Charging Infrastructure

Athena Commissioning Manual

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 Content
1 General Principle ....................................................................................................................... 1
1.1 Purpose of this Document ............................................................................................................... 1
1.2 Definition of Warning Sign ............................................................................................................... 1
2 Preparation before Commissioning ............................................................................................ 2
2.1 Safety Notice................................................................................................................................... 2
2.2 Outside Appearance of EVSE ......................................................................................................... 4
2.3 Datasheet ....................................................................................................................................... 6
2.4 Specification of Power Module ........................................................................................................ 7
2.5 LED Light Indication ........................................................................................................................ 8
2.6 Commissioning Tools ...................................................................................................................... 9
3 Commissioning Process .......................................................................................................... 11
3.1 Commissioning Flowchart ............................................................................................................. 11
3.2 Installation Recheck ...................................................................................................................... 12
3.2.1 Basic Check ................................................................................................................................................. 12
3.2.2 Insulation Resistance Check of Input Power Cable ..................................................................................... 13

3.3 Check before Power on ................................................................................................................. 15

3.3.1 Using Condition Check ................................................................................................................................. 15
3.3.2 Internal Wiring Check ................................................................................................................................... 15
3.3.3 Check the Insulation Resistance of Charging Cable ................................................................................... 15

3.4 Check after Power on.................................................................................................................... 17

3.4.1 Power ON sequence .................................................................................................................................... 17
3.4.2 Basic Check ................................................................................................................................................. 17
3.4.3 Web Configuration ....................................................................................................................................... 18
3.4.2.1 Connection ........................................................................................................................................... 18
3.4.2.2 Web-Quick Setup ................................................................................................................................. 32
3.4.2.3 Web-Software Setting ........................................................................................................................... 34
3.4.2.4 Web-CP Configuration .......................................................................................................................... 40
3.4.2.5 Web-Power Unit Configuration ............................................................................................................. 42
3.4.2.6 Power Module Address Configuration .................................................................................................. 44

3.5 Charging Function Check .............................................................................................................. 47

3.5.1 Charging Test ............................................................................................................................................... 47

4 Customer Training ................................................................................................................... 52

Appendix 1 Customer Training Record Sheet ................................................................................ 53
Appendix 2 Commissioning Report ................................................................................................ 54
1 General Principle
1.1 Purpose of this Document
The purpose of this document is In In order to facilitate the normal successful use of Athena after installation.
The information supports to discover and eliminate the failure or issues hidden dangers of the charger caused
by factors such as installation quality, site conditions or and the environment (such as power voltage).
Thereby establishing a fully operational charger that functions safe, stable, and efficient. Ensure that the
charger can be put into operation safely, stably, and efficiently.

1.2 Definition of Warning Sign

Item Sign Definition
“Warning” indicates danger.
Please pay attention to the operation sequence. Any incorrect operation or
1 practice will lead to personal injury or death. Operations marked “Warning”
symbol can only be performed if the indicated conditions are fully understood
and met.
“Attention” indicates danger.
Please pay attention to the operation. Any incorrect operation or practice will
2
lead to the product damaged. Operations marked “Attention” can only be
performed if the indicated conditions are fully understood and met.

“Notice” indicates useful operation skills or information.

3 The operation will be marked “Notice” symbol if any useful skill and information
is available. No warning or attention

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2 Preparation before Commissioning
2.1 Safety Notice
Warning!
Only manufacturer’s engineers or engineers trained by manufacturer are allowed to
do commissioning to EVSE. Star Charge will not be responsible for any loss caused by
the operation of any third-party engineers without Star Charge’s authorization.
Each step of commissioning must be handled carefully. If any problem, the test must
be stopped at once until the problems are identified and resolved.
In case of rain, snow, sandstorm and other harsh condition, no any commissioning
operation is allowed!
1) The engineers operating the commissioning must have basic electrical safety knowledge, understand the
technology and performance of EVSE, and know how to handle the emergency caused by electric shock
or other danger, so that they could identify and handle any emergency on the site of commissioning.
2) When operating on the site, engineer must be concentrated on the operation. Drinking and fighting is
absolutely prohibited on the operating site. The engineer is not allowed to operate if feeling
uncomfortable.
3) During commissioning operation, insulation protection shoes and gloves must be worn. Safety helmet
and other protection equipment should be worn when necessary. All the insulation equipment, device
and tools must be checked to be good and reliable.
4) Any electrical equipment and lines are deemed to be powered on before being checked by the operator,
and are not allowed to be touched. Before touching electrical equipment, the engineer must strictly
follow the operation process of powering off the equipment, checking, discharging (if equipment has
capacitance), rechecking, and hanging a warning sign of “No power on, someone is working” or other
preventive tools to prevent power on when operating.
5) Before operating, please strictly follow the procedure of power off, hanging warning sign and lock.
6) Please try the best to operate without power. If it’s necessary to operate with power, there must be a
specific engineer who is qualified to monitor the process. And during the operation, the engineer who
is qualified to monitor the process must not be allowed to do any other job.
7) When operating with power, please clearly identify the L line, N line and PE line, and choose proper
operation place. Touching the energized part and grounding part at the same time is prohibited during
operating.

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8) Without authorization and approval, any change of connection and structure inside of the EVSE is not
allowed.
9) After operating, please put the components back to the original place, count the tools to prevent missing,
and clean the operation site.
10) In case of any emergency, please launch the emergency response plan immediately, report the situation
to the responsible person according to the plan, and carry out the on-site emergency treatment in the
first time to control spreading, and rescue person and property.
11) In case of electric shock, cut off the power and start the first-aid immediately, call ambulance for medical
help and report to the leader at the same time, and keep the accident into record.
12) Power on sequence: high voltage power, low voltage input and output, load (substation → power
distribution → EVSE);
Power off sequence: load, low voltage input and output, high voltage power (EVSE → power distribution
→ substation)

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2.2 Outside Appearance of EVSE
⚫ Ground-mounted

Figure 1 Outside Appearance of EVSE

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⚫ [A] -- 7-inch touch screen
⚫ [B] -- Display mechanical buttons
⚫ [C] -- LED status indicator
⚫ [D] -- RFID card reader
⚫ [E] -- Charging connector
⚫ [F] -- Charging Cable Management systerm
⚫ [G] -- POS
⚫ [H] -- Pedestal
⚫ [I] -- Emergency stop button
⚫ [J] -- Electric meter reading window
⚫ [K] -- Air outlet

⚫ Wall Mounted

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2.3 Datasheet
Athena
CCS2 ChAdeMO
Input Rating 400Vac±10%, 3-Phase, 50/60 Hz, L1+L2+L3+PE
Power Factor 0.99 at nominal output power
Power Input
Current THD ≤5% at nominal output power
Efficiency Rectifier ≥95% at nominal output power
Output Interface 2 x CCS2 & CCS2+ChAdeMO
Output Power 60kW max.
Power Output
Output Voltage 150-1000Vdc 150-500Vdc
Output Current 200A max. 125A max.
Display 7'' LCD Touch Panel
User Interface Simplified Chinese, English, Other languages available
Support Language
upon request
& Control Push Buttons Emergency stop button
RFID Reader ISO/IEC 14443 A/B Mifare RFID reader
Network Interface 4G, Wi-Fi, Ethernet
Communication
Protocol OCPP1.6J
Operating Temperature -30℃~55℃
Storage Temperature -30℃~70℃
Environmental
Humidity 5%-95% no condensation
Altitude ≤2000m
Ingress Protection IP54
Enclosure Protection IK10 (Screen IK08)
Cooling Forced air
Charging Cable Length 5m
Mechanical
Dimension (WxHxD) 750*750*310 mm
approx. 125kg (with power modules, without cable
Weight
management)
Installation Ground-mounted, Wall-mounted
Regulation Certificate CE, TR25, RCM

Table 1 Datasheet of EVSE

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2.4 Specification of Power Module
Athena uses Star Charge 30kW 1000V power module, which has a feature curve as follows:

Figure 2 Feature curve

Module High-voltage Low-voltage
Parameter Value Value
Range of output voltage 200～1000V 150～500V
Rated output voltage 1000V 500V

Rated output current 30A 60A

Table 2 Datasheet of power module

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2.5 LED Light Indication

LED Light State Definition

Steady green Normal

Flashing green RFID card identified

Steady yellow There’s some fault which doesn’t affect charging.

Steady blue Charging

Steady red Fault

Flashing red Fail to verify RFID Card

Table 3 LED light indication

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2.6 Commissioning Tools
Please check and prepare the following tools before commissioning:

Item Tools Usage Example

1 Laptop Configure the settings and read logs

2 Ethernet cable Web configuration

3 J – LINK tool Programming

4 5/6 pin adaptor and flat cable Programming

5 Micro SD Card and reader Programming

6 Screwdriver set Assemble and disassemble the screws

7 Wrench set Standby

8 Electrical multi-meter Electric measurement

9 Megohmmeter Test the insulation

10 Safety Sign Warn potential danger on site

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 Electrician protective
11
gloves
Safety protection
Electrician protective
12
Shoes

Table 4 Tool list

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3 Commissioning Process
3.1 Commissioning Flowchart
The commissioning flowchart of DC EVSE is as follow:

Commissioning Flow Chart for DC EVSE

Installation Technical Support
Commissioning Engineer QC
Engineer Engineer

Installation
recheck

Whether the
Corrective
installation meets the NO
maintenance
requirements

YES

Check before
power on

Whether the appearance,

internal wiring, insulation
resistance and input NO
voltage meet the Corrective Corrective
requirements maintenance maintenance

YES

Check after
power on

Whether the voltage

and hardware function NO
meet the requirements Corrective Corrective Corrective
maintenance maintenance maintenance

YES

Parameter
configuration

Whether the
configuration is ok and
NO Corrective Corrective
EVSE is connected to
backend maintenance maintenance

YES

Charging
function check

Whether the hardware

work according to the NO
Corrective Corrective
requirements
maintenance maintenance

YES

Training and
report finishing

Figure 3 Commissioning flowchart

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 Warning!
During the commissioning process, the engineer cannot leave when the cabinet is
opened and must remind any other people of staying far away. Make sure that all
doors of the cabinet are closed when leaving the commissioning site.

3.2 Installation Recheck

Commissioning must be operated by the engineers qualified by local special operation regulations.
The installation must be carried out in accordance with the requirements of “Installation Manual”. The local
laws and regulations must be observed during construction and installation. Any problem relating to the
installation found during the recheck must be recorded accordingly in time.

Notice!
Before commissioning, make each procedure of this part must be carried out carefully
and protective equipment (protective shoes, gloves and etc.) must be worn. Refer to
local regulations and policies for safe operation requirement.

3.2.1 Basic Check

1) Foundation: whether fixed and sealed well.
2) Input power cable: Check whether the specification of all the cable used meet the requirement of EVSE,
whether there is any break, damage, or scratch, whether the electrical connection is correct and
complete, whether the connection is stable and solid, whether the grounding is reliable.
3) Insulation resistance: The inlet cable insulation resistance must be ≥10MΩ. The specific value should
comply with the requirements of local standard.

4) Outside appearance of EVSE: The surface of cabinet is intact without any dirt, and the charging cable is
not broken or damaged. All doors of cabinet can be opened, closed and locked. The EVSE is not tilting,
shaking or reverse assembling.
5) Nameplate and sign: Check whether nameplate and other signs are printed correct and complete,
whether the safety sign is posted in correct place.
6) Documents with EVSE: Check with the customer whether the configuration information of the EVSE on
site complies with the contract requirements and whether the accessories are complete.
7) Others: Whether the fireproof material inside of the EVSE is in place to prevent insects or dirt from
entering the cabinet.

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 Notice!
It’s unnecessary to check again, if the checkpoint is accepted and listed in the
construction acceptance report. The requirement listed above is the basic
requirement. It is subject to the local laws and regulations.

3.2.2 Insulation Resistance Check of Input Power Cable

Step 1: Turn off the switch in the power distribution cabinet corresponding to the EVSE; turn off the switch
inside of the EVSE.

Figure 4 Power OFF sequence for insulation resistance check.

Step 2: Take out all the power modules inside of the EVSE, detach it from the socket at the end of each
power module, remove the grounding line of the surge protector, and remove the DC+ and DC- ports on
the insulation testing board.

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 Figure 5 Insulation resistance check of input power cable 2#
Step 3: Get the megohmmeter ready.
Step 4: Connect the megohmmeter to item to be tested. The black test lead E connects to the PE terminal
of EVSE, connect red test lead L to the inlet cable L1, L2, L3 and N of EVSE. The insulation value should be
≥10MΩ. The specific value should comply with the requirement of local standard.

Figure 6 Insulation resistance check of input power cable 3#

Step 5: Recover the situation inside of the EVSE to the original state after the test.

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3.3 Check before Power on
3.3.1 Using Condition Check
1) Working temperature：-30℃~50℃；
2) Working humidity：5%~95%, no condensation;
3) Working altitude：≤2000m

3.3.2 Internal Wiring Check

1) Short circuit: Check the input power cable connecting power distribution cabinet to the EVSE. Check
whether there’s any short circuit between 3-phase live wire, neutral wire and grounding wire and
whether the phase sequence is correct. Refer to the Appendix 2 for specific checkpoint.
2) Screws fasten: Check whether the fastening torque of each line connection, connector, terminal with
screw and brass plate can meet the requirement, and whether there’s any looseness, poor connection
and etc. Refer to the Appendix 2 for specific checkpoint.
3) Voltage check before power on: Before powering on the equipment, check whether the input voltage
of the main breaker inside of the EVSE is correct, and make sure there’s no fault such as phase loss,
overvoltage, undervoltage and wrong phase sequence.

3.3.3 Check the Insulation Resistance of Charging Cable

Step 1: Turn off the switch in the power distribution cabinet corresponding to the EVSE; turn off the switch
inside of the EVSE.

Figure 7 Power OFF sequence for insulation resistance check.

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Step 2: Take out all the power modules inside of the EVSE, detach it from the socket at the end of each
power module, remove the grounding line of the surge protector, and remove the DC+ and DC- ports on
the insulation testing board.

Figure 8 Disconnect IMD board DC+ and DC- for Insulation Resistance Check

Step 3: Get the megohmmeter ready

Step 4: Connect the megohmmeter to the item to be tested. The black test lead E connects to the PE
terminal of EVSE, connect red test lead L to the DC+ copper bar or DC- copper bar of EVSE. The insulation
value under 500V should be＞1MΩ.

D D
D

Figure 9 Insulation resistance check of charging cable 3#

Step 5: Recover the situation inside of the EVSE to the original state after the test.

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3.4 Check after Power on

Notice!
The equipment must be powered on strictly in accordance with the following steps.
Pay attention to the risk of electric shock, and wear protective gloves and shoes.

3.4.1 Power ON sequence

Figure 10 Power ON sequence

Step 1: Turn ON MCB which provides power to PCB.
Step 2: Turn ON all 3 main breakers which supply power to SPD and RCB for AC contactor.
Step 3: Turn ON 2 RCB for AC contactor.

3.4.2 Basic Check

1） Voltage check after power on: Check whether the output voltage of the main breaker inside of the EVSE
is correct, and make sure there’s no fault such phase loss, overvoltage, undervoltage and wrong phase
sequence.
2） Touch screen: Check whether the touch screen displays normal, has obvious dead pixel, displays words
clearly, is operated well and clear UI.
3） LED indicator light: Check whether the LED indicator light on the EVSE works as the design requirement.
4） Switch mode power supply: Switch power supply can provide stable voltage power. Use electrical
multimeter to check whether the output voltage of switch mode power supply inside of the EVSE meets
the requirement.

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3.4.3 Web Configuration
3.4.2.1 Connection
To connect to the network, insert the SIM (mini-SIM) according to the location of 4G communication
module.

Figure 11 SIM card

Figure 12 Port to insert SIM card

Connect the LAN port of router to the laptop by an Ethernet cable, and set the IP address as shown in the
following picture (192.168.1.xxx, xxx can be any number but 136, 200, 201)

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 Figure 13 Set IP address
Open the browser and input 192.168.1.136, log in with username (wbdh) and password (Wbdh26835941.)

Figure 14 Log in Web panel

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 Figure 15 Web panel
Change the language:

Figure 16 Change the language

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Update
Notice!
Program update is not the necessary step of commissioning. Contact with Star Charge
engineer for specific program version information.

Firmware Update:
Click “Upload and download” – “Brows” – “firmware.zip” – “Submit”.

Figure 17 Firmware update

Update SECC via Micro SD Card:

1) Insert Micro SD card into laptop (specific card for programming, don’t use the Micro SD card put in the
EVSE).
2) Enter the folder (A6G2C-WB128LI-Flash), double click the file (m6g2c_burn_script.bat).

Figure 18 Update SECC via SD card 1#

Commissioning Manual 21
3) Enter the driver of Micro SD card. For example, the driver of my Micro SD card is F.

Figure 19 Update SECC via SD card 2#

4) If there’s warning shown as picture, enter y to confirm and wait for the file to be copied completely.

Figure 20 Update SECC via SD card 3#

Figure 20 Update SECC via SD card 4#

5) After that, press any key to exit and finish the programming Micro SD card.

Commissioning Manual 22
 Figure 21 Update SECC via SD card 5#
6) Insert Micro SD card, switch both 2 switches marked red shown in the picture on. (Very important!)

Figure 22 Update SECC via SD card 6#

Commissioning Manual 23
7) Power on again, the LED light will be flashing all the time during the updating. When the LED light on
the core board is steady lighting (flashing all the time before), wait for 30 seconds and then power
offer, switch both 2 switches back to position 1 and 2 (very important!).

Figure 23 Update SECC via SD card 7#

8) Insert the Micro SD card inserted in the module before, power on again and finish programming. It will
take a little longer for first reboot.

Commissioning Manual 24
Update A7 via Micro SD Card:
1) Insert Micro SD card into laptop (specific card for programming, don’t use the Micro SD card put in the
EVSE).
2) Enter the folder (A6G2C-WB128LI-Flash), double click the file (m6g2c_burn_script.bat).

Figure 25 Update A7 via SD card 1#

3) Enter the driver of Micro SD card. For example, the driver of my Micro SD card is F.

Figure 24 Update A7 via SD card 2#

4) If there’s warning shown as picture, enter y to confirm and wait for the file to be copied completely.

Figure 25 Update A7 via SD card 3#

Commissioning Manual 25
 Figure 26 Update A7 via SD card 4#
5) After that, press any key to exit and finish the programming Micro SD card.

Figure 27 Update A7 via SD card 5#

6) Insert Micro SD card, switch both 2 switches marked red shown in the picture on. (Very important!)

Commissioning Manual 26
 Figure 30 Update A7 via SD card 6#
7) Power on again, the LED light will be flashing all the time during the updating. When the LED light is
steady lighting (flashing all the time before), wait for 30 seconds and then power offer, switch both 2
switches back to position 1 and 2 (very important!

Figure 28 Update A7 via SD card 7#

Commissioning Manual 27
8) Insert the Micro SD card inserted in the module before, power on again and finish programming. It will
take a little longer for first reboot.

Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink:

1) Connect Jlink with M4 board;

Figure 29 Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink 1#

M4 board

Figure 30 Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink 2#

2) Open on the laptop;

3) Choose file “.jlash”;

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 Figure 31 Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink 3#
4) Open file “.mot”;

Figure 32 Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink 4#

5) Connect;

Commissioning Manual 29
 Figure 33 Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink 5#
6) Erase Chip;

Figure 34 Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink 6#

7) Program & Verify (If fail, try one more time);

Commissioning Manual 30
 Figure 35 Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink 7#
8) Start Application;

Figure 36 Update M4 Board/PDU Control Board/Environment Monitoring Board via Jlink 8#

Commissioning Manual 31
3.4.2.2 Web-Quick Setup
In this page you will face some common configurations.

Figure 37 Web-quick setup 1#

ChargePoint ID:
1) Enter ChargerPoint ID;
2) Click “Submit”.

Figure 38 Web-quick setup 2#

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OCPP Setting:
Take http://36.153.57.202:3400/steve/websocket/CentralSystemService as an example. The information
needs to be filled in is shown as below:
1) “IP or Domain Name”: Enter IP address or domain name of the backend;
2) “SSL_Enable”: The value is “enable” when the backend uses TLS for access, otherwise the value is
“disable”.
3) “Port”: Enter Port number of backend
4) “Path”: Enter the path after IP in “Path”
5) “Authorization key”: If the backend doesn’t use Basic authorization, just leave it blank. (No need to fill in
most cases)
6) Click the “Submit” in OCPP Part to confirm delivering the setting information to the backend.
7) “Certificate Import”: Load in the CA certificate offered by customer when using TLS; otherwise, leave it
blank.
8) Click “Submit” to deliver certificate if loading in the certificate.

Figure 39 Web-quick setup 3#

4G configuration:
1) Click “Enable modification”;
2) Set APN, User, Psw, Pin according to actual usage;
3) Click “Submit”.

Commissioning Manual 33
 Figure 40 Web-quick setup 4#
3.4.2.3 Web-Software Setting

Figure 41 Web-software setting 1#

Network Priority:
1) Find “Network priority”;
2) Set the priority, Ethernet>4G>WIFI for default;
3) Click “Submit”.

Commissioning Manual 34
 Figure 42 Web-software setting 2#

4G:
1) Find “4G configuration”;
2) Click “Enable modification”;
3) Set APN, User, Psw, Pin according to actual usage;
4) Click “Submit”.

Figure 43 Web-software setting 3#

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Ethernet:
1) Connect Ethernet cable;
2) Find “Ethernet configuration”;
3) Click “Dhcpc enable” to get IP address automatically or set IP address manually;
4) Click “Submit”.

Figure 44 Web-software setting 4#

Figure 45 Web-software setting 5#

WIFI:
1) Find “Wifi configuration”;
2) Click “Enable modification”;
3) “Mode selection” choose “STA”;
Commissioning Manual 36
4) Fill in “SSID” (WIFI ID), “Psw” (WIFI password), “Encryption” (EncryMode, generally choose wpa2);
5) Click “Dhcpc enable”;
6) Click “Submit”.

Figure 46 Web-software setting 6#

Operation Backend:
Take backend address: 36.153.57.202:3400/steve/websocket/CentralSystemService as an example. The
information needs to be filled in is shown as below:
1) Find “CP Backend”;
2) “URL”: Enter IP address or domain name of the backend;
3) “Path”: Enter the path after IP in “Path”;
4) “Port”: Enter Port number of backend;
5) “SSL_O”: The value is 1 when the backend uses TLS for access, otherwise the value is 0;
6) “Authorization key”: If the backend doesn’t use Basic authorization, just leave it blank. (No need to fill in
most cases);
7) Click the “Submit” in “CP Backend” to save settings;
8) “Certificate Import”: Load in the CA certificate offered by customer when using TLS; otherwise, leave it
blank;
9) Click “Submit” to deliver certificate if loading in the certificate.

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 Figure 50 Web-software setting 7#

Maintenance Backend:
Take backend address: 114.215.178.206:6668/ocppj, EVSE ID: 11111111 as an example. The information
needs to be filled in is shown as below:
1) Find “Maintenance Setting”;
2) “URL”: Enter IP address or domain name of the backend;
3) “Path”: Enter the path after IP in “Path”;
4) “Cpid”: Enter EVSE ID;
5) “Port”: Enter Port number of backend;
6) “SSL_O”: The value is 1 when the backend uses TLS for access, otherwise the value is 0;
7) Click the “Submit” in “Maintenance Setting” to save settings.

Commissioning Manual 38
 Figure 47 Web-software setting 8#
Card Type：
1) “Card Not Authentication”: Local start-stop card, the EVSE can work by swiping the card without
connecting to the backend;
2) “Card Authentication”: Authentication card, the UID of RFID card must be entered into backend before
using, and EVSE must connect to the backend;
3) “Local PnC”: plug in and charge;
4) “Mac Start”: The MAC Code of the EV must be entered into backend. The EV will be charged
automatically when the charging cable is inserted;
5) Click “Submit” after the configuration.

Figure 48 Web-software setting 8#

Commissioning Manual 39
3.4.2.4 Web-CP Configuration

Figure 49 Web-CP configuration 1#

Enter ChargerPoint ID, Group Number (if no, default is 12345678), EVSE ID: 1-1 (means could use both
charging cables at the same time)
#1 Gun Address: 1, #2 Gun Address: 2
Enter QR code for the two charging cables.

Figure 50 Web-CP configuration 2#

Output parameters for each charging cable:
Gun Type: choose based on the actual situation;
Maximum Voltage (V): maximum output voltage for the charging cable, default and maximum value is
1000V, 500V in case of ChAdeMO;
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Minimum Voltage (V): minimum output voltage for the charging cable, default and minimum value is 150V;
Maximum Current (A): maximum output current for the charging cable, default and maximum value is
200A for CCS2 and 125A for ChAdeMO;
Maximum Power (W): maximum output power for the charging cable, enter based on the quantity (X) of
the power modules installed, default and maximum value is X*30kW;
Maximum Temperature (℃): maximum temperature for the charging cable, default value is 90℃;
Meter, Insulation Board, PLC Board and Pre-precharge set as shown below.

Figure 51 Web- (CCS2) CP configuration 3#

Figure 52 Web- (ChAdeMO) CP configuration 4#

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3.4.2.5 Web-Power Unit Configuration

Figure 53 Web-Power unit configuration 1#

Select “180_relay” and click “Submit”.

Figure 54 Web-Power unit configuration 2#

Under-voltage Protection(V): minimum input voltage, default value is 173V;
Over-voltage Protection(V): maximum input voltage, default value is 260V;
Module Amount: Enter X (1 to 2) if there are X (1 to 2) power modules installed;
Module Type: Select “Star Charge 30kW 1000V”;
Module SN and Group Number: Enter from 1 to X if there are X power modules installed.

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 Figure 55 Web-Power unit configuration 3#

Commissioning Manual 43
3.4.2.6 Power Module Address Configuration
Insert X power modules in the below X holes.

Figure 60 Power module address configuration 1#

Disable the door sensor.

Figure 56 Power module address configuration 2#

Commissioning Manual 44
Turn on the AC contactor.

Figure 57 Power module address configuration 3#

Set power module address (A&G) from 01 to 0X according the figure below.

A01, G01

A02, G02

Figure 58 Power module address configuration 4#

Commissioning Manual 45
1) Press ▲ or ▼, change the interface;
2) Press ▲ or ▼ for about the 2.5s, the value will be flashing;
3) Press ▲ or ▼ to change the value;
4) Press ▼ for about 2.5s to save the value.

Turn off the AC contactor.

Figure 59 Power module address configuration 5#

Enable the door sensor.

Figure 60 Power module address configuration 6#

Commissioning Manual 46
3.5 Charging Function Check
3.5.1 Charging Test
The EVSE operation has two parts, connection and start charging. To use the product, the user must connect
the EVSE to the vehicle first, and then carry out relevant charging operations through the touch screen
interface.
⚫ Connection
Step 1: Confirm the EVSE is normal and indicator light is green.
Step 2: Confirm the EV us normal. Take the charging connector and plug in EV.
Step 3: Confirm the connection and follow the steps below to start charging.
⚫ Start Charging
Step 1: Take the charging connector and plug in EV.

Figure 61 Charging Test 1#

Step 2: After plug in, display will change automatically.
Step 3: Swipe RFID card or scan QR code to start charging.

Commissioning Manual 47
 Figure 62 Charging Test 2#
Step 4: During charging, the charging status interface is displayed on the display.

Figure 63 Charging Test 3#

Commissioning Manual 48
 Figure 64 Charging Test 4#
Step 5: Click "Stop" to enter the stop charging interface, and swiping card again or scanning QR code to
stop charging.

Figure 70 Charging Test 5#

Commissioning Manual 49
Step 6: Charging results are displayed on the EVSE screen after charging is fully charged or stopped.

Figure 65 Charging Test 6#

Step 7: Unplug the charging connector from the vehicle, reposition it in the charging connector slot.

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Hardware Function Test
1) Limit switch: Open the door of EVSE when charging, the EVSE should stop charging.
2) Emergency stop: Press the emergency stop button on the EVSE when charging, the EVSE should stop
charging.
3) Fan: Check whether the fan inside of EVSE and fan of power module during charging.
4) Meter: Check whether the meter measures accurately during charging.
5) Charging cable: There’s no burrs, no sharp edges, no ignition or burning, no loosen insulation cap on
the easy touch surface of the charging cable. It’s neither too tight nor too loose when inserting and
pulling out the charging cable.

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4 Customer Training
After the commissioning work for the EVSE, the engineer should give a basic training relating to the main
characteristics of the EVSE to guide the customer on using and some basic knowledge. The training form
can be through either document or practical explanation on-site. The training content should cover safety
knowledge, basic charging procedure and etc.
After confirming customer’s satisfaction, get the training file signed and recorded properly. Refer to
Appendix 1 “Customer training record sheet” for details.

Commissioning Manual 52
Appendix 1 Customer Training Record Sheet

Customer Training Record Sheet

Customer：

Product Trainer

Training method Training Date

Training Department

Training Content

Training Purpose

1.Basic charging operation procedure□

Outline of Training 2.Using scenario of emergency stop□

handout 3.Common sense of safety and emergency□

4.Troubleshooting process□

Trainee Signature

Customer feedback

Commissioning Manual 53
Appendix 2 Commissioning Report

Commissioning Report

Date：
Commissioning Engineer：
Charging Station：
Address：
Commissioning Manual 54
1 Details of EVSE
Power Charging
Power Firmware
ID Specification module Installation cable Backend
module type version
quantity length

Commissioning Manual 55
2 Installation Recheck
Object Content Conclusion Remark

Foundation Check whether the foundation is fixed completely

Check whether the cable specifications meet the power
requirements of EVSE, no break, damage, or scratch, whether
Power Cable the electrical connection and wiring are correct and complete,
whether the connection is solid, and whether the grounding is
reliable
Insulation The insulation resistance of power cable meets the
Resistance requirements
The surface is clean.
The charging cable is not broken.
Surface
The door could be closed and open.
The EVSE is not tilted.
No missing safety warning mark and the nameplate is
Sign
clear.
The EVSE meets the requirements. The accessories are
Requirements
complete.

Others The fire-proof material is blocked in place.

3 Check before Power on

3.1 Working Environment
Object Content Conclusion Remark
Temperature -30℃~50℃
Humidity 5%~95%
Elevation ≤2000m

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3.2 Check the Internal Circuit (When using a multimeter to test the following items, ensure that the
device is powered off.)
Object Content Conclusion Remark

Input L1 and L2 Open Circuit

Input L1 and L3 Open Circuit
Input L2 and L3 Open Circuit

Input L1 and N Open Circuit

Input L2 and N Open Circuit
Input L3 and N Open Circuit
Input L1 and PE Open Circuit
InputL2 and PE Open Circuit
InputL3 and PE Open Circuit

N and PE Open Circuit

Input L1 and DC+/DC- Open Circuit
Input L2 and DC+/DC- Open Circuit
Input L3 and DC+/DC- Open Circuit
N and DC+/DC- Open Circuit
DC+ and DC- of charging Open Circuit
cable

DC+ and DC- of output Open Circuit

copper bar
DC+ of charging cable and
Close Circuit
DC+ of output copper bar
DC- of charging cable and DC-
Close Circuit
of output copper bar
All screws are fastened without loosening or
All screws of input
missing
All screws are fastened without loosening or
All screws of main breaker
missing
Screws on the input and All screws are fastened without loosening or
output of the power module missing

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 Object Content Conclusion Remark

socket
All screws are fastened without loosening or
All grounding screws
missing
Screws on DC+ and DC- All screws are fastened without loosening or
copper bar missing

Each plug on the main control Each plug is firmly without loosening, and the
board plug connection is firmly without loosening
All screws are fastened without loosening or
Switch mode power supply
missing

3.3 Voltage check Before Power on

Object Content Conclusion Remark
Input voltage of the main breaker 400V（±10%）

3.4 Check the Insulation Resistance of Charging Cable

Object Content Conclusion Remark

DC+ and PE ≥1MΩ

DC- and PE ≥1MΩ

DC+ and DC- ≥1MΩ

4 Check after Power on

4.1 Voltage Check after Power on
Object Content Conclusion Remark
Output voltage of the main breaker 400V（±10%）

4.2 Basics
Object Content Conclusion Remark
Touch Screen The screen shows normally
Indicators The indicator lights work normally

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 Switch mode power The switch mode power supply can provide 12V/24V
supply power supply voltage normally and stably

4.3 Parameter Configuration

Content
Object Conclusion Remark

Configuration Configure according to the requirements

Backend connection Connect successfully

5 Charging Function
5.1 Charging Testing
Object Content Conclusion Remark
Charging via APP Start and stop charging via APP
Charging via swiping the
Start and stop charging via swiping the RFID card
RFID card

5.2 Hardware Function

Object Content Conclusion Remark
When the device is in the charging state, if its
cabinet door is opened, the device should stop
Limit switch
charging instantly according to the design
requirements.
When emergency stop button is pressed, the EVSE
Emergency stop
should stop.

Fan The fan can work normally.

The meter could calculate during the charging
Meter
process

The surface of charging cable is normal.

Charging cable
Plug in and out smoothly

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6 Conclusion
Required voltage Required current Output voltage Output current
EV type Remark
(V) (A) (V) (A)

Conclusion Remark

□Qualified □Unqualified

Commissioning Engineer: Customer:

Date:

Commissioning Manual 60