PT.

POWERINDO PRIMA EV CHARGER DC 2 X 100

PERKASA
kW
Manual Instruction
 EV CHARGER DC 2 X 100 KW

CONTE
DADADACONTENT
SAFETY PRECAUTION 3
MARKING INSTRUCTION 4
o ELECTRICAL SAFETY 4

o OTHER 4

DIMENSION 6
APPEARANCE 6

TECHNICAL SPECIFICATION 7
PRODUCT FEATURE 8
SYSTEM ARCHITECTURE 9
o ELECTRIC 9
o COMMUNICATION 9
INSTALATION PROCEDURE 10
o INSTRUCTION 10
o SAFETY INSTRUCTION 10
o OUT OF BOX AUDIT 10
o OPENING OF THE CABINET OUTDOOR 10
INTERNAL STRUCTURE 11
SPACE REQUIREMENT 12
CIVIL / BASIC REQUIREMENT 14
ELECTRICAL REQUIREMENT 15
NETWORK CONNECTION REQUIREMENT 15
INSTALLATION INSTRUCTION 16
SAFETY INSTRUCTION 16
CABINET INSTALLATION INSTRUCTION 16
TRANSFER HANDLING 16
CONNECT CABLE POWER 18
CONNECT GROUNDING CABLE 18
CONNECT THE AC INPUT 19
INSTALLATION OF MODULE 20
PROCCES OF POWER ON 20
CHARGING OPERATION 21
EMERGENCY OPERATION 22

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 EV CHARGER DC 2 X 100 KW

SETTING 23
CONFIGURATION/RECORD/ALARM/OTHER INFORMATION 23
INSPECTION AND DEBUGGING 24
POWER – ON CHECK 25
CHARGING OPERATION 25
PLATFORM INTERCONNECTION 26
CONNECTED TO POWERCORE PLATFORM 26
CONNECT OPERATION 26
AFTER SALES MAINTENANCE 27
AFTER SALES SERVICE 27
DISCLAMER 27
DAILY MAINTENANCE 27
REGULER MAINTENANCE 27
ON SITE MAINTENANCE 28
REMOTE MAINTENANCE 28

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 EV CHARGER DC 2 X 100 KW

SAFETY PRECAUTION
Before starting operation,please carefully read the instructions an precautions to
reduce accident,The “ care,attention,warning,danger “ items the product and product
manualdo not represent all safety matters to be observed,adding only to various operational
safety precautions.
During the operation of our product ada equipment, we must abide by the safety
spesificationof the relevant industries, and strictly observe the relevant equipment precaution
and special safety instruction provide by Nanjing Powercore Co, LTD.
MARKING INSTRUCTION

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 EV CHARGER DC 2 X 100 KW

ELECTRICAL SAFETY

The installation of AC power supply equipment must comply with the safety
regulations of the relevant industries.
It is strictly prohibited to wear watches, bracelets,rings and other easy conductive
object on the wrist while operating.
When water of humidity is found in cabinet, please turn off the power immediately.
When operating in wet environment, moisture should be strictly prevented from entering the
equipment.
No operation sign must be hung on swiches and buttons which not be allowed to
operate during installation.

In thunderstorm weather, strong electromagnetic fields will be produced in the

atmosphere. Therefore, in order to avoid lighning damage equipment, it is necessary to do a
good of the equipment in time

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 EV CHARGER DC 2 X 100 KW

The polarity of cable and interface terminals must be strickly checked in DC live
operation.
DC distribution operation space is compact,any operation should pay attention to
select operation space.
The operartion must use insulation tools
When charger operation, we must pay attentionto the hand, wrist and arms to
maintain tension, to preven the skid of the tool or human activity and accident.

OTHERS

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 EV CHARGER DC 2 X 100 KW

EV Charging 2x100 kW is and DC integrated electric vehicle charger.It use CCS2

and CCS2 plug.The system can be installed outdoor ( but for the safety reason, it should not
be used in rain or snowif the water height reaches the charger connector.

DIMENSION

Scenario Parking / public charging station

Material Metal Housing
Dimension ( mm ) 749 x 922 x 1885
Installation method Floor stand type
Cable layout Bottom
Weight 350 – 480 kg
Cable lenght 5 meter
Charging socket CCS2+CCS2

APPEARANCE

A E

B
F

D
G

A. Screen B. Emergecy Stop C. Charger Gun

D. Front Door E. Cable Port F. Air Intake

G.Cable Gun H .Foundation

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 EV CHARGER DC 2 X 100 KW

TECHNICAL SPECIFICATION

Standart IEC EN 61851-1:2011;IEC 61851-23:2014/AC:2016-06

IEC EN 61851-24:2014;IEC EN61000-6-1:2007;IEC EN
Standart 61000-6-3:2007 +A1:2011
Certificated CE Certificate with manufacture PT.Powerindo Prima
Perkasa
Application scenes Parking lot / Public charging station
Certificated CE
Housing material Metal case
Dimension 700 x 920 x 1885
Structure Installation Method Floor stand type
Description Cable routing Bottom inlet wiring, up outlet wiring
Weight 500 – 600 kg
Cable length Minimum 4 meters
Charging outlet CCS2+CCS2
Input voltage 3 phase 440 Vac
Input frequency 50 Hz
Rated power DC 2 x 100 kW
Measuring Level 0.5 / 1
accuracy
Electrical DC output voltage CCS2 150 – 750 Vdc x 2
Specification DC output current CCS2 0 – 200 Adc X 2
Efficiency ≥94%
Power factor ≥0.99
User interface Emergency stop button, LED indicator, card swipe,touch
screen
Charging standart IEC 61851-1/IEC 6181-23/-24:2014/ISO15118-1-2013
ISO 15115-2-2014/ISO 15118-3:2015/IEC 6219-1-2014
Function User Autorization MIFARE RFID card
Design Charging model Time/Amount/Energy/SOC/AUTO
selection
Communication PLC,CAN,PWM.Etherneyt,OCPP1.6,wifi,3G/4G/GPRS
Application plate Indoor/Outdoor
Working -30°C~+70°C ( Output degreaded aboved 50° )
temperature
Working humidity 5%~95% without condesation
Altitude <2000 m
Protection grade IP55/IK10
Environment Cooling Forced air cooling
condition MTBF 100000 hours
Special protection Anti UV Protection
Safety standart IEC EN61851-1:2011;IEC EN 61851-23:2014/AC:2016-
06;IEC EN 61851-24:2014
Security design Over voltage/under voltage,overload protection,current
leakage protection,over temperature protection,lightning
surge protection

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 EV CHARGER DC 2 X 100 KW

PRODUCT FEATURE

Has modern appearance design and humanized operation interface, which is mainly for
commercial usage. Modular design and overall output power can be configure arbitrarily to
improve charger utilization and easy to operate and maintain.
Safety
o CE/TUV
o Basic protection measure such as lightning protection, over voltage, over
current, short circuit, connection failure and emergency stop.
o IP 55
o EMC classB/C
Intelligence
o Intelligent connection of terminal EV Charger and cloud OCPP platform
o Remote diagnosis, remote upgrade
o Compatible of ISO15118/DIN70121/Chademo Standart
o Integration of AC and DC charging modes
o Multi-gun simultaneous charging
o DC Output of Dual-Gun shared power
o OCPP smart Charge
o Support for Dynamic load balancing ( trough additional load balancing
devices )
o Support Credit/Debit Card Payment ( Option function )
o Support OCPP 1.6 ( can be directly upgraded to 2.0 later )
Convenient
o Wireless or wired communication mode, and flexible networking
o Open communication protocol support code-scanning charging, credit card
charging and API service
Screen heating function ( Option Function )
o Select the whole machine heating dehumidification to avoid cold winter LCD
display may occur display or touch problems
o Plug and play ( charging )

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 EV CHARGER DC 2 X 100 KW

SYSTEM ARCHITECTURE
ELECTRIC `

COMMUNICATION `

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 EV CHARGER DC 2 X 100 KW

INSTALLATION PROCEDURE
INSTRUCTION

o SAFETY INSTRUCTION
High operating voltage and current inside the charging system, in order to ensure personal
safety, the following provisions shall always be observed.
1. Only those who have been trained in charging system and have full knowledge of
charging system can install charging system. During installation, always comply with
the safety precaution and local safety regulation after the directory.
2. To operate inside the charging system, ensure that the the charging is not charged.
The power input of the charging must be disconnected.
3. Distribution cable wiring should be reasonable and protective measure to avoid
accidental contact when operating power supply equipment.

o OUT OF BOX AUDIT

The packing box can only be disaseembled for inspection after the goods arrive at
the installation site. When inspection, first open the packing box attached with the packing
box, take out the packing list and check item by item against the packing list.Secondly,check
the number and serial number of the box identification.
After the arrival product,comfirm whether the package is damaged,whether the label
is complete and correct,if any abnormal, please immediately contact the manufacture to
discuss prosessing.
According to the packing list, count the product accessories and shipping document (
refer to the shipping list ),keep the assesories and document properly.
Visual inspection to ensure that the product is free of
collision,scratch,crack,depression, corrosion,breakage,lacquer peeling and other
abnormal conditions.
Sign document, record the situation,document timely preservation.

o OPENING OF THE CABINET DOOR

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EV CHARGER DC 2 X 100 KW

INTERNAL STRUCTURE

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 EV CHARGER DC 2 X 100 KW

SPACE REQUIREMENT
Installation space should be reserved to ensure the safe and reliable
operation,ventilation and maintenance of the equipment.
Space requirement for installation 1950 x 1990 mm , The spatial calculations are as
follows:
Charger size W x D x H : 750 x 590 x 1885 mm

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 EV CHARGER DC 2 X 100 KW

Reverse space at front ≥ 800 mm , Ensure that main gate switch is normal and
related operation is smooth
Reverser space at left ≥ 600 mm , Ensure the left door switch is not blocked and
open air flow
Reverse space at right ≥ 1600 mm , Ensure the right door switch is not blocked and
open air flow
Reverse space at back ≥ 600 mm , Ensure the back door switch is not blocked and
open air flow

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 EV CHARGER DC 2 X 100 KW

CIVIL/BASIC REQUIREMENT
The foundation may not be built when the equipment is installed indoor or in other
high and dry places, but the ground flatness error mest not exceed 1.5 ± per square meter
mm, and the ground strength grade of the installation position shall not be less than C30
degress.When the equipmentis installed outdoor and terrain is low and easy to accumulate
water, cement or channel steel base must be installed.The cement base is 200 mm higher
than the basic ground,and 4 M12 steel bolt are embedded on the mounting surface.Bolt
thread expose to the ground 30±3 mm.
The cable enter trough the bottom of the EV charger, and the inlet hole requires
Excavate a hole not less than size ( shown below ) on ground to install EV charger
Ensure that the cable is accessible from either side of the diagram and the aperture
is not less than 100 mm
Site cement pours the concrete foundation as shown in the figure below
Suggest the EV charger base to be at least 200mm above ground, can effective
reduction of flooding risk
Reserved cable length should be at lest 1 m above the the base,for external wiring
connection
Fill the holes inside the base with sand, and the inlet should be blocked with fire mud
to prevent rodents and other small animal from entering the equipment

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 EV CHARGER DC 2 X 100 KW

ELECTRICAL REQUIREMENT
Type of cable : Three phase five fire system, Confimation of additional shielding, as required
by local laws of term
If there is a shield layer, both end of shield mesh are safly connected to the PE
Cable diameter requirement are determined by the contactor or electrical engginering
according to the power, distance and industry standart, or recommendation
PE safety ground wires require the same as N line, or recommendation
The distribution input line diameter of the EV charger should be lower than following
recommended values, and should have independent circuit breaker and leakage protection

NETWORK CONNECTION REQUIREMENT

The recommended network connection is the 4G wireless communication / Wifi module
access integrated via EV charger.User need to prepare SIM card that meet local setting
requirement.The Local signak strength is sufficient and stable,otherwise contact the
communication operator to install the signal amplifier
If no local signal 3G/4G,a standart cable internet connection cab be used.Cable
connection must meet the following requirement.
RJ45 Ethernet
o Network cable type : Super 5 class and above ,8P+PE,shield line
o Suggest 75mm long inside,greater than 75 m long aboce need costomized
engginering solution
Min bandwidth

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 EV CHARGER DC 2 X 100 KW

o Upstream : 128 kbps

o Downstream : 4 Mbps
Reliability of demand connection : 99%
For special configuration,please contact us

INSTALLATION INSTRUCTIONS
SAFETY INSTRUCTION
The internal working voltage and current of the charging systemare high.To ensure personal
safety, the following regulations should be observed at all times.
Only personal who have received charging system training and fully mastered the
charging system knowledge can instal charging system.During the installation
process, always follow the safety precaution and local safety regulation in front of the
catalog.
If you want to operate inside the charging sytem,make sure the charging is not
charged.The main input of the charging system must be disconnected
The wiring of power distribution cable should be reasonable and protective measure
should be taken to avoid touching these cable when operating the power supply
equipment

CABINET INSTALLATION INSTRUCTION

o TRANSFER HANDLING

Elevated or mobile equipment shall be operated by means os special load bearing

forklip/crane,trailer or other professional load bearing tranfer device and by
professional personal
Do not dump impact the equipment
Use hole bolt or hoisting ring bolt to tighten the bolt hole fixed top four corner
Securely connected to hoisiting equipment, the rings need to balance
connection,balance force
Carefully lift the EV Charger to the mounting position
Remove the ring in place,Instal the M16 plug to the ring hole and srew
If there is no ring, use a strong rope and pass through the forklip hole instead

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EV CHARGER DC 2 X 100 KW

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 EV CHARGER DC 2 X 100 KW

CONNECT CABLE POWER

o CONNECT GROUNDING CABLE

The charging system adopt the common grounding mode, and the grounding copper
row of the charging cabinet is connected with the main grounding row of the engginering
installation by the grounding cable.

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 EV CHARGER DC 2 X 100 KW

o CONNECT THE AC INPUT

1. The AC input cable start wiring from the users distribution switch, and only when it is
finnaly ready to be electrifield is the cabke connected to the output terminal of the
user swich.The user distribution stich should have over current,short circuit,lightning
strike and other protetive device,the capacity of the distribution switch should not be
less than 1,5 times of the actual load capacity.
2. The L1 phase , L2 phase, L3 phase and N zero is marker as local regulation
3. Broken,damaged or scratched cable are not allowed

INSTALLATION OF MODULE
The power modules and the charger cabinet are oacked separately,and its prohibited
to insert the Power Module into charger cabinet and ship together.
After the instaling of the charger cabine on site, The power module need to be
inserted into the module slot inside of the charger cabinet for normal operation.
Since the connector sub-reeds at the rear Power Module are force sensisitive
device,the pluging action of the module need to be carried out slowly, gently pushing and
pulling out, to prevent the terminal reeds from being deformed and damaged
After module is unplugged, it need to stand for mode than 10 second,and the power
again after the discharge ends to prevent the socket from sparking and damaged
As the sytem considers expansion requirement, 12 module are reserved, and the
power module at the corresponding position is used according to the actual power
Similiarly,for system configuration of different power,the number of module need to
be devided as much as possible.The deviding line between group A and B is as shown in the
figure

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 EV CHARGER DC 2 X 100 KW

Distribution map of Charger Module

PROCESS OF POWER ON
After ensuring that the charger is installed stably,the wire connection reliable,and the
module debugging is completed, the charger can be energized.
Confirm that the AC circuit breaker,contactor, and leakage protection are in the off
state,connect the AC incoming line, and check that there should be no alarmor abnormal
state on the charger.
Close the AC circuit breaker,leakage protection and other switching device, the
charger sceen and indicator light should be on, the interface displays the access control
alarm, and the fault indicator lighting is on,indicating that the access control system is
working normally.
Close the cabinet door after checking that the component are working properly,and
the fault should be eliminated

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 EV CHARGER DC 2 X 100 KW

CHARGING OPERATION
Three ways to start charging 1.APP 2. RFID card 3.Credit or Debit card ( optional )
Click on the charger screen to get the chargers output capacity and operating status
information. When the operating status is an alarm, charging cannot be performed.It need to
be charged after touble shooting with the fault identification or fault code.

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 EV CHARGER DC 2 X 100 KW

EMERGENCY OPERATION
Refer to this section only when there is an abnormality or missoperation
In a emergency,remove the transparent cover quickly, press the red “ emergency stop button
“, the system will cut off the out put power.Do not use “ emergency stop button “ during
normal shut down.
o Emergency stop button + location

It is forbidden to forcibly plug out during the charging proses !

If you cannot stop normally,its recommended to press the emergency stop button
Then manually unlock,and pulling out the gun forcibly is prohibited

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 EV CHARGER DC 2 X 100 KW

SETTING
CONFIGURATION/RECORD/ALARM/OTHER INFORMATION

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 EV CHARGER DC 2 X 100 KW

INSPECTION AND DEBUGGING

Before debugging,you need to prepare and confirm that the following conditions are met
All preparation,construction,installation,connection and other work have been
completed
The input power of the charger has been connected and the charging capacity has
been equipped

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 EV CHARGER DC 2 X 100 KW

If there is no 3G/4G signal,you need to connect to the network through a network

cable
A full time safety officer is required on site to be responsible for safety supervision
Arrangge the operation representative and accept the on site guidance of charging
operation

POWER-ON CHECK

The charger is connected to the AC power supply.In the standby state,cek whether
the charger has a fault alarm.whether the indicator light displayed normally and
whether the Power module is working normally.Then configure network
information,check that network connection status should be normal,the signal
strength should be appropriate and stable and there should be no disconnection.

CHARGING OPERATION

Connect an electric car or test equipment,the charger shows that the electric car is
connected
Ther charger starts charging by scanning the card or APP and the charger start
normally
Check that the charger has no fault alarm, the indicator light is normal,the module is
operating normally, and there is no abnormal light – emitting or heating phenomenon

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 EV CHARGER DC 2 X 100 KW

PLATFORM INTERCONNECTION
CONNECTED TO POWERCORE PLATFORM
After charger is connected to the platform of Powercore charging facilities, it can
realize function such as remote management diagnosis.configuration,maintenance and
upgrade.

Data Interaction of Powecore platform ( +APP QR code )

CONNECT OPERATION
The factory default platform connection URL is PowerCore.As long as the charger is
connected to the internet, it will automatically connect to the PowerCore platform
If you need to connect to other platform,please change URL. Now it support
websocket (ws://) and websocket secure (wss://)

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 EV CHARGER DC 2 X 100 KW

AFTER SALES MAINTENANCE

AFTER-SALE SERVICE

1. Two-year warranty for all part

2. During warranty,if any part are damaged ( not including non-quality factor damage
).We will provide free accessories,and customers can replace them by themselves
3. One-to-one technical engginer support

o DISCLAMER
The product equipment needs to be used normally within a certain range of
conditions.PowerCore will not be liable for any of the following conditions that cause an
accident or damage.
All damage caused by human factor and use in abnormal working environment
Failure and damage cause by using without the instruction or usingin the un-allowed
indicator environment as the instruction
Damage caused by poor transportation after delivery
Normal use of old,worn,broken and soaked etc
Product that don’t belong to out company ( such as fake )
Unauthorized disassembly,repair,and modification of product without consent of the
company
Damaged caused bu other ireesistable force ( such as
flood,fire,lightking,typoon,earthquake

DAILY MAINTENANCE
Regular maintenance can keep the charger is a safe stable and good condition.The
following is the recommended maintenance cycle.Customer can define the maintenance
cycle and content according to the use environment and frequency.
REGULAR MAINTENANCE

Monthly
o Check the verticality of the charger
o Dirt degree of external surface
o Condition of paint surface damage
o Charging output and cable usage
o Status of indicator&display
Quaterly
o Grounding screw,grounding resistance ( not more than 1 ohm )
o Module indicator is normal, no abnormality & alarm
Semiannually
o Tightening force of fixed anchor screw bolt
o Check the air filter cotton an dust screen and determine wheter it needed
to bu be purged or replaced according to the ventilation capacity of the air
filter element
Annualy
o Check the leakage protection device once ( in standby state )
o Check whether is rust or water stains of the paint surface and sheet metal
of the cabinet

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 EV CHARGER DC 2 X 100 KW

ON SITE MAINTENANCE
The device is an Internet of Things charger with intelligent functions such as pre-charge
selft check,daily regular self-check,on line monitor of electrical part and operating
paramenter, etc
Normal Operation,only daily maintenance,don’t need overhaul and maintenance
If the operation is abnormal,please refer to the following trouble shooting, and contact
the PowerCore customer service center or supplier in time

REMOTE MAINTENANCE
The charger has the functionof connecting with the device cloud platform to minitor to
the status of the charger in real time.When connected to the PowerCore platform,the
platform can provide complete remote diagnosis, remote service and remote upgrade
service and can promply find and locate actual problem in the actual problem in the actual
operation procees and provide correspondensing solutions accordingly to help the operartion
center analize remote service.And the software can be upgrade remotely to solve the
problem and of end user and realize unattented operation.
Daily self-check of the system and report to the background if there is any
abnormality
If there is abnormal operation,please contact PowerCore customer service cebter or
local supplier in time
PowerCore service engginers can query logs,update configuration and procedure,
and implement remote maintenance action such as
management,diagnosis,configuration and upgrade.

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