rapidas operations owners manual

RAPIDAS Instruction manual 2011-10

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Contents

1. INTRODUCTION........................................................................................................................................... 3

2. SAFETY PRECAUTIONS.............................................................................................................................. 3

Disclaimer ............................................................................................................................................... 5

3. PRODUCT FEATURES................................................................................................................................. 5

4. NAMES AND FUNCTIONS OF PARTS......................................................................................................... 6

Charging stand ....................................................................................................................................... 6

Control panel .......................................................................................................................................... 7

Inside the control panel........................................................................................................................... 8

Opening and closing the control panel door............................................................................................ 9

5. ITEMS PROVIDED WITH THE PRODUCT................................................................................................... 9

6. CHARGING................................................................................................................................................. 10

Before charging ................................................................................................................................... 10

Preparation .......................................................................................................................................... 10

Standby................................................................................................................................................ 11

Selecting the charging time.................................................................................................................. 13

Charging .............................................................................................................................................. 13

Starting charging.................................................................................................................................. 15

Completing charging............................................................................................................................ 16

7. CONTROL MENU OPERATIONS ............................................................................................................... 19

Error history list..................................................................................................................................... 19

Time setting .......................................................................................................................................... 20

Maximum current setting....................................................................................................................... 20

8. EMERGENCY STOP BUTTON ................................................................................................................... 20

Reset after the emergency stop button was pressed............................................................................ 20

9. COMPATIBLE BATTERIES AND GUIDELINES FOR CHARGING TIMES.................................................. 21

10. SPECIFICATIONS..................................................................................................................................... 21

11. MAINTENANCE......................................................................................................................................... 22

Inspections performed by the customer ............................................................................................... 22

Inspections performed by JFE Engineering ......................................................................................... 23

Cleaning the product............................................................................................................................ 23

12. WARRANTY AND AFTER-SALE SERVICE .............................................................................................. 23

Warranty certificate (separate document) ............................................................................................. 23

Parts ..................................................................................................................................................... 23

Regular inspections designated by JFE Engineering............................................................................ 23

Contact ................................................................................................................................................. 24

13. TROUBLESHOOTING .............................................................................................................................. 24

14. OTHER INFORMATION ............................................................................................................................ 26

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1 Introduction

Thank you for your purchase of a JFE Engineering RAPIDAS Rapid Access System for EV charging.

• Please read this instruction manual carefully and use the product safely and correctly.

• Be sure to read the "Safety Precautions" before using the product.

• Store this manual in a safe location after reading it.

2 Safety Precautions ∗ Be sure to read these "Safety Precautions" carefully before using the product and always use the product

correctly.

∗ The precautions listed here are intended to ensure safe and correct use of the product and to prevent

danger or harm to the users.

All of these precautions are important for safety. Be sure to observe them.

In this instruction manual, safety precautions are classified for explanation according to the following

indications.

The meanings of WARNING and CAUTION are as shown below.

The information in this space concerns the risk of death or serious injury in the event that the product is used incorrectly.

The information in this space concerns the risk of injury or damage to property in the event that the product is used incorrectly.

The types of information which must be observed are classified for explanation according to the following

symbols.

This symbol indicates a prohibited act which must not be performed.

This symbol indicates a required act which must be performed.


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When the power is ON, never open the front door of the control panel and touch the connector or terminal block electrodes. These parts are electrified with high voltage and there is a danger of electric shock.

When the power is ON, do not touch the charging cable or connector. There is a danger of electric shock if there is a problem with the charging cable or connector.

If there is a burning smell or any other abnormality, immediately discontinue operation and turn OFF the power breaker.

Do not allow the charging cable to be damaged, for example by placing an object on the cable or pressing a sharp object against it. Doing so may result in a fire or electric shock.

Do not hang from the power cable or pull strongly on it. Doing so may result in an injury or malfunction.

Do not operate the control panel with wet hands. There is a danger of electric shock.

Do not use the charging cable or charging connector if it has become damaged. Doing so may result in an electric shock, short circuit, or fire.

Never attempt to disassemble, modify, or repair the product. Doing so may result in a fire, electric shock, or injury. For repairs, contact JFE Engineering.

Be sure to turn the power breaker OFF before performing maintenance of the charging stand or control panel. Failure to do so may result in an electric shock.

If the product will not be used for a long period of time, turn OFF the power breaker. Failure to do so may result in a fire caused by an electrical leakage.

Do not use close to flammable sprays. Do not allow benzene, paint thinner, gasoline, or other flammable substances in the area close to the product. There is a danger of ignition and a fire caused by sparks at the contacts of the electrical components.

Do not allow water to contact the control panel. Doing so may result in an electric shock or fire.

Use only for the specified purpose and within the ratings prescribed in the specifications.

Do not use this product for charging anything other than an electric vehicle (vehicle equipped with a lithium ion battery). Using the product for any other purpose may result in a malfunction.

There is a danger that pacemakers and implantable cardioverter defibrillators may be affected by the radio waves that are emitted from the charger. Persons who use such devices should remain as far as possible from the charger during charging.

Doing so may result in injury or accident caused by the unit tipping over or by falling objects.

Do not block the exhaust port on the side of the control panel or insert any objects into it. If the flow of air which cools the inside of the control panel is blocked, the internal temperature may rise, possibly resulting in a malfunction or fire.

When it is raining, take care that the end of the charging connector does not become wet. Contact with water may result in a malfunction.

Prec

autio

ns fo

r use

Take care that the charging cable does not contact the vehicle. There is a possibility that the vehicle will be scratched.


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Disclaimer JFE Engineering shall bear no responsible for any of the following.

1) Damage due to natural disasters such as earthquakes, lightning, wind or floods

2) Damage caused by third parties

3) Incidental damage caused by use or disuse of the product (including the various effects resulting from an

inability to charge)

4) Damage which occurred when the procedures for installation and use that are described in the instruction

manual and installation manual were not observed

5) Conditions occurring when this charger is transported to a country other than the one where it was installed

3 Product Features This product is a rapid charging system for electric vehicles.

Using a commercial power source in combination with the storage battery installed inside the charger provides

the following advantages.

1) Rapid charging is possible with a low-voltage power supply.

2) An 80% charge can be supplied in 30 minutes (conforming to CHAdeMO standards).

3) Provides low running costs (use of nighttime electric power, low-voltage power supply contract)

4) Allows effective use of stored electric power (eases demand/provides power during power shortage)

* currently under development


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4 Names and Functions of Parts Charging stand

- Explanation of parts -

Emergency Stop Button Use this button to stop the system in an emergency. To stop the system under ordinary conditions, use the STOP button ( ).

START button Use this button to start charging.

STOP button Use this button to stop charging.

Display panel Displays charge status and error messages when errors occur.

Charging connector Use this connector to connect to an electric vehicle. This connector is used for charging.

Charging connector holder This is where the charging connector is stored.

Charging cable This is the cable that carries the electricity when charging an electric vehicle.

LED lamp This lamp illuminates when the charging stand is ready to be used. The charging stand cannot be used when this lamp is not lit.

Card authorization system: Card reader Bring the authorization card close to the reader in order to read the card information before starting charging.


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Control panel


Control panel unit

Front door open/close lever

Use this lever to open and close the front door. Keep it locked at all times except during maintenance.

Power lamp

This lamp illuminates when the power is ON.

Control circuit internal cooler

This cooler starts automatically when the internal temperature rises and exceeds the set temperature,

cooling the inside of the control panel. It stops automatically when the temperature drops below the set

temperature.

Battery internal cooler

This cooler starts automatically when the internal temperature rises and exceeds the set temperature,

cooling the battery inside the control panel. It stops automatically when the temperature drops below the

set temperature.

Communications antenna

This antenna is used to transmit information related to the charger operating status, status of the internal

battery, etc. via the Internet.

Exhaust port

This port is used to discharge cooler exhaust heat. Air is discharged from this port when the cooler is

operating.


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Inside the control panel


Main power

This switch is used to input 3-phase AC power into the charger.

Inverter power

This is the power circuit switch for converting three-phase AC power to DC power.

Control panel power

This is the power switch for the charger control system.

Stand power

This switch is used to supply power to the charging stand.

Insulated cover

Converter

Insulated cover

Storage battery


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Opening and closing the control panel door

Panel door

• Insert the key into the key cylinder to unlock the door.

• Pull the handle towards you. • Rotate the handle counterclockwise to

disengage the door lock and open the door.

Door stopper

• Fasten the door with the stopper. • If the door is not fastened, there is a risk of

injury occurring if the door shuts suddenly after being caught by the wind or due to another cause.

After closing the control panel door, be sure to lock it to prevent electric shock due to misuse.

5 Items Provided with the Product • Instruction manual

• Shipping investigation results report

• Key for control panel door

• Warranty certificate

• Device specifications


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6 Charging

There is a danger that the operation of pacemakers and implantable cardioverter defibrillators may be affected by the radio waves that are emitted from the charger. Persons who use such devices should remain as far as possible from the charger during charging.

Before charging

Power

• Open the control panel door and turn ON the main power breaker.

• Next, turn ON the inverter power and charging stand power breakers. Finally, turn ON the control power breaker.

• Check that the power lamp is illuminated, then close and lock the control panel door.

Preparation

RAPIDAS system start screen

• Check that the system start screen appears on the charging stand display panel.

• If the system start screen is not displayed, press the STOP button once.

• Touch the screen to change to the pre-charging check screen.

Pre-charging check

• Check that the power of the electric vehicle is turned OFF.

• Check that the shift lever is in the Park position.• After the check is complete, touch [OK].

The screen changes to the card authorization screen.


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Standby

Authorization selection screen

Select the authorization method.

ID/Password input

ID/Password input screen

Enter the ID and password.

Card authorization

Card authorization

• Place the registered card close to the card reader.

• Several minutes may be required for card authorization.

• When the card is authorized, the light on the reader changes from blue to green.

Authorization screen

The system is verifying the ID and password. Please wait until authorization is completed.


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Card authorization complete

Card authorization is complete. The screen changes to the charging instructions screen.

If the screens below are displayed, charging is not possible.

* Display may vary depending on the system you are using.

Card not registered

• This screen appears when a card which has not been registered is used.

• Perform authorization again using a registered card.


No reservation

• This screen appears when no charging reservation has been made.

• Make a charging reservation, then perform card authorization again.


Reserved by another user

• This screen appears when card authorization is performed during a time period which another user has reserved for charging.

• Check the time period in the charging reservation.


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Out of service

• This screen appears when a command to suspend system service is received from the center.

• Please contact the reservation center.

Selecting the charging time

Charging time selection screen

Select the charging time.

Charging

1) Prepare the vehicle for charging. Open the vehicle charging lid (the cover on the charging port). For details about how to open the lid, refer to

the vehicle instruction manual. 2) Remove the charging connector. Remove the charging connector from the charging stand.

[Important] If the lever is not lowered all the way, a lock mechanism is engaged and the connector cannot be removed.

Removing the charging connector from the charging stand

Press the release button and lower the lever until a click sound is heard.


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Removing the charging connector from the charging stand

Grasp the grip and remove the charging connector while holding down the release button.

3) Connect the charging connector to the vehicle.

[Important] • Do not pull the lever before the connector reaches

the stopping point. • If the lever is pulled, the lock arm cannot move and

it will not be possible to insert the connector. Do not use excessive force when inserting the connector. Also, do not press the release button.

Inserting the connector into the vehicle charging port

Grasp the grip and insert the connector into the port along the guides all the way until it stops.

Inserting the connector into the vehicle charging port

• Continue to grip the lever until a click sound occurs and the lever does not return.

• When charging starts, the LED illuminates and a solenoid holds the lever in place.


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Starting charging

Starting charging

• Press the START button on the charging stand. A lock engages automatically to prevent the charging connector from being disconnected, and the LED illuminates.

• Never touch the connector while charging is in progress. There is a danger that the charging connector or the charging port of the electric vehicle will be damaged.

Checking connection

The system is checking that the charging connector has been connected correctly.

Performing insulation test

The system is checking that there are no insulation problems with the connector.

Charging

• If the connection with the vehicle is correct, charging will be started.

• During charging, the level of vehicle battery charge (percent display) and remaining time until charging is completed are displayed.


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Charging

During charging, the level of vehicle battery charge (percent display) and remaining time until charging is completed are displayed.

Charging complete

The system is performing the completion process to finish charging and allow the connector to be safely disconnected.

Completing charging

When the charging completed screen is displayed on the panel, charging is completed.

Charging complete

Charging is completed and the system will now progress to the end sequence screen.


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1) Disconnect the charging connector from the vehicle charging port. While pressing the release button on the charging connector, disconnect the charging connector from the

connector on the vehicle and return it to the holder on the charging stand.

[Important] If the lever is not lowered all the way, a lock mechanism is engaged and the connector cannot be removed.

Removing the charging connector from the vehicle charging port

Press the release button and lower the lever until a click sound is heard.

Removing the charging connector from the vehicle charging port

Grasp the grip and remove the charging connector while holding down the release button.

[Important] • Do not pull the lever before the connector reaches

the stopping point. • If the lever is pulled, the lock arm cannot move and

it will not be possible to insert the connector. Do not use excessive force when inserting the connector.

• Also, do not press the release button.

Inserting the connector into the charging stand

Grasp the grip and insert the connector into the holder port along the guides all the way until it stops.


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Inserting the connector into the charging stand

Continue to grip the lever until a click sound occurs and the lever does not return.

Charging complete

Press the STOP button.

2) Close the vehicle charging port. Close the vehicle charging lid (the cover on the charging port). For details of how to close the lid, refer to the

vehicle instruction manual. Charging work is now finished.


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7 Control Menu Operations The following operations are available from the control menu.

• Error history list

• Time setting

• Maximum current setting To display the control menu screen, hold down the charging stand STOP button and press the START button 3

times. The screen changes to the password entry screen. Enter the designated password.

Password input

The screen shown on the left appears. Enter the designated password and press [ENT] to display the control menu screen.

The control menu screen appears.

Management menu

• Pressing any of the menu items changes to the corresponding screen.

• Press [Back] to return to the control menu screen.

Error history list

Error history list

• This list displays the details of past errors. • Press [←] and [→] to change to the previous

and next error list screens. • Press [Back] to return to the control menu

screen.


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Time setting

Date/time setting

• This operation is used to correct the date and time of the charger internal clock.

• Press the part which you want to change. • Press [Back] to confirm the changes and return

to the control menu screen.

Maximum current setting

Max current setting

• This operation is used to change the maximum value of the charging current. The default value is 125A.

• Press the number part to change the value. • Press [Back] to confirm the changed current

value and return to the control menu screen.

8 Emergency Stop Button In the event of an emergency, press this button to forcibly stop operation of the system.

Emergency Stop Button If you discover that the charging stand or control panel has been damaged due to a collision with a vehicle or another cause, press the emergency stop button to stop operation of the system regardless of whether or not charging is currently in progress. Then contact JFE Engineering.

Reset after the emergency stop button was pressed

Rotate the emergency stop button in the clockwise direction to cancel emergency stop.

After reset, press the STOP button to display the RAPIDAS logo screen.


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9 Compatible Batteries and Guidelines for Charging Times

This product can be used to charge electric vehicles that contain charging ports which conform to CHAdeMO standards. As of October 2011, this product is compatible with the following vehicles. • Mitsubishi i-MiEV • Nissan Leaf Because charging of an electric vehicle is performed according to commands received from the vehicle, the charging time varies depending on the vehicle model and the remaining battery charge. As a general guideline, 30 minutes are required to provide an approximately 80% charge. <Important information> • Charging is performed using a combination of the power stored in the charger storage battery and a

commercial power source. • Therefore when the power level in the charger storage battery is low, the message "Error: Low Storage

Battery Voltage" may be displayed and charging may stop at a lower charge level than usual. • If this occurs, press the STOP button and wait for approximately 10 – 15 minutes, then press the START

button and resume charging.

10 Specifications

Model RAPIDAS Input 3-phase 200 V, 50 – 60 Hz Rated input 20 kW Output power DC 50 – 500 V Output current Max. 125A Rated output 50 kW Efficiency 90% or higher Storage battery capacity (30 kW h)

Supply power connector

• Conforms to JEVS G105 * This product is for the CHAdeMO system. It cannot be used for any other system. • Conforms to IEC62196-1 • Conforms to UL2251

Communications with vehicle Conforms to CHAdeMO protocols

Structure/dimensions Charging stand: outdoor free-standing structure W 540 mm x H 2660 mm x D 830 mm

Control panel: outdoor free-standing structure, indoor free-standing structure W (1300 mm) x H 2000 mm x D (850 mm)

Service environment Service temperature range: -10ºC to +40ºC Dustproof and waterproof structure IP33 or higher

( ): Variable depending on charger storage battery


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11 Maintenance

Inspections performed by the customer The following inspections should be performed regularly so that the charger remains in the correct conditions for use. If an abnormality is found at any time, not just during the inspections listed below, immediately discontinue use of the charger and contact JFE Engineering.

Check the leakage breakers once a month. • Use the provided key and open the front door on the control panel, then press the test

button on each leakage breaker located inside and check that the power turns OFF.

Check the charging connector once a month. • Check the charging connector unit (release button, release lever, and other parts) and

the charging cable for damage. There is a danger of electric shock or injury caused by the connector falling.

Check the charging cable once every 6 months. • Check the insulation of the charging cable that is connected to the charging stand for

damage.

Inverter power Test button Stand power

Control power Test button


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Inspections performed by JFE Engineering So that the product can provide reliable service over a long time, have it inspected regularly (at customer's expense) by us at least once a year. For details of regular inspection costs, please contact JFE Engineering. Please store the results of regular inspections in a safe location.

Cleaning the product

• To clean the charging stand and control panel, wipe gently using a cloth moistened with water or similar means.

• Use an air gun or similar means to remove dust from the charging connector. • Do not use benzene, paint thinner, gasoline, polishing powder, detergent, or other substances as these may

harm the paint and plastic parts.

Do not use close to flammable sprays. Do not allow benzene, paint thinner, gasoline, or other flammable substances in the area close to the product. There is a danger of ignition and a fire caused by sparks at the contacts of the electrical components.

12 Warranty and After-Sale Service

Warranty certificate (separate document) • This product is provided with a warranty certificate. • Please check the following when you receive the warranty certificate. • Read the warranty certificate carefully and store it in a safe location. • The warranty period is 1 year from the product delivery date or the date of the receiving inspection following

the performance check. • Malfunctions occurring during the warranty period when the product was used in accordance with the

directions in the instruction manual will be repaired by JFE Engineering or a maintenance company designated by JFE Engineering at no charge to the customer.

• The capacity of the storage battery installed in the charger will gradually decrease according to the conditions of use and over time. This decrease in capacity is due to the intrinsic properties of the storage battery which is used and does not represent a malfunction.

Parts

• Parts which are removed for the purpose of warranty repairs are in general the property of JFE Engineering. • A supply of performance parts for repairs will be maintained for a period of 8 years following the end of

production. • "Performance parts for repairs" refers to the parts that are required in order to maintain the function of the

product.

Regular inspections designated by JFE Engineering • The regular inspections designated by JFE engineering consist of work that is performed by us at charge to

the customer. For details of regular inspection costs, please contact JFE Engineering. • Removal of dirt from the external air intake filter and cleaning work are included in the regular inspection

items and will be performed by JFE Engineering.


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Contact If you have any questions or would like to discuss repairs, maintenance, or other matters, please contact us using the contact details below.

Contact

JFE Engineering Corporation

RAPIDAS Project Team

2-1 Suehiro-cho, Tsurumi-ku, Yokohama-shi, Kanagawa-ken 230-8611

Tel: 045-505-6574

Available hours: 8:30 – 17:00

(Except company holidays including Saturdays, Sundays, public holidays, and the end of year and new

year holidays)

13 Troubleshooting If an error screen appears and charging stops during charging, press the STOP button on the charging stand.

Fault occurred • This screen is displayed when an error

occurs in the charger. • Press the STOP button to display the

RAPIDAS logo screen. If the screen does not return to the RAPIDAS logo screen, please contact JFE Engineering.

• If the screen returns to the RAPIDAS logo screen, press the START button on the charging stand. If the error screen appears again, contact JFE Engineering.


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If the level of the storage battery is too low • The message "Low storage battery

Voltage" may appear below the "Press the STOP button to reset" instruction on the error screen.

• If this message appears, the level of the battery installed in the charger is too low. This is not a malfunction.

• Press the STOP button, and wait for approximately 10 – 15 minutes after the RAPIDAS logo screen appears.

• While waiting for 10 – 15 minutes, sufficient power will be stored in the charger battery to charge one electric vehicle.

• The START button can then be pressed to charge the electric vehicle. However if the storage battery time was too short, there is the possibility that charging may stop again due to the low storage battery level.


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14 Other Information

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RAPIDAS Rapid Access System for EV charging

Instruction manual Model: RAPIDAS

Document code:

Issue date: October 2011

Printing date: October 2011

Edited and issued by: JFE Engineering Corporation

rapidas operations owners manual

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