Charging infrastructure

30kW DC WallBox Commissioning Manual

Version Number/Document number：2.0/DCY0210TYTS

Wanbang Digital Energy Co. Ltd.

 Contents
1 General .................................................................................................................................................... 1

1.1 Purpose of document ............................................................................................................................... 1

1.2 Scope of application ................................................................................................................................. 1
1.3 Definition of warning symbols ................................................................................................................. 1
2 Preparation before commissioning ......................................................................................................... 2

2.1 Safety precautions before field commissioning ....................................................................................... 2

2.2 Structure ................................................................................................................................................... 4
2.3 Datasheet ................................................................................................................................................. 5
2.4 Module specification ................................................................................................................................ 6
2.5 LED status indicator .................................................................................................................................. 6
2.6 Commissioning tools ................................................................................................................................ 7
3 Commissioning steps ............................................................................................................................... 9

3.1 Commissioning flow chart ........................................................................................................................ 9

3.2 Construction review ................................................................................................................................. 9
3.3 Check before power on .......................................................................................................................... 13
3.3.1 Visual inspection of equipment appearance ................................................................................... 13
3.3.2 Internal circuit inspection of charger............................................................................................... 14
3.4 Test after charger powered on............................................................................................................... 15
3.4.1 Parameter checking ......................................................................................................................... 15
3.4.2 Hardware ......................................................................................................................................... 20
3.4.3 Charging function ............................................................................................................................. 21
4 Customer Training Instruction ............................................................................................................... 27
1 General
1.1 Purpose of document
In order to ensure the normal delivery of DH-DC0300HG57-X after installation. Discover and eliminate
the failure or hidden dangers of the charger caused by factors such as installation quality and the
environment (such as power voltage). Ensure that the charger can be put into operation safely, stably and
efficiently.

1.2 Scope of application

It is suitable for the commissioning work of DH-DC0300HG57-X before delivery.

1.3 Definition of warning symbols

No. Symbol Content
“Electrical hazard” symbol indicates danger
Failure to pay attention to the procedures, practices or improper
1 implementation may cause installer injuries and death. Only after the
conditions referred to are fully understood and fulfilled, the operation
accompanied the "electrical hazard" symbol can be performed.
"Be careful" symbol indicates danger
Failure to pay attention to the procedures, practices or improper
2 implementation may cause product damaged or destroyed. Only after
the conditions referred to are fully understood and fulfilled, the
operation accompanied the "be careful" symbol can be performed.
“Prompt” indicates usage tips or useful information
3 Tips and useful information are marked with “prompt”. It does not
contain information to warn about dangerous or harmful functions.

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2 Preparation before commissioning
2.1 Safety precautions before field commissioning
1) The engineer should have knowledge of electrical safety, understand the principle and performance of
chargers, and be proficient in electric shock first aid and emergency treatment measures, so that
various hidden emergencies can be discovered and treated before commissioning.
2) When working, the engineer must be clear, focused, not drunk or troubled; those who are not well are
forbidden to work.
3) During work, the engineer must wear insulated shoes, insulated gloves, and if necessary, safety
helmets and other protective supplies. The insulated appliances, instruments, and tools used must be
intact and reliable.
4) Before any electrical equipment or wiring is checked, it must be regarded as having power and shall not
be touched. When contact operation is needed, the upper power supply should be cut off, and after
the electricity and discharge (capacitive facilities) are tested again, the power is qualified. Hang the
power switch handle with a "No Closing, Someone Work" sign or take other measures to prevent
switching on.
5) The superior power supply must be cut off before work, and the lockout and tagout procedures must
be strictly implemented.
6) When possible, power off before work, if the engineer needs to operate with power, he must have
someone to monitor. The person shall meet the professional requirements and shall not engage in
operations or do anything unrelated to monitor when operating.
7) When carrying out live work, the engineer should first divide L, N, PE, and choose the working position.
When working, do not touch the conductive part and the zero (ground) part at the same time.
8) Without permission and approval, the original wiring and structure in the charger must not be
changed.
9) After the work is completed, restore the components to their original state, check the tools to prevent
omissions, and clean and organize the site.
10) In case of safety accident, immediately start the emergency plan for production safety, and report to
the relevant person in charge immediately as required, and conduct on-site emergency treatment in
accordance with the emergency plan for the first time, control the spread and expansion of the
accident, and rescue personnel and property.

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11) If an electric shock occurs, immediately cut off the superior power, perform rescue according to the
emergency rescue method, and call the local rescue phone at the same time, seek professional help
and report to the leader, and make a record.
12) The power transmission sequence is: high-voltage power supply side, low-voltage incoming and
outgoing line side, and load (box transformer → distribution cabinet → charger);
The power cut sequence is: load, low-voltage incoming and outgoing line side, high-voltage power
supply side (charger → distribution cabinet → box transformer).

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2.2 Structure

Figure 1 Structure

 [A] ——Touch screen

 [B] ——LED indicator light and card reader area
 [C] ——Electricity meter
 [D] ——Air inlet and outlet
 [E] ——Lock
 [F] ——Emergency stop button
 [G] ——Charging cable slot

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2.3 Datasheet
Model Star Charge
General
Product name 30kW Charger
parameters
Product number DH-DC0300HG57

Rated input AC400V±10%, 3-Phase, 50/60 Hz, L1+L2+L3+N+PE

Power factor 0.99 (Normal load)

Input parameters
Total harmonic current: ≤5% (Normal load)

Efficiency 95% (Normal load)

Output Interface DC CCS2*1

Output output voltage 200-500V DC

parameters Output current 80A max.

Output Power 30kW

Display 7＂Touch screen

Support language Chinese, English, other language available upon request

User Interface&
Mechanical button Emergency button
control
RFID card reader ISO/IEC 14443 A/B Mifare RFID reader

Start method APP scan code/ swipe card start

Network Interface 4G/Wi-fi/Ethernet

Communication
Communication protocol OCPP1.6J

Operating temperature -30℃~50℃

Storage temperature -40℃~70℃

Environment
Humidity 5%~95%

Altitude ≤2000m

Ingress Protection IP55/IK08

Cooling Forced cooling

Mechanical Dimensions (W*D*H) /

680*440*280mm/approx. 45kg (with power module)
Weight

Installation Wall-mounted/Floor-mounted

Regulatory
Certificate CE Ready, CB Ready
requirements

Table 1 Datasheet

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2.4 Module specification
DH-DC0300HG57-X uses Star Charge 30kW power module. Voltage and current graph of power
module is as follows:

Figure 2 Voltage and current graph

Parameter Value Remarks

Output voltage 150 ~ 500V -
Maximum output power 30kW Maximum power of module: 30kW (no special
customized requirements)
Maximum output current 80A -
Rated current 60A 500V
Table 2 Parameter sheet

2.5 LED status indicator

Status General status and fault identification

Glow Green Normal

Pulsate Green RFID card detected

Glow Yellow There is alarm fault, but it will not affect normal charging

Glow Blue Charging

Glow Red Malfunction

Pulsate Red RFID card validation failed

Table 3 LED Status

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2.6 Commissioning tools
Before you go to the site, please prepare the following tools.
No. Description Usage Figure

Parameter setting and intercept the

1 Laptop
passage

2 J - LINK Flash program

3 232 tool Intercept message and flash program

0.8*4*100 slot type

4 Terminal strip wiring
screwdriver

5 PH2 cross screwdriver Install and remove power modules

Disassembly fasteners and other

6 No.5 allen driver
components

T15 six-angles Remove and install shutters and filter

7
screwdriver cotton

8 Screwdriver set Standby

9 Wrench Standby

10 Multimeter electrotechnical measurement

11 Test pencil electrotechnical measurement

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12 Megohmmeter Measure insulation resistance

13 Safety signs Safety warning

Electrician protective
14
gloves
Safety protection
Electrician protective
15
rubber shoes

16 TF card Flash program

17 Ethernet cable Web setting

Table 4 Commissioning tools

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3 Commissioning steps
3.1 Commissioning flow chart
The commissioning flow chart of DH-DC0300HG57-X is as follows:
DC Charging Point Commissioning Flow Chart
Character Position Stage of commissioning
Yes Yes
Commiss Whether
Whether Whether ioning the Fuctions
Check
Member of on-site operation and

the hardware, Whether Train the

Whether before the after commiss Yes
Review of relevant Yes the
to meet power appearan Power power IP address Yes ioning customers
constructi compon fuctions
maintenance group

the on ce and on on and

on work ents be are Output
Operation and requirem internal platform Feedbac
before powered normal
maintenance ents of circuit meet the k and Customer training
commissio No Feedbac
engineer the
Feedbac meet the on
No Feedbac requireme No record record form and
ning k and k and k and
《Installa No requirem nt problem commissioning
record ents No Feedbac record record
tion s acceptance
problem k and problem problem
Manual report
s record s s
》 problem
s
Provincial
Engineering
department

Troubles Troubles Troubles

engineering
Member of

Manager / Third hooting hooting hooting

Party
Construction
Team
Member of

departmen
quality

QA Troubles Troubles Troubles

t

engineer hooting hooting hooting

support group
Member of

Troubles Troubles Troubles

technical

Technical
hooting hooting hooting
support
engineer

Figure 3 Commissioning flow chart

Warning! During the commissioning, when the door is open, the engineer shall not
leave, and remind other personnel of dangerous matters and prevent the
third-party personnel from being curious and accidentally electrocuted. When
leaving the site, make sure that all doors of the charger are closed and locked.

3.2 Construction review

Equipment commissioning must be conducted by engineer with special operation certificate
(electrician certificate).
The installation must be carried out according to the requirements of the "Installation Manual".
During construction and installation, the engineer must follow local laws and regulations. During the review,
the engineer must record and report the problems which have been found.
Tips!
Before commissioning, each step of this part must be carefully implemented, wear
safety protective equipment (insulated shoes, insulated gloves, etc.)!

1） Check whether the base is fixed and sealed.

2） Check whether the internal components of the charger are tight and reliable.
3） Check whether the specifications of the cables used meet the power requirements of the charger, no

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 breakage, damage, scratches, electrical connections and wiring are correct and complete, and the
connections are secure.
4） Check whether the protection level of the equipment meets the requirements, especially at the cable
entry at the bottom of the charger.
5） Check the appearance, marking, completeness and cleanliness.
6） Check the grounding resistance / insulation resistance check. The grounding resistance must be ≤4Ω,
and the cable insulation resistance must be ≥7MΩ.

Note!
When the item has been checked and accepted in the construction acceptance
report, retesting may not be performed; the above requirements are the minimum
requirements for the equipment, and the specific standards are subject to local laws
and regulations.

Measure the ground resistance

Use a ground resistance tester to measure the resistance of each grounding part of the charger. The
ground resistance should be ≤0.1Ω.
Method:
The E terminal button on the instrument is connected to 5m wire, the P terminal button is connected
to 20m wire, the C terminal button is connected to 40m wire, and the other end of the wire is connected to
the ground electrode Eˊ of the measured object, the potential probe Pˊ and the current probe Cˊ, Pˊ and Cˊ
should be kept straight with a distance of 20m.
Connect the two E-end buttons on the meter, and perform the measurement as shown in the figure
below.

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 Figure 4 Abridged general view
Measure the insulation resistance.
Step 1: Turn off the switch in the distribution cabinet. Turn off the air switch in the charger.

Figure 5 Schematic diagram of internal structure#1

Step 2: Pull out all the power modules in the charger. Remove the ground wire of the surge protector.

Figure 6 Schematic diagram of internal structure#2

Step 3: Prepare a megohmmeter.
Note:
When the megohmmeter makes an abnormal sound after being turned on, please do not test.
If the battery cover is open, do not take any measurements.
When the live line warning symbol A is displayed or the buzzer emits a warning sound, the
measurement cannot be performed.
The location and data that need to be measured refer to the " Site acceptance report of charger”.
Instructions:

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 Connect the red and black test lead wires to the corresponding sockets; set the megohmmeter
voltage knob switch to the corresponding voltage of 1000V. The screen will display as shown below.

Figure 7 Megameter
Step 4: Connect the test lead or clip to the test object. The black test lead E of the megohmmeter is
connected to the PE terminal of the charger. The red test lead L is connected to the DC + copper bar (the
upper and lower ends of the output relay) or DC-copper Row (upper and lower end of output relay).

Figure 8 Schematic diagram of internal structure#3

Step 5: Press the red test knob of the instrument to enter the test state. At this time, the buzzer will
intermittently emit "Di, Di", and the high voltage indicator light will be on. The screen displays the following
contents during the measurement until the resistance value does not change.
Release the test key (or twist the knob back to the original position from the lock state), and the

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instrument will automatically release the high voltage generated by the test. The high voltage indicator
light will go off, and the high voltage alarm sound "Di, Di" will disappear. The meter line can only be
removed when the screen displays "0V"：

Figure 9 Megameter
Then relevant photos can be collected with test values recorded. Charger insulation resistance IEC
Standard requirements: not less than 7MΩ.
Note: check the resistance unit. 1TΩ = 1000GΩ; 1GΩ = 1000MΩ; 1MΩ = 1000kΩ; 1kΩ = 1000Ω.
Once measuring the DC +, DC - charger, if the value is less than 7MΩ, need cable line will be removed
(main demolition charge cable line DC+, DC-, PE, shielded wire) to measure, and measure the charging
cable DC+, DC- two charger to ground resistance, such as less than 7MΩ, cable line needs to be replaced.
Step 6: Restore the internal environment of the charger after the test.
3.3 Check before power on
3.3.1 Visual inspection of equipment appearance
There are four visual inspection items listed below. The engineer should check all the items below and
expand the inspection contents. If there are any unqualified items, please record them and contact the
corresponding person in charge.
1) Appearance: check whether the appearance of the charger is damaged, whether there is any damage
such as paint loss, scratch, scratch and deformation, and whether the structure of charger is damaged
during transportation.
2) Sign: check whether the nameplate of charger is correct, clear and complete, and whether the safety
warning sign is posted in place.
3) Documents: check with the customer whether the configuration information of on-site charger
conforms to the requirements of the contract, whether the accessories are complete, whether the
user manual, factory inspection report and qualification certificate are complete.
4) Fire clay: check if there is fire clay sealing in the charger to prevent insects or dirt from entering the
cabinet.

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3.3.2 Internal circuit inspection of charger
1) Short circuit: check whether the distribution cabinet is connected to the charger, and whether there is
short circuit between the fire line, neutral line and earthing line and whether the phase sequence is
right.
2) Line screw fastening: check every line connection, connector and screw fixed terminal and bronze
plate. Check whether the tightening torque meets the requirements and there is no loosening, poor
connection and other conditions.
3) Voltage before power on: before powering on the charger, first check whether the power supply
voltage at the molded case circuit breaker of the distribution cabinet is normal, and there is no
abnormality such as missing phase, overvoltage, undervoltage, and phase sequence.

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3.4 Test after charger powered on

Tip! Follow the steps to power on the charger. Pay attention to the risk of electric
shock. Wear protective gloves and insulating shoes.

3.4.1 Parameter checking

Set according to the following requirements.
Step 1: Connect the computer to the mainboard with an Ethernet cable. Set the IP address
(192.168.88.xxx, xxx don’t use 206.)

Figure 10 Ethernet cable connection

Figure 11 IP setting
Step 2: Open a browser (Chrome is recommended), type in website address “192.168.88.206”. Then

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type in user name and password.

Figure 12 Login interface

Figure 13 Home
Step 3: Click “Register”. Click “Refresh”. Type in SN code and activate code. Click “Submit”.

Figure 14 Configuration diagram

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 Figure 15 Configuration diagram

Figure 16 Configuration diagram

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 Step 4: Click “Software Setting”. Set OCPP. No modification is required normally.
Type in OCPP address.

Figure 17 Configuration diagram

Step 5: Click “Hardware Setting”. Type in pile number.

Figure 18 Configuration diagram

Step 6: Power module setting.
Type in module number, module type.

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 Figure 19 Configuration diagram
Step 7: Click “Software Setting”. Set the network. No modification is required normally.

Figure 20 Configuration diagram

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3.4.2 Hardware
1) Touch-screen: check whether the touch screen display is normal, whether there are obvious white
spots, whether the display is clear, whether the operation is flexible and reliable and whether the
interface is clear.
2) Switching power supply: The switching power supply can provide 12V/24V power supply voltage
normally and stably. Use a multi-meter to measure whether the voltage at the output terminal of the
switching power supply inside the charger is consistent with the label.
3) Travel switch: When the device is in the charging state, if its cabinet door is opened, the device should
stop charging instantly according to the design requirements.
4) Emergency Stop Button: When the device is in the charging status, if the user presses the emergency
stop button at the front door of the charger, the device should stop charging immediately according to
the design requirements.
5) Fan: Check whether the fan of the charger and the fan of the power module can work normally during
charging.
6) Indicator light: Check whether the indicator lights the charger is consistent with the design.

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3.4.3 Charging function
Swipe Card
The steps are as follows:
Step 1: Click the screen to turn the touchscreen interface on.

Figure 21 Home
Step 2: Enter the charging mode selection interface, please select the swipe card mode.

Figure 22 Choose charge method

Step 3: Place the card before the card reader area for 3 seconds to start charging.
Step 4: During the charging process, the screen shows as shown below. Click "Details" to view the
charging details of the charger.

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 Figure 23 Charging process

Figure 24 Charging details

Step 5: Click "Stop". Then swipe the card again to stop charging.

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 Figure 25 Stop charging interface
Step 6: After stopping charging or the battery is fully charged, the screen will show the charging
result.

Figure 26 Finish Screen

Step 7: Pull the charging cable out from the vehicle and put it on the slot.

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 Scan QR code
The steps are as follows:
Step 1: Click the screen to turn the touchscreen interface on.

Figure 27 Home
Step 2: Enter the charging mode selection interface, please select scan QR Code mode.

Figure 28 Choose charge method

Step 3: Open the APP and scan QR Code.
Step 4: During the charging process, the screen shows as shown below. Click "Details" to view the
charging details of the charger.

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 Figure 29 Charging process

Figure 30 Charging details

Step 5: Click "Stop”. Then click “stop” on the APP to stop charging.

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 Figure 31 Stop charging
Step 6: After stopping charging or the battery is fully charged, the screen will show the charging
result.

Figure 32 Finish
Step 7: Pull the charging cable out from the vehicle and put it on the slot.

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4 Customer Training Instruction
After completing the commissioning of the charger, the engineer needs to provide customers with the
basic knowledge and instructions on the use of the charger according to the characteristics of the charger.
The training methods can be in the form of documentary explanations or live demonstrations. The training
content should include safety emergency common sense and basic charging process. After confirming the
customer's satisfaction after the training, the commissioning personnel form a training record and the
customer will sign for confirmation. Please refer to Appendix 1 "Customer Training Record Form".

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