EV DC Charger Manual

July, 2022
Preface
To make sure that you can safely use the Euro standard DC charger and remove trouble
timely once it occurs, please read this manual carefully before using this product.

The charger applies to lithium ion power battery, provides power output less than the rated
power, and keeps a higher output voltage and current accuracy; the display screen is the
most important human-machine conversation interface of the charger, and its main function
is to show the state of charge, state of batteries, failure state, etc.

The charger strictly implements IEC 62196-3-2014 <Plug, Socket, Vehicle Connectors and
Vehicle Sockets Electric Vehicle Conductive Charging Part 3 :Size Compatibility and
Interchangeability Requirements for DC and AC-DC Pins and Vehicle Coupler Conducting
Tube>, IEC 61851-23-2014 (Electric Vehicle Conductive Charging System Part 23: DC
Electric Vehicles Charging Station), relative requirement of <IEC 61851-1-2019 (Electric
Vehicle Conductive Charging System-Part 1: General Requirements)> and realizes the
intelligent communication with on-board device in accordance with <IEC 61851-24-2014
(Electric Vehicles of Electric Vehicle Conductive System- Part 24 :Communication Protocol
between DC Electric Vehicle Charging Station and Electric Vehicles for Controlling DC
Charging.)

This manual is only applicable to the European standard and Japanese standard series
electric vehicle DC chargers. The contents of the manual will be updated with the upgrade of
the control software and display interface software without prior notice.

Please keep the instruction manual in a safe place for future reference.

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CONTENT

Operating Conditions and Safety Matters.................................................................................................................. 3

1. Overview................................................................................................................................................................ 5

1.1 Function Description........................................................................................................................................ 5

1.2 Appearance Instruction................................................................................................................................... 5

1.2.1 Operational Zone..................................................................................................................................... 5

1.2.2 Charging Connector................................................................................................................................. 6

1.3 Main Technical Parameter.............................................................................................................................. 7

2. Method of Application............................................................................................................................................ 7

2.1 Installation instruction...................................................................................................................................... 7

2.1.1 Structure installation................................................................................................................................ 7

2.1.2 Electrical Installation Instruction............................................................................................................13

2.1.3 Outline Dimension Drawing...................................................................................................................15

2.2 Power-on Preparation................................................................................................................................... 15

2.2.1 Requirements for the operators.............................................................................................................15

2.2.2 Inspection matters before use............................................................................................................... 15

2.3 Network Matching Requirements for Charger...................................................................................................16

2.3.1 Preparing for the Internet....................................................................................................................... 16

2.4 Charging System Introduction.......................................................................................................................16

2.4.1 Charging Procedures............................................................................................................................. 17

2.4.2 Other System Information......................................................................................................................21

2.4.3 System Setting....................................................................................................................................... 22

3. Equipment Storage and Maintenance Instruction................................................................................................23

3.1 Charger Storage............................................................................................................................................ 23

3.2 Maintenance of Charger................................................................................................................................ 24

4. Common Fault Solution....................................................................................................................................... 27

5. Warranty.............................................................................................................................................................. 28

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 Operating Conditions and Safety Matters

Operating Environment

Working Working Atmospheric DC Output

Product Model Power
temperature Humidity Pressure Current
IOC030HY1 -30℃～+55℃ 5%～95% 80kPa～110 kPa 30kW Power/Voltage
Constant
Power Range
IOC060HY2 -30℃～+55℃ 5%～95% 80kPa～110 kPa 60kW Lowest Value

（1） Safety Instructions

 Charger should be operated according to operation instruction provided by Xiamen Galaxy

Camphol Technology CO., Ltd;

 Nonprofessionals are forbidden to open charger cabinet and dismantle screen touch

without permission, sharp objects are forbidden to operate on the screen;

 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;

 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;

 Under urgent circumstances, press red emergency stop button on the charger and cut

down charger internal power supply;

 Smoke and fire are forbidden around the charger and pay attention to ventilation;

 The fuse must be replaced with the same type fuse and can’t be replaced by copper

and iron wire;

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

danger;

 Charger upper circuit breaker and power distribution cabinet should be chosen,

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installed and operated by professional electricians;

 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;

 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;

 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 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.

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1. Overview

1.1 Function Description

This integrated DC charger can realize single connector fast charging, as well as two connectors equal
power charging at the same time.

1.2 Appearance Instruction

1.2.1 Operational Zone

The operation area includes indicator light, display screen, card reading area and emergency stop
button. The indicator light can display the power, charging gun and fault status; the display screen is
used to display the charging information; the card reading area is used to identify the charging card
and provide simple operation instructions; the emergency stop button is used to cut off the power in an
emergency to avoid accidents , it is forbidden to use when power off normally.

Figure 1-1 Schematic diagram of the operation area of the charger

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1.2.2 Charging Connector

Figure 1-2 CCS 2 interface diagram

Figure 1-3 CHAdeMO interface diagram

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1.3 Main Technical Parameter

NO. Technical Index Name Technical Index Content Remarks

1 Input cable voltage 400V±15%

2 Input voltage type AC 3-phase Three phase five wire system

3 AC grid frequency 45-65Hz

4 Output voltage 150—1000V Continuous adjustable

5 Output voltage error ≤0.5％ Full output range

When Output current≥30A:≤±1％

6 Output current error When Output current＜30A:≤±0.3A Full output range

7 Stabilized voltage precision ≤0.5％ Full output range

8 Stabilized current precision ≤0.5％ Full output range

9 Ripple factor ≤0.5％ Full output range

10 Average efficiency ≥94% 50% and above load

11 Power factor ≥0.99 50% and above load

12 Leakage current ≤10mA

Power frequency 1 min no insulation breakdown

13 2500VAC
withstand voltage and flashover

14 Insulation resistance ≥20MΩ Test voltage 1000VDC

15 Noise ≤60dB

16 IP level IP54

17 Cooling method Forced air cooling

2. Method of Application

2.1 Installation instruction

2.1.1 Structure installation

（1）Foundation drawing

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The charger is installed on the ground, and the installation should be reliable and firm. The
recommended foundation diagram is shown in the following figure:

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 Figure 2-1 Foundation drawing

（2）On-site installation steps of the charger

1. After unpacking the box, open the back cover of the column, place the column on the concrete
foundation, pass the cable reserved in the center of the foundation from the bottom of the column, and
then align the bottom plate hole of the column with the anchor bolt and place it with spacers. and nuts
to fix the column;

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2. Connect the reserved cable to the terminal block behind the column;

3. Place the charging pile cabinet on the steps in front of the column. First, pass the reserved cable
under the cabinet through the cable entry hole on the left side of the column, then center the cabinet,
and connect the column and the cabinet with M5 screws. Be careful to tighten the screws to prevent
the cabinet from falling;

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4. Open the air inlet window on the left side of the cabinet (with special anti-theft bolts and a
professional screwdriver in the box), and put the charging module in the column box into the cabinet
from the left window according to the marked position. Pull the module to the left as appropriate, then
push to the right again until the module can be screwed in place;

5. Connect the reserved cables under the cabinet to the wiring bar behind the column;

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6. After checking that the wiring is correct, fix the back cover of the column and the air inlet window on
the left side of the cabinet, and use M4 screws to fix the junction box on the lower left side of the
cabinet.

Cable Comparison Table

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 Power AC Incoming Cable Terminal Remark

30kW YJV-3*35+2*16 SC35-8,SC16-8

60kW YJV-3*50+2*25 SC50-8,SC25-8

1. Select the appropriate AC input cable according to the power comparison table. It is recommended
to choose a flame-retardant cable, which is slanted through the φ100 insulation and flame-retardant
electrical pipe, and the cable is 800mm above the ground size;

2. The foundation is poured with C25 concrete, and the M12 stainless steel anchor bolts are pre-
buried, and the exposed part of the bolt is 40mm and kept vertical, and the dimensions refer to the
concrete pouring section drawing. /T96 large washer c-grade), spring washer, M12 nut (8.8 grade) 1
each; ensure 10 years not to rust;

3. During the construction of the foundation, pay attention to compacting the ground in the area with
loose soil to ensure that the charging pile will not tilt for a long time; pay attention to adjusting the level
of the charging pile. When adjusting the level of the charging pile, the cabinet shall prevail;

4. The threading pipe should prevent rainwater from pouring into the cable hole, and be pre-buried at
an inclination to reduce the cable laying resistance. The flatness of the installation surface of the
concrete boss should not be greater than 3mm;

5. Protective measures such as protective railings or car stalls shall be provided on the periphery of
the concrete abutment;

6. The side walls of the concrete abutment exposed above the ground should be brushed with yellow
and black warning lines at 45° to the horizontal ground (warning line width 100mm).

Installation Precautions：

Drainage measures should be taken at the installation location of the charger to avoid flooding of the
charger and affect normal use.

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During installation, it is necessary to ensure that there are no obstacles within two meters on the left
and right sides of the charger to ensure the normal heat dissipation of the charger; a certain distance
should be reserved in front of the charger to facilitate operation.

After the cabinet is fixed on the base, the vertical inclination of its installation should be no more than
5%. When fixing, the recommended nut tightening torque is 28.5 N•m.

The place of use should avoid direct sunlight, and a sunshade (rainproof) shed should be installed
outdoors.

The noise of this charger is only guaranteed to meet the national standard for charger noise, but in
order to avoid unnecessary disputes, if it needs to be installed near residential areas or other places
with special requirements for noise, please test the noise in advance or perform sound insulation
treatment before installation.

2.1.2 Electrical Installation Instruction

The electrical installation of the DC charger must be guided by professional technicians. Remove the
back cover of the column and connect the incoming wire to the lower terminal, as shown in Figure 2-3.

Figure 2-3 Incoming cable position

It is recommended to select a copper core cable that meets the requirements, and use a terminal that
matches the cross-sectional area of the cable to be crimped. The exposed part of the terminal joint
must be insulated with heat shrinkable sleeve or insulating tape. Tensile strength requirements for wire
crimp terminals of various sizes:

Crimping tensile Crimping tensile

Conductor siz（mm2） Conductor size（mm2）
strength（N） strength（N）
0.13 (AWG#26) 13 30 2300
0.2 (AWG#24) 22 38 2500
0.3 (AWG#22) 36 50 2900

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 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 in the table, the tensile strength corresponding to the approximate
size can be selected for inspection.

The AC incoming wire is fed from the bottom of the charger and connected to the AC input terminal
and the ground wire terminal inside the charger. The AC input must be wired according to the
incoming line identification, and the neutral line and the phase line must not be reversed, otherwise it
will cause an irrecoverable failure of the charger. The circuit breaker and power distribution cabinet at
the upper level of the charger must be selected and operated by professional electrical personnel. The
recommended installation torque for electrical installation is 24 N.

！Note: When wiring, it is necessary to first remove the rear baffle of the column, and then use a
socket wrench to tighten the terminal screws. It is forbidden to use a screwdriver to operate.

2.1.3 Outline Dimension Drawing

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2.2 Power-on Preparation

2.2.1 Requirements for the operators

The operators should pass the operation training before operating the charger. During the working
period, they should wear work clothes and insulating shoes according to the regulations, and
comrades with long hair should wear safety helmets.

2.2.2 Inspection matters before use

 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;

 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;

 Switch the breaker to OFF, the breaker is off, turn off the air switch of control circuit and connect

AC inlet well;

 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;

 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.

2.3 Network Matching Requirements for Charger

2.3.1 Preparing for the Internet

Prepare a SIM card (traffic ≥ 300MB) and insert it into the position as shown in the figure below,
restart the charger, if you still cannot connect to the Internet, please contact us.

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2.4 Charging System Introduction

Introduction of charging method

Power on the charger and the screen will show the main interface after self-system check, see Figure
2-4. It is showing charging connector type, connector status, station code, and QR code.

IP address is available on the left bottom, and icons are on the right bottom showing the network and
connection status.

Figure 2-4 Main interface

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2.4.1 Charging Procedures

(1) Start Charging, click and select the charging connector, and start charging via swiping the RF ID
card or scanning the QR code, see figure 2-5;

Figure 2-5 Choose the charging connector

Figure 2-6 Start charging

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(2) Charging: Parameters are available with Power, Voltage, Current, Energy, Duration, and also the
Battery Capacity during charging process. Further details are also available once you click the
charging page again;

Figure 2-7 Charging process

Figure 2-8 Charging details

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(3) Stop charging: Select the connector in use and swipe the RFID or control via mobile App to stop
the charging process. It will be showing the stop reason and charging session will be finished;

Figure 2-9 Stop charging

Figure 2-10 Finish charging

(4) Simultaneous Charging: If one charging connector is in use, it will be showing sharing information
when charging session is initiated with another charging connector;

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 Figure 2-11 Simultaneous charging

(5) Reservation: Users may reserve the charging connector via mobile app, and it will be showing
connector reserved on the screen, and also the reserved time left.

Figure 2-12 Reservation

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2.4.2 Other System Information

There will be also other message shown on screen indicating the charging station status.

Figure 2-13 Prompt information

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 Figure 2-14 Charger connector unavailable

Figure 2-15 Charger connection failure

2.4.3 System Setting

Users may click the language position to set different languages.

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 Figure 2-16 Language setting

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 III
Category I Environment Category II Environment
Equipment Environment
Limited Storage Period Limited Storage Period Remarks
Name Limited Storage Period
(Year) (Year)
(Year)

EV Charger 1 0.8 0.5

Storage ambient condition corresponding relations：

Storage Environment
Temperature ℃ Relative Humidity % Remarks
Condition Classification

I 15~ 25 ℃ ≤65 %

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 II -5 ~ 30 ℃ ≤75 %

III -35~55 ℃ ≤90 %

It is forbidden to put products with corrosive materials at the same site!

3.2 Maintenance of Charger

User daily maintenance can guarantee that the charger is under good condition, main works includes:

（1）Regularly check whether there is dust in the cavity, and clean it regularly to prevent the decline of
the internal insulation performance; use a vacuum cleaner or an air compressor to clean the bottom,
sides and parts of the cabinet;

Open the front door to observe the dust

（2）Regularly check whether the ground wire is reliably grounded;

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 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;

Check if the fan is normal

（ 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;

 After metal dust screen and black filter dry, install the metal dust screen, ventilating shutter and
black filter, then lock with screw tightly.

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 Left and right filter
（5） Regularly check the charging cable and winding tube. If there is aging or wear, it should be
replaced in time to ensure safe use. The charging connector is loose and needs to be tightened in
time;

Check the aging and wear of the charging cable and winding tube

Maintenance operation should be done every month, if there is severe environment, it can shorten the
maintenance time according to actual situation.

（6）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.

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 Cleaning charging connector or socket

Notes: Nonprofessionals are not allowed to dismantle equipment

assembly!

4. Common Fault Solution

Serial
Fault Causes Measures
No
1 Power on failure explanation
Power supply system Cable inside the cabinet Find the cable burnt inside the
1.1
protection trip peeling cabinet and change the cable
Press emergency stop Rotate to unlock emergency
button stop button then operate
After breaker trip, system
1.2 Reset breaker to OFF status
can’t power on Turn off charging cabinet
manually then turn to ON
abnormally
status
2 Abnormal status explanation after power on

2.1 Display screen not on Power supply cable loose Fasten power supply cable
display screen installation Relax screw of screen at the
too tight back side
Display screen key no Check whether front door is
2.2 Display screen deformation
response deformed
Display screen damaged Repair display screen
Check control circuit
Contactor not attracted
conductivity
2.3 All the fans not starting
Check fan power supply cable
Loose cable line
loose or not
2.4 Lines are disabled Check cable is pressed and off
2.5 Cable line fault Check corresponding cable conductivity
2.6 Fan damaged Change the fan
Notes: when the switched button is pressed, breaker closes, when the controller is in normal
operation, indicator shows rhythmic sparkle.
3 Charging Abnormal Explanation

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 Check charging connector
Vehicle BMS not started
Charging handshakes not 12/24V output
3.1
successfully Check cable connection inside
Communication cable loose
the cabinet
Charging module fault Contact manufacturer
3.2 Charging voltage is 0
Output contactor not closed Repair contactor 3KM~6KM
Charging module fault Contact the manufacturer
3.3 Charging current is 0
Fuse open circuit Change the fuse
Check corresponding cable is
Cable line fault
open circuit or loose
Charging connector has no Use multimeter to check the
3.4 Contactor control line open
12V output voltage and fasten the cable
circuit
line
Contactor open circuit Change contactor
Check corresponding cable is
Cable line fault
open circuit or loose
Use multimeter to check the
3.5 Output contactor not closed Contactor control cable
voltage and fasten the cable
open circuit
line
Contactor open circuit Change the contactor
Notes: when all the switches are on, start charging
4 Other common fault explanation
Overtime protection Restart
Abnormal charging and
4.1 Vehicle BMS sending over Wait battery temperature
stop
temperature decreasing and recharge
Attached common fault code instruction table

Fault Fault
Fault causes Fault Causes
code code
0 No fault 1~9 Reserved
10 Charger electronic locking error 11 Reserved
12 BMS communication overtime 13~18 Reserved
19 Charger contactor fault 20 Reserved
Communication fault between
21 power adaptor and main control 22 Charger over temperature fault
panel
Abnormal connection of charging
23 Connector pulling out and stop 24
connector
Communication fault between charging
25 Module fault 26 connector controller and main control
panel
Low voltage auxiliary power supply
27 28 Charger output current over limit
abnormal
29 Charger voltage output abnormal 30 Charger AC input abnormal
31~32 Reserved 33 Battery reverse connection fault
34~39 Reserved 40 Charger communication overtime
41~46 Reserved 47 Vehicle BMS parameter abnormal

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 48~63 Reserved 64 Battery parameter abnormal
65~73 Reserved 74 Device door open
Charging connector over Charger insulation resistance
75 76
temperature and jump abnormal
77~78 Reserved 79 Insulation test failure
80~256 Reserved 257 Inner communication fault
258 Press emergency stop button 259 Module combination fault
260 BMS insulation fault 272 Charging card balance insufficient

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.

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