Steps...............................................................................................17
5.3 Charger User Interface .............................................................................. 17
5.4 Connector Operation Instructions ............................................................. 18
5.5 Emergency unlock method of the connector ............................................. 19
5.6 Precautions for using the connector .......................................................... 19
6. Maintenance ......................................................................................................... 19
6.1 Distribution System....................................................................................19
6.2 Simple Troubleshooting ............................................................................ 20
6.3 Maintenance .............................................................................................. 22
6.4 Emergency measures ................................................................................. 24
7. After-sales Service ............................................................................................... 24
7.1 Disclaimer ................................................................................................. 25

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1. Safety Instructions
1.1 How to Use the Product
The product is anAIO charger which available in both indoor and outdoor areas
for GB electric vehicle charging, charging to other national standard electric

vehicle is restricted.
The product is a high power and high voltage electrical equipment, any

construction and maintenance professional must get the electrician certificate and
network permission for operation.

When the equipment is installing, must strictly obey the regional and national
implementation of the relevant construction standards and safety regulations.

Product information packages with the product when they shipped from factory,
please use and keep the document safety.

The equipment’s research, development, production, inspection and recording are

based on the relevant safety standards; therefore, the product would not cause any
property damage or hazard for human health normally if the instruction of using
and the notification of security technology have been complied.

All of the instructions in this guidance must be strictly observed, otherwise may
cause security hazard or safety device failure. Although there are some

explanations about the relevant safety guide, but it is still necessary to pay
attention on the security and accident prevention regulations about the

corresponding application situation.

Please contract the equipment provider directly if you have any question or fault
during the process of using, any security consequences which caused by the

maintenance from third party or other non-professional without permission are

borne by the user.

At the first time to use the equipment, the user needs to change the password and
keep it secret.

The installation environment for charging equipment should be far away from
fire and other hazards.
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 1.2 Safety Operations
Please read the guidance carefully before using and following the steps to operate
strictly based on the guidance.

Disassembling the product or other the improper operations without permission is

not allowed, any adverse consequences caused by those improper operations are
borne by the user.

Touching the plug or the charging socket of electric vehicles is not allowed, keep
the plug dry and do not use the wethand to touch the plug.

Keep using the charging equipment under the charging gun cable leakage or
insulation skin damage situation is not allowed.

Please press the stop button immediately if the product has any leakage or other
situation occurs during the operation.

Please ensure that there are no any items in the charging plug or the charging socket
of the electric vehicle.

Operating the Maintenance under the condition of the power equipment is not
completely shut down is not allowed, the charging pile of superior switch must be
cut off and the maintenance symbol must be hung.

Using the emergency stop button under the non-emergency situation is not allowed,
otherwise the consequence at one’speril.

2. Brief Product Instruction

Electric vehicle charger is an indispensable electric vehicle energy service
infrastructure after the large-scale industrialization of electric vehicles. In order to
satisfy the national demand for the development of new energy electric vehicles and
accelerate the construction of new energy electric vehicle charging infrastructure,
Sinexcel independently developed the new generation of 240kW, 320kW and 400kW
outdoor AIO machine.
Through the flexible power distribution, the charging machine can control the

charging gun to charge the electric vehicle, which cannot only satisfy the requirements
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of double guns charging, but also satisfy the requirements of the fast-slowly charging
for double guns. Thus, the power allocation between single and double guns get the
maximum satisfy; in addition, it effectively reduces the cost of station construction such
as bus stations and social operation parking lot those large charging stations, it will
provide more convenient charging experience to the costumers.

The product adopts modular design, has multiple protection functions, intelligent
power automatic distribution and charging control system, it also has the characteristics
of high conversation efficiency, stable output current and high reliability, through CAN
communication reliable control charging terminal for high power charging vehicles.

2.1 Basic Model Parameters

Basic Model Parameters

240kW 320kW 400kW

Dynamic Dynamic
Parameter Name Split charge Split charge
charge for charge for
for two for two
two two
connectors connectors
connectors connectors
Input Voltage 380Vac

Output Voltage 200-1000Vac

Voltage Range for
Constant Power 600-1000Vac
Output
Output Power 240kW 320kW 400kW

Maximum Output 400A 500A

Current
Maximum Output
Current for One 200A 250A 250A 250A
Single Wire

Protection Level IP54

Size(L*W*H) 800mm*650mm*1700mm

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 Weight ≤500kg

2.2 Detailed Performance Parameters

Detailed Performance Parameters

Input Format TN-S（A+B+C+N+PE）

AC Input Range of Input Voltage 323~437Vac

Input Frequency 45~65Hz

Voltage Stabilization
≤±0.5%
Accuracy
Current Stabilization
DC Output ≤±1%
Accuracy
Peak Coefficient≤0.5%；Effective
Output Voltage Ripple
Value≤0.5%
Power Factor ≥0.99
Peak Efficiency 95%
Standby Power
≤0.1% Rated Output Power
Consumption
Performance
Current Imbalance ≤±3%
&
Function Input Under/Over Voltage Protection,
Output Under/Over Voltage Protection,
Short circuit Protection, Over Current
Protection
Protection,
Over Temperature Protection,
Lightning Protection

-20℃ ~ +65℃ ,
Operating Temperature
The derating work begins when
Environment temperature over 50℃
Condition
Relative Humidity 5%～95%（No Condensation）

Altitude ≤2000m, The derating work begins

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 when altitude over 2000m

2.3 Function Introduction

The double guns charging mode can switch the power module according to the
actual charging demand sent by the vehicle BMS, so the product can achieve the
purpose of single gun high power fast charging and double guns charging with
equal power

Adopting modular design, there are multiple modules work in parallel, the product
can fully operate even one of modules gets failure.

The charger CAN exchange data with the vehicle in realtime through the total line
of CAN to achieve the purpose of intelligent charging.

The charger adopts 7-inch LCD touch screen, it can display bright color even in
the high brightness environment at outdoor and would not bother the operation
from user.

Having local Ethernet, 3G/4G wireless communication and real-time

communication of background monitoring platform; it can report the status of
equipment operating in time to ensure the monitoring platform can monitor the
charging pile at real-time.

The charging system has the function ofremote and local upgrade, and the software
can be upgraded remotely when necessary.

3. Installation Instruction
3.1 Product Dimension

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 Size of Charger: 800mm(L) * 650mm(W) * 1700mm(H) (Shown in Fig 1);

Figure 1 View of Charger

3.2 Installation
3.2.1 Installation Requirement

The front door and left-right door of the charging machine can open, so operation
space should be reserved around the charging machine. The detailed reserved size
can view at Fig.3.2.1-A;

The cabinet be installed on the concrete or channel steel foundation is

recommended. The detailed size of the hole dimension at the base can view at
Fig.3.2.1-B;

The cable is embedded in advance. The detailed reserved length of the cable can
view at Fig.3.2.1-C;

The height of the installation foundation sets 200mm is recommended (too high is
difficult for operation and maintenance), the vertical inclination of the installation
should not exceed 5%;

The installation surface can embed 4 M12 stainless steel bolts and the bolt thread
for each one should set 30±3mm out ofthe ground. OR the installation surface also

can embed 4 M12(GB/T22795-2008)ZM type – cone cap expansion anchor.

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3.2.2 Installation Steps

Prepare the corresponding tools;

Drilling 4 holes with a diameter of 16mm and a depth of about 100mm on the
cement base, and then insert the expansion blot into the drilled holes through the
expansion part of the wall (If the blots have been embedded in advance on the
installation foundation surface, ignore this step); Drilling instructions are as
follows.

Remove the outer package;

Target the right hole places on the cement base, then set the equipment on them,
tighten and lock the equipment with M12 nuts (add elastic flat pad on them);

Connect the power distribution cable;

Seal with the sealing mud;

3.3 Power Cable Installation

3.3.1 Configure the Requirements of Power Distribution Cable

The input power wire of the system is introduced from the bottom of the charging
machine, and the power cable should be laid through the cable trench;

AC power supply system of charging machine adopts TN-S system;

The AC power wire should use copper core wire, the cross-section area of the wire
should be suitable with load;

The outdoor power wire shall be laid in accordance with the power regulations,
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 and the power wire laying shall be separated from the signal wire;

The AC entry wire starts from the user’s distribution switch and is connected to the
copper row of the input wire end of the charging machine’s input wire switch. The
user’s distribution shall have protection devices such as overcurrent, short circuit
and lightning strike;

The AC power wire has yellow, green, red, light blue, and yellow green, they
correspond to A, B, C, N, and PE respectively in AC. If the power line has only
one color, it needs to be labeled with the wire number (or sleeve with a label);

Broken, damaged or scratched power wires are not allowed to use.

3.3.2 Recommended AC Input Cable Specifications(Copper Core Wire)

Recommended AC Input Cable Specifications

Capacity Cable Specification Screw Specification Terminal Type

Two wires , each M10 for A/B/C/N,

240kW
4*95mm²+1*50mm² M8 for PE
Two wires , each M12 for A/B/C/N, Must be Fitted
320kW with Cable and
4*150mm²+1*70mm² M10 for PE Screw
Two wires , each M16 for A/B/C/N,
400kW
4*185mm²+1*95mm² M10 for PE

3.3.3 Schematic Diagram of Charger Connection

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3.3.4 Wiring Diagram inside the Cabinet

3.4 After-Installation Check

3.4.1 Tightness

According to the requirements of the design and protection level, the junction of
the cabinet and the foundation must be sealed with fireproof mud to prevent insects
or dirt from entering the cabinet.

3.4.2 Stability

After the pile installed, shake the cabinet from different directions, the cabinet

should not be obvious loosening and shaking.

3.4.3 Clean Up

All ofthe materials come from transpiration and packaging should be appropriately
clean based on the local laws and regulations;

Clean up the sundries inside and outside around the cabinet such as small cables,
binding straps, screws/bolts, etc. Do not leave any installation tools on the site or
13
 inside the pile (record all of the type and quantity of tools to avoid the omission);
Wipe the insulated part with anti-static cloth, do not use any corrosive solvent.

3.4.4 Checking list

Check whether the base is fixed and seal;

Check whether the fastening device inside the equipment is reliable;

Check whether the electrical connections and wiring is correct and complete, and
the connection is secure, check whether the around is reliable

Check whether the protection level of the equipment is satisfying the requirement,
especially at the bottom of the pile at the entrance of the cable;

Check appearance, tag, integrity, and cleanliness;

Taking a comprehensive checking base on the basis installation drawing to

compare with the installation of equipment.

4. Debugging Instructions
To start debugging, you need to configure the local network, server information,

pile number, service hotline, etc.

4.1 Configure the local network

Power on the device, enter the password to enter the administrator interface, and
click "Settings" -> "MCU" to enter the local network setting interface. This
interface is used to configure the network parameters of the pile end. According to
the actual network situation on site, choose "Wired" or "Wireless". When setting
up a "Wired" network, you need to connect the access cable to the stub monitor
and turn on the DHCP function. If you use 4G communication, select "Wireless"
on the interface, and the pile will automatically dial. When the icon in the upper
right corner of the screen is yellow, it indicates that the local network configuration

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 is complete.

4.2 Configure the server information

Click "Next" on the local network setting interface to enter the server information

setting interface.

4.2.1 Connect to the server using IP

It is necessary to set the "Server IP Address", "Port Number"', and close the
"Domain Connection". After the pile is connected to the server, the icon in the
upper right corner of the screen turns green.

4.2.2 Connect to the server using domain name

It is necessary to set the "Service domain name" and "Port number". After the pile
is connected to the server, the icon in the upper right corner of the screen turns
green.

4.2.3 Connect to municipal platform

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If the pile needs to connect to the Hangzhou municipal platform, you need to turn
on the municipal platform switch and set the municipal platform IP and port
number.

4.3 Configure Charger Number and Service Hotline

As shown in the figure, on this page, you can configure the pile number; you can
also modify the administrator password, click "New Password" and "Confirm
Password" in turn, the administrator password can be modified after entering the
passwords respectively.

Click "Next" on this page to configure the service hotline. The post factory service
hotline is invalid information.

5. Instructions
5.1 Charging Precautions
Make sure the charger system is in normal state before charging.

Before charging, make sure that the charging cable is not damaged, and that there
is no water in the charging gun. If the charging gun is flooded, please do not charge
it directly.

Before charging, the user should read the complete user manual and be familiar
with the safety operation instructions to prevent dangerous operations.

Before charging, the user should be familiar with the charging operation steps to
prevent improper operation.

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5.2 Charge Steps
Scan code to charge: This method is the mainstream method of the current charger,
start the charging remotely by directly scanning the QR code with mobile phone.
During the entire charging process, you only need to insert the gun and use the APP
to start charging, wait for automatic charging or use the APP to terminate charging
in advance, and end the whole process after pulling out the gun. Therefore, there
is no need to operate the screen throughout the process.

5.3 Charger User Interface

Standby charger interface (the screen lights up automatically when the car is

charged) is as shown in the picture below.

When the car is charged, the charger interface is as shown in the figure below.

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After the user scans the code to start charging, the charging interface is as shown
in the figure below.

When the charging stops, the charger interface is as shown in the figure below.

5.4 Connector Operation Instructions

Step1: Press down the mechanical locking rod and pullout the connector. Do NOT
shakeup and down while pulling.

Step2: Plug the connector directly into the electric vehicle, make sure the
mechanical lock has been pushed to the correct place.

Step3: When charging ends, press down the mechanical locking rod to poll out the

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connector.
Step4: Replace the connector.

Under normal circumstances, emergency unlocking is not allowed!

5.5 Emergency unlock method of the connector

Watch the unlocking video by scanning the QR code on the charging gun and learn

the operation steps of unlocking the charging gun.

5.6 Precautions for using the connector

Check whether the charging socket on the car is normal, whether there are objects
or dust in the socket or socket contact, and clean it if there is any.

Cleaning is only allowed when the charging cable is not connected to the vehicle.

Clean the charging gun wire and dirty contacts with a dry cloth. Do not use
corrosive cleaners, water spray or steam jet cleaners.

It is forbidden to immerse the charging gun head in the liquid.

6. Maintenance
6.1 Distribution System
The steps for switching on and off the power distribution box are as follows:
Check whether the power supply voltage is normal.
Closing: firstly close the main switch of the distribution box, and then close the
19
 switches of each branch circuit in turn.
Pull the switch: firstly pull the switch of each branch circuit, and then pull the main

switch of the distribution box.

6.2 Simple Troubleshooting

During the installation and debugging process, the alarm phenomenon of the
charging pile is a normal phenomenon in the process. After mastering the general
fault handling process, you can find the root cause of the fault according to the
fault phenomenon, analyze it, and eliminate the fault. Common fault analysis and
processing methods are like this: Upon receiving the waring information, we need
to analyze where it comes from; According to the function log and monitoring log
we can track level by level until we find the broken part or reset relative parameter.

Troubleshooting

Alarm or Fault
Number Processing Method
Name

Please check the status of the SPD. If the visible

1 SPD failure window of the SPD is red, it means it is damaged
and please replace it.
Please check if the product has an emergency stop
Emergency stop button which is not pulled out. If the fault is
2
failure resolved, please pull out the emergency stop button
and cover the emergency stop protection cover.

1. Reconfirm whether the gun is inserted

correctly, and the mechanical rod of the
3 Control boot failure charging gun is ejected normally.

2. Confirm that the SW3 dial inside the cabinet is

normal

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 Failure to lock the
connector, please Please follow the correct way for reliable gun
4
re-align the insertion.
connector.

Please check whether the cabinet door of this

product is completely closed; confirm that the door

5 Access Protection is closed,but the alarm is still displayed, please

check the status of the micro switch, if it is
damaged, please replace it.
1. Please check whether the air duct of the system

is blocked and whether the dust filter has

Air outlet over
accumulated too much dust.
6 temperature
2. Please check whether the fan at the air outlet of
protection
the charging stack is working normally. If the
fan is faulty, please replace it.
1. Please check whether the gun temperature
value and charging current meet the derating

output requirements at this time.

Gun temperature 2. If there is still over-temperature protection,
7
derating protection please continue to derate until the fault is
eliminated.
3. If the fault still persists, please replace the

charging cable.

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Common fault analysis and processing methods

Warning: In order to prevent personal electric shock accidents,

it is necessary to cutoff the power supply of the equipment and
the front end of the equipment during fault detection and
processing, and take protective measures, otherwise the
consequences will be at your own risk.

6.3 Maintenance

Maintenance Information

Routine Inspection
Inspection Method Solution
inspection item cycle
Every half Whether the fan is functioning
Fan Overhaul
year normally.
Whether the indicator light is burnt
Every half out, whether it is fixed firmly, and
Indicator Light Overhaul
year
whether the display status is normal。

Whether the circuit components are

firmly fixed, whether there is a
Every half phenomenon of ignition and burnout
Components Overhaul
year at the connection of the components,
and if abnormalities are found, replace
the parts in time.

For details, please refer to the manual

Dustproof Within half
of "Operation Instructions for Charger Cleaning
Cotton year
Dust Removal".
Whether the fixing buckle of the
charging gun is damaged, whether the Cleaning
Every half pin of the charging gun is oxidized and
Connector ,
year discolored, whether it is obviously
worn and deformed, and whether there Overhaul
is object in the socket of the gun head.
Module Every half Whether the module communication
Overhaul
Communication year of the charging pile is normal.

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 Every half
Display Screen Whether the display screen is normal. Overhaul
year
Whether the emergency stop button is
Emergency Every half working normally, after the emergency
Overhaul
Stop Function year stop is pressed, confirm that the
control circuit is disconnected.
Component Every half Check for loose, disconnected or
Overhaul
Grounding year altered grounding of the equipment.
Whether the crimping part of the
electrical grounding system is
System Every half
corroded, whether the grounding mark Overhaul
Grounding year
is complete and obvious, and whether
it is lost or damaged.
Mainboard Every half Check for dust buildup on the
Overhaul
Dust year motherboard.
Whether there are stains on the
appearance of the cabinet, whether the Cleaning,
Charger Every half sheet metal of the cabinet is deformed touch-up
Appearance year
or rusted, and whether the paint is painting
damaged.
Whether the trunking is firmly fixed,
whether the cover plate is complete
Trunking Every year and tight, whether the joints are loose Overhaul
or distorted, and whether the fasteners
are loose, corroded or rusted.
Press the TEST button of the circuit
Switch
Every year breaker to see if the circuit breaker can Overhaul
Protection
trip normally.
Whether the connection between the
cable and the switch is tight, whether
the grounding is reliable, whether the
power cable is heated or damaged (for Overhaul,
example: the color of the outer skin of cable
Cable Every year
the cable changes, sticks, the cable replaceme
becomes hard), whether the insulation nt
resistance of the cable meets the
requirements, whether the sealing
measures for cables entering the box
23
 are intact, and whether the holes are
sealed tightly.
Conduct a full inspection of the
grounding of electrical equipment, and
check whether the grounding wire and
the grounding terminal point are
Grounding Every year Overhaul
intact. Use a multimeter to check
whether the grounding resistance
exceeds the standard and whether it
meets the grounding requirements.

Damage caused In case of floods, earthquakes,

by force Immediately impacts, switch trips, etc., check the Overhaul
majeure whole machine immediately.

6.4 Emergency measures

In order to maintain the uninterrupted DC power supply of the charger system, it
is necessary to take some emergency measures for failures that threaten the DC
power supply.

The possible failures of the power system that causeDC output interruption mainly
include: irrecoverable damage to the AC power distribution circuit, short circuit of
the DC load or DC power distribution, shutdown caused by damage to the
monitoring module, module blockade caused by DC output overvoltage, etc.

Major natural disasters such as heavy rainstorms and strong typhoons cause
flooding or damage to the device, please do not try to charge;

In the event of an electric shock accident, the power supply must be turned off
immediately;

If a fire accident occurs, it is necessary to leave the scene immediately;

In case of special circumstances, you can call the customer service number.

7. After-sales Service
If you have any questions or problems, please contact the equipment manufacturer.
Before requesting after-sales service:

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Please check the troubleshooting measures in the chapter "6.2 Simple
Troubleshooting".

Please check the individual troubleshooting measures in the vehicle manufacturer's

manual.

Please record the model and serial number of the device (nameplate of the device).

7.1 Disclaimer
Product design, interface design, process and content display are subject to the
actual product. Copyright belongs to our company, all rights reserved. Contents are
subject to change without notice.

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 Appendix A: Module Group Number Setting Instructions
240kW with Two 320kW with Two 400kW with Two
Connectors Connectors Connectors
M10(G0 A10)
M8(G0 A8) M8(G0 A8)
M6(G0 A6) M6(G0 A6) M6(G0 A6)
M4(G0 A4) M4(G0 A4) M4(G0 A4)
M2(G0 A2) M2(G0 A2) M2(G0 A2)
M9(G0 A9)
M7(G0 A7) M7(G0 A7)
M5(G0 A5) M5(G0 A5) M5(G0 A5)
M3(G0 A3) M3(G0 A3) M3(G0 A3)
M1(G0 A1) M1(G0 A1) M1(G0 A1)

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