Training for Titan V3

Trainer: Ruo, Thiago and Yassine

Technical Support Engineer
20.03.2023
Agenda

◼ Brief Introduction of Titan

◼ Installation

◼ Commissioning

◼ Q&A

2
Brief Introduction
Overview

High efficiency >95%

Dual connector (each could be up to 180kW max. output)

Automatic load balance

Simultaneous charging

Output current: 300A max

Wide output voltage 200-1000Vdc

Modular design, easy upgrade.

4
Overview

[1] – sheet metal cabinet

[2] - 10.4-inch highlight screen
[3] - meter window
[4] - Payment terminal
[5] - connector holder
[6] - air inlet side
[7] - door handle
[8] - E-stop switch

5
Specifications

General Information
Input Rating 400Vac±10%, 3 phases, 50/60Hz, L1+L2+L3+N+PE (No neutral line for IT system)
Power Factor ≥0.98 @ Full Load
Efficiency ≥94% @ Full Load (Peak)
Grid Type TN-S, TN-C, TN-C-S, TT, IT
Output Interface CCS2+CCS2 or CCS2+CHAdeMO
CCS2: 180kW max. (150kW max. & 120kW max. are optional)
Output Power
CHAdeMO: 62.5kW max.
Output Voltage CCS2: 200-1000Vdc, CHAdeMO: 200-500Vdc
Output Current CCS2: 300A max., CHAdeMO: 125A max.

Mechanical
IP Rating IP55
IK Rating IK10
Cooling Forced Air
Charging Cable Length 5m or 7m(optional)
5m cable @ approx. 3m operating range (cable will not touch ground)
Operating Range with Cable
6m cable @ approx. 4m operating range (0.3m cable will be on ground)
Management System
7m cable @ approx. 5m operating range (1.2m cable will be on ground)
Dimensions (WxHxD) 800*2050*750mm (without connector holder and cable management system)
Weight Approx. 395kg (excluding power modules 15kg*6)
Installation Ground mounting

6
Installation Process
• Requirements
• Workflow
• Inspection
Installation Requirements

1.Site conditions for installation

Ambient temperature -30℃ ～ ﹢55℃

Altitude ≤2000m

Humidity 5%～95%rH

Degree of dust ≤1mg/m3

Corrosive substances No pollutants, such as salt, acid, smoke, etc.

Vibration ≤1.5mm/s2

Moisture Do not work in rainy days

Fire prevention No flammable substances near charger

 Installation Requirements

2.Requirements for grid capacity

• If the charging pile operates at full power, the grid capacity shall meet 200KVA

• Phase to phase voltage 400V (±10%)

• Three-phase input, maximum: 290A per phase

• Recommended parameters of superior circuit breaker Ue = 400VAC, In >= 400A, thermal

magnetic type, Icu > =100kA, Ics >= 70 kA, 3Poles

• Earthing system: TN/TT/IT, N line is optional

Installation Requirements

3.Maintenance distance

The space at the rear

side is optional
 Installation Requirements

4.Installation ground

The charger shall be installed on a hard mounting floor (e.g. cement floor), if there is no appropriate
mounting floor on site, a concrete foundation is recommended.
The size of the concrete foundation is 900mm*900mm*600mm, and the buried depth of the
foundation is 400mm, which is 200mm higher than the ground height. The foundation is filled with C20
concrete
 Installation Requirements

4.Installation ground
 Installation Requirements

5.Power cable specification

For full output power (180kW) :

• TN /TT earthing system, 3 * 150mm² + 2 * 70mm²
• IT earthing system, 3 * 150mm² + 1 * 70mm²
The core material is copper.
 Installation Process

1. Unpacking inspection

Photo description Package dimension

Name Quantity Accessories list
(before unpacking)
(mm)

Key*3
180kW DC 1100*1050*2222 IC card*2
1
charger Lifting bolt M12 * 4
（W*D*H）
Operating handle * 1

800*595*700 Screws*4 per

Power module 6
module
（W*D*H）

Check the following items:

• packing list number and equipment quantity.
• equipment nameplate information.
• whether the documents are complete.
• whether spare parts and accessories are complete
• Factory inspection report and certificate.
• whether the appearance of equipment is in good condition
 Installation Process

2.Prepare the foundation

• 4 M10 anchor bolts shall be pre-embedded into the floor in advance according to the drawing
positioning, with 30-40mm threads exposed from the upper surface of the floor.
 Installation Process

3.Prepare the cables

• Please lay the required cables in advance.

o power cable: 1m above the floor

o If network cable is needed, 2.6m above the floor.

o The terminal of tubes can be sealed with polyurethane

foam or fireproof mud.
 Installation Process

4.Lifting preparation

First remove the front and rear sealing plates of the base by screwdriver.
 Installation Process

4.Lifting & Fixing

• Lift charge by crane or forklift (use the hoisting bolts at the top or the holes at the bottom of charger).

• Lower the charger slowly.

• Align 4 holes at the bottom of the charge with the embedded bolts on the foundation.

• Fix the nuts and reinstall the sealing plate.

 Installation Process

5.Input cable handling

Open the right door of charger and pass each phase line through the cable gland at the bottom.

Reserve the corresponding length of the power cable above the cable gland: L1-440mm, L2-390mm,

L3-345mm, N-300mm, PE-600mm.

The threading of the gland is M32 for cable 14 – 25mm

 Installation Process

5.Input cable handling

If the network cable is needed, lead the network cable from the cable gland to the switch

on the front of the charger.

 Installation Process

6. Grounding/Insulation testing

• Check the civil grounding resistance, must be ≤ 4Ω.

• Check the civil insulation resistance, must be ≥10MΩ.

 Installation Process

7. Electrical wiring

• Connect the power cable to the terminal.

• Make sure the screws of the wiring are fastened. When

installing and connecting, avoid the damage of the cable
insulation.

• Add label to cables

Installation Process

8. Insert power modules

Insert 6 power modules and fix each module with 4 screws

 Installation Process

8. Fixation of charging cable

Fix the charging cable on the clamp of the charging cable management system(CMS), the
length of the charging cable from the gland to the clamp is 2.3 m. During the whole
installation process, keep the charging cable drooping naturally to avoid knotting and twisting
caused by external force.
Installation Process

Demo video
Commissioning
• Tools required
• Workflow
Commissioning Tools

Item Tools Usage Example

Configure the settings, read the log,

1 Laptop
Troubleshooting

2 Ethernet cable Connect laptop to charger

3 J – LINK tool Firmware update

4 TF Card and reader Firmware update

Assemble and disassemble

5 Screwdriver set
the screws
Commissioning Tools

Item Tools Usage Example

6 Wrench set Standby

7 Electrical multimeter Electric measurement

8 Megohmmeter Test the insulation

9 Safety Sign Warn potential danger on site

Electrician protective
10
gloves
Safety protection
Electrician protective
11
Shoes
 Commissioning Flowchart

Commissioning Flow Chart for DC EVSE

Commissioning

Whether the Whether the Whether the

Engineer

Whether the appearance, internal Whether the

voltage and configuration is ok
Installaltion installation Check before wiring, insulation Check after Parameter Charging hardware work Training and
YES YES hardware YES and EVSE is YES YES
recheck meets the power on resistance and input power on
function meet
configuration
connected to
function check according to the report finishing
requirements voltage meet the requirements
requirements the requirements backend
NO NO NO NO NO
Installation
Engineer

Corrective Corrective Corrective

maintenance maintenance maintenance

Corrective Corrective Corrective Corrective

QC

maintenance maintenance maintenance maintenance

Technical Support
Engineer

Corrective Corrective Corrective

maintenance maintenance maintenance
Installation Recheck
Basic Check

1. Pedestal: whether fixed and sealed well.

2. Inlet cable: 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. Grounding/Insulation resistance: The external grounding resistance must be ≤4Ω. The input
power supply cable insulation resistance must be ≥10MΩ

4. Outside appearance of cabinet: 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 cabinet 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.
Installation Recheck
Insulation Resistance Check of Input Power Cable
1. Turn off the switch in the external power distribution cabinet; turn off all switches inside of the Titan.

Switch for
control boards

Switch for Switch for SPD

power modules
Installation Recheck
Insulation Resistance Check of Input Power Cable
2. Pull part of the power module out to separate each power module from the slot. Remove the grounding line of
the surge protector. Remove the DC+ and DC- ports on the insulation testing board.

Pull part of the

power module out Remove the DC+
to separate the and DC- ports on the
power module from insulation testing
the slot board

Remove the
grounding line from
the surge protector
Installation Recheck
Insulation Resistance Check of Input Power Cable
3. Get the megohmmeter ready.
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.
Installation Recheck
Insulation Resistance Check of Charging Cable

5. 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.
6. Recover the situation inside of the EVSE to the original state after the test.
Commissioning workflow
2. Check before power on charger

• Short circuit: Check the inlet cable in charger and ensure there is
no short circuit.

• Fasten screw: Check and ensure screws or nuts on each cable

connection inside charger are fastened.
Commissioning workflow
2. Check before power on charger

• Input Voltage : check whether the input voltage of the charger main breaker is correct.
There should be no fault such as phase loss, overvoltage, undervoltage and wrong
phase sequence.
Commissioning workflow
3. Check after power on charger

1. Touch screen: Check whether the touch screen displays

normal. The display image should be clear.

2. LED indicator light: Check whether the LED indicator light

on the charger. The LED light should be green.

3. Switching power supply: It provides 12V DC power to

control boards. Use electrical multimeter to check the 12V
DC voltage.
Commissioning workflow
4. Parameter configuration

Software settings needs to be configured:

• Internet communication (4G, Ethernet, Wifi)

• OCPP backend and remote maintenance platform

• Charger authentication method

• Output power configuration

• Power module configuration

Commissioning workflow
4. Parameter configuration

Preparation:
If SIM card is needed for internet communication, insert the SIM into the slot in A7
mainboard
Commissioning workflow
4. Parameter configuration

Preparation:
To configure the software settings, first connect laptop to router via Ethernet cable and then
configure the IP address of laptop

1
Commissioning workflow
4. Parameter configuration

Log in:
Open a browser (e.g. chrome, edge) and enter IP address of charger 192.168.1.136
Username wbdh The username and password may change in new
Password Wbdh26835941. firmware version. If you have issue during log in,
please contact Star Charge service tam
Commissioning workflow
4. Parameter configuration

If you cannot access the charger through the router, connect the ethernet cable directly to
the A7 main board and configure the computer's IP address to 192.168.88.xx

Open a browser (e.g. chrome, edge) and enter IP

address of charger 192.168.88.206
Commissioning workflow
4. Parameter configuration

Collection of the most used settings

Settings for 4G, Ethernet, Wifi, OCPP and authentication methods
Charger connector settings for connector type, output power limit, etc.

Check the internet and backend connection stauts

Settings for power unit assignment

Check the status of power unit status

This function is still under development…

Firmware update and log download
Commissioning workflow
4. Parameter configuration

Firmware update:
In the first commissioning of a new charger, the firmware of the charger is usually relative old and
needs to be updated to newest version to optimize the charger performance.
To check the firmware version, go to “Software setting”and find “version” data.
StarCharge engineer will provide you the newest firmware version and guide you do the update.
Commissioning workflow
4. Parameter configuration

Firmware update:
Depends on the original firmware version in the charger, some control boards needs to be updated
during the commissioning, such as:
• A7 control board
• M4 control board
• PDU control board
• SECC board and PLC board
For detailed workflow of firmware update, please check this manuals.
Note: Just in case of big firmware update. But usual firmware update can be OTA with zip file in web
configuration.
Commissioning workflow
4. Parameter configuration

Software settings needs to be configured:

• Internet communication (4G, Ethernet, Wifi)

• OCPP backend

• Charger authentication method

• Output power configuration

• Power module configuration

Commissioning workflow
4. Parameter configuration
Internet communication (4G, Ethernet, Wifi)

1. Click “Enable modification”

2. Enter data for APN, User, Psw and Pin
3. Click “Submit”
Commissioning workflow
4. Parameter configuration
OCPP backend and remote maintenance platform

For OCPP backend

Set CP backend: Enter data for URL, Path, Port and
SSL_ON according to OCPP backend address
Commissioning workflow
4. Parameter configuration
OCPP backend and remote maintenance platform

For OCPP backend

Set CP Identity: Enter the charger ID number which is
registered in the OCPP backend
Commissioning workflow
4. Parameter configuration
Star Charge Operation Maintenance Center

For remote maintenance platform (Star Charge Operation Maintenance Center)

• Enter data for URL, Path, Port and SSL_ON for the remote maintenance platform
• Enter CP ID which is registered in maintenance platform

The first 8 digits is the ID

Commissioning workflow
4. Parameter configuration
Star Charge Operation Maintenance Center
Router:
Open a browser (e.g. chrome, edge) and enter IP address of router 192.168.1.1 or 18.18.1.1
Username: admin
Password: admin

SIM Card
Commissioning workflow
4. Parameter configuration
Charger authentication method

Following authentication method can be selected:

Commissioning workflow
4. Parameter configuration
Charger authentication method

Following authentication method can be selected:

Authentication method Principle
Card Authentication Use authenticated IC card to start charging session card. The IC card
must be whitelisted in backend platform and EVSE must always
connect to the backend

Card Not Authentication Use the IC cards from charger accessories to start charging session.
No authentication.

Local PnC Once plug in the charger connector, the charging session
automatically begins without any authentication.

Mac Start Similar to PnC mode, but with MAC code authentication. The MAC
Code of the EV must be registered in backend.
Commissioning workflow
4. Parameter configuration
Output power configuration

According to the use scenarios and grid

capacity, the output power of each charger
connector can be individually configured .
• Maximum Voltage
• Minimum voltage
• Maximum current
• Maximum power
Commissioning workflow
4. Parameter configuration
Power module configuration
Assign sequence number to
power module in software
setting.
Depending on the quantity of
power module used, 1,2,3…
are assigned to each power
module.
Commissioning workflow
4. Parameter configuration

Power module configuration Top

All power modules from factory have the same default

sequence number A1 saved in hardware.
After inserting them into charger cabinet, during the first
commissioning, technician needs to manually assign sequence
number for each power module.
Set the power module sequence as the picture shown :
From bottom to top: A1 to A6.

Bottom
Commissioning workflow
4. Parameter configuration

Power module configuration

Workflow:
Step 1: disable door sensor. If the door sensor is active, the input power of power
module will be automatically cut off, when the door is opened.
Commissioning workflow
4. Parameter configuration

Power module configuration

Workflow:
Step 2: Open the AC relay to manually turn on the supply power for power module

Tips: there is inappropriate translation in

webpage. Such “Open” actually means turn on
and “Close” means turn off.
Commissioning workflow
4. Parameter configuration

Power module configuration

Workflow:
Step 3: click the button on power module to set the sequence number

1. Press ▲ or ▼, change the interface;

2. Press and hold ▼ for about the 3s, the value will be flashing;
3. Press ▲ or ▼ to change the value;
4. Press and hold ▼ for about 3s to save the value.
Commissioning workflow
4. Parameter configuration

Power module configuration

Workflow:
Step 4: close AC relay.
Step 5: enable the door sesnor
Commissioning workflow
5. Charging test

Plug in the charger connector to an EV and then swip IC card or use App to start charging session

Plug charger
gun into EV

1 2 Swipe RFID
card or use
App to start
Swipe RFID card or
use App to stop

4 3
Commissioning workflow
5. Charging test

During the charging session, check / test following items

1. Door sensor: 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 the wind speed and direction of fan of inside.
4. Meter: Check whether the meter measures accurately during charging.
5. Charging cable: There is no sharp edges, no overheating, no loosen insulation cap of the charger cable.
The charging cable is neither too tight nor too loose when inserting and pulling out the charging
cable.
Spare parts of Titan V3
Circuit Diagram of Main Components

AC-DC DC output
DC CCS2
PDU 1# Fuse Contactor DC meter Connector EV
Power
distribute Unit
Control
Pilot

SECC
Environment RFID Card RS485 Insulation Supply Equipment
Monitoring Reader Monitor Board
Communication
Board Controller
SPD
Surge protection
AC input Unit
device RS232
CAN RS232

MCB
Micro circuit
A7 Carrier Board M4 Driven Board
breaker
I/O interface Main function: Main function:
Communication with
CAN Power Module distribute board
MCCB M4 Driven Board Communication with
AC AC-DC
AC Grid Moulded case
circuit breake contactor Module
POS machine RS232 SECC Driven Board
Insulation Monitor Board
PDU Main RFID Card Reader
Board HMI
DC Meter I/O interface
RCD Main function: CAN
I/O interface
Residual I/O
Current Device interface with PWM fan control
PDU etc.
SMPS CAN RS232
Switch Mode LVDS
power supply

HMI Insulation SECC

RS485 Supply Equipment
Human Monitor Board Communication
Machine Interface
AC input Control Unit Control Unit Controller

Control
AC-DC DC oputput Pilot

Power Circuit PDU 2#

DC CCS2
Power Fuse Contactor DC meter Connector EV
Communication circuit distribute Unit
I/O interface DC output
AC Input
Part No. Component Manufacturer/trademark Type / model Technical data

U_e: 230V/400V
U_c: Differential mode :350V L/N
1 AC contactor Schneider Electric Industries SAS LC1G300LSEC
Common mode :260V N/PE
Common mode :440V L/PE
Rated operating voltage: 380/400/415V;
Molded case circuit Shanghai Liangxin Electrical Rated operating current: 400A;
2 NDM2L-400H
breaker (MCCB) Co.,Ltd.
I△n: 30mA
Rated operating voltage: 400/415V;
Residual Current Device Shanghai Liangxin Electrical
3 NDB2LM-63 Rated operating current: 63A
(RCD) Co.,Ltd.
I△n: 30mA

4 Power supply (SMPS) MEAN WELL Enterprises Co., Ltd. WDR-120-12 12Vdc, 10A

Rated operating voltage: 380/400/415V;

Miniature Circuit breaker Shanghai Liangxin Electrical
5 NDB1-63
(MCB) Co.,Ltd. Rated operating current: 63A

Ue : 230V/400V
Surge protective device A9L040601 Uc : Differential mode :350V L/N
6 Schneider Electric Industries SAS
(SPD) iPRU 40r 3P+N Common mode :260V N/PE
Common mode :440V L/PE

1 2 3 4 5 6
AC Input
AC Input

Left side Front side Right side

AC-DC Converter

Part No. Object Manufacturer/trademark Type / model Technical data

Rated output voltage:150-1000V;

1 Power module Shenzhen UUGreenPower Electrical Co.,Ltd UR100030-SW
output current: Max 100A

SCII-QKP180-DH120H Maximum operation load: 180kW

2 PDU module Shanghai CII Electronics Co., Ltd.
Dielectric Strength: 3600VAC/5S/≤0.5mA

1 2
AC-DC Converter

2
DC Output

Part
Object Manufacturer Type / model Technical data
No.
DC
1 connector Brugg eConnect AG Purwil Connect 500 DC 300A, 1000V
for CCS2
Umax:100V
2 DC Meter DZG Metering GmbH GSH01 Imax 650 A
Class B
3 DC contactor TDK HVC500B 500A，1000V
Xian Sinofuse Electric RS306-01-T5Z-
4 Fuse 315A, 1250V
Co., Ltd. 315A1250V

1 2 3 4
DC Output
Control Boards

Front side

5 6 4
7

6
1
2

3
4
5 4
7
Front door
Right side

2
7 7
3
Control Boards

Object Main function

M4 Driven board It has various Serial Interface and CAN resources. It controls the DC power.

PDU Main board It is mainly used to control the PDU power distribution module.

Ithas RS232 RS232, CAN and RS485 interfaces. It is used for exchanging data
A7 Carrier board
with the other control board

PLC Communication
It is used for communication between EV and charger.
Controller

It can not only monitor the insulation resistance of the DC system. but also
Insulation Board
estimate the leakage capacitance and DC bus voltage of the system.
Control Boards

6 4
7

1
2

5 4 1
7
Control Boards

6 4
7

1
2

5 4
7 4
Spare Parts

① ADQDPD0169, Display
1
② ADQCOM0345, RFID Card Reader

③ DC Charging connector
2

④ ADQTFP0180, POS 4
3 3
Spare part list

① ADQCPN0192, SGEnvironMonitorBoard
2 1
② ADQCPN0621, AngleSwitchBoard

③ ADQCOM0380, 4G Communication Board

8
④ ADQCPN0170, A7 Main Board 3
4
⑤ ADQBCP0154, A7 Core Board

⑥ ADQCOM0405, Router 5

⑦ ADQCPN0314, SECC Board

⑧ ADQCPN0604, SecuredBoard

7 6
Spare part list

1 2 2 1

① ADQCPN0167, Insulation Detection Module

② ADQCPN0629, Precharge Board

Spare part list

1 1
① ADQDMT0150, Meter
4 4
② ADQCPN0629, Fuse Protector

③ ADQFUS0051, Fuse Micro Switch

3 2
④ ADQDRL0044, DC Relay 4 4
3
2
Spare part list

① ADQMCC0318, Residual Current Action Molded Case Circuit Breaker

② ADQMCC0320, Leakage module (used with molded case circuit breaker)

③ ADQMCC0308, Auxiliary contact of MCCB

1 2 3
Spare part list

① ADQSPS0014, Switch Mode Power Supply

② ADQIRL0183, Intermediate Relay

1 1 5 6
③ ADQIRL0051, Protection module of Intermediate Relay

④ ADQIRL0052, Base of Intermediate Relay

⑤ ADQMCB0322, Residual Current Action Miniature Circuit Breaker

⑥ ADQMCB0323, Leakage module (used with Miniature circuit breaker)

2
4
3
Spare part list

1
① ADQPWM0195, Power Module

1
Spare part list

① ADQCPN0169, M4 Board
1
② ADQCPN0168, PDU Control Board

2
Spare part list

① ADQMCB0321, Miniature Circuit Breaker 2

② ADQSPD0142, Surge Protector
Spare part list

① AJGVEN0260, Fan

1
Spare part list

1
① ADQDPD0169, Display

② ADQCOM0345, RFID Card Reader

③ ADQSGB0166, T Shape RGB Led Board

2
④ ADQCPN0138, Connector Light Board

3 3

4 4
Spare part list

1
2
1
2
1
2
1
① ADQMTC0066, Power Module Socket 2
1
② ADQMTC0057, Power Module Socket
2
1
2
Spare part list

① ADQDRL0041, PDU

1
Spare part list

① ADQCTR0164, AC Contactor 1
Mobile Power Grid Ecosystem

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