Circontrol CCL-PT3 SMART, CCL-PT3 SMART 3G Installation Manual

INSTALLATION MANUAL

CCL-PT3 SMART

CCL-PT3 SMART 3G

SEMI FAST CHARGE STATION FOR

ELECTRIC VEHICLES

SMART POST PT3 Installation manual

This document is copyrighted, 2014 by Circontrol, S.A. All rights are reserved.
Circontrol, S.A. reserves the right to make improvements to the products
described in this manual at any time without notice.

No part of this manual may be reproduced, copied, translated or transmitted in
any form or by any means without the prior written permission of the original
manufacturer. Information provided in this manual is intended to be accurate
and reliable. However, the original manufacturer assumes no responsibility for
its use, or for any infringements upon the rights of third parties that may result
from its use.

All other product names or trademarks are properties of their respective

owners.

V1.5, April edition 2014

INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

CONTENTS

1 PREFACE ............................................................................................................................. 2

2 IMPORTANT SAFETY INSTRUCTIONS .............................................................................. 3

3 PRODUCT OVERVIEW ........................................................................................................ 4

4 COMPONENT PARTS LOCATION ...................................................................................... 5

5 PRODUCT DIMENSIONS ..................................................................................................... 6

6 INSTALLATION .................................................................................................................... 7

6.1 PREREQUISITES ......................................................................................................... 7

6.2 FOUNDATION DRAWING ............................................................................................ 8

6.3 FOUNDATION PROCEDURE ....................................................................................... 9

6.4 ASSEMBLY MAIN BODY ............................................................................................ 16

7 INSERT THE SIM CARD (FOR 3G MODELS) ................................................................... 19

8 ETHERNET CONNECTION ................................................................................................ 21

9 ELECTRICAL INSTALLATION .......................................................................................... 22

10 CLOSING THE UNIT........................................................................................................... 23

11 UNIT VERIFICATION .......................................................................................................... 24

12 TECHNICAL DATA ............................................................................................................. 25

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

THE FOLLOWING SYMBOLS ARE USED FOR
IMPORTANT SAFETY INFORMATION IN THIS

DOCUMENT

The unit must be disconnected from any power source before
performing any maintenance, repair or handling of any
equipment connections.

Do not modify the unit. If modified, CIRCONTROL will reject
all responsibility and the warranty will be void.

Certification

 Complies with IEC 61851, Electric vehicle conductive charging system (IEC

61851-1)

 Complies with IEC 62196, Plugs, socket-outlets, vehicle couplers and vehicle

inlets -

 Conductive charging system (IEC 62196-1 and IEC 62196-3).
 RFID complies with ISO 14443A

1 PREFACE

This manual provide commissioning information for SMART POST SERIES, which has
been designed and tested to allow electric vehicle charging, specified in IEC 61851.

This document has different sections where describes electrical components inside the
charge station and a step-by-step installation procedure.

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

2 IMPORTANT SAFETY INSTRUCTIONS

 Read all the instructions before using and install this product.
 Do not use cables there are not in perfect conditions.
 Do not use this unit for anything other than electric vehicle charging

Charging modes are expected in IEC 61851-1.

 Do not modify this unit. If modified, CIRCONTROL will reject all

responsibility and the warranty will be void.

 Comply strictly with current safety regulations according to your

country rules.

 Do not make repairs or manipulations with the unit energised.
 Only trained and qualified personnel should have access to low-

voltage electrical parts inside the device.

 Check the installation annually by qualified technician.
 Remove from service any item that has a fault that could be dangerous

for users (broken plugs, caps that don’t close...).

 Use only Circontrol supplied spare parts.
 Do not use this product if the enclosure or the EV connector is broken,

cracked, open, or shows any other indication of damage.

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

1. Rear Beacons

2. Charge Status indicator

3. Liquid Cristal Display

4. RFID Reader

5. Vandal doors

6. Plug A – Type 2

7. Plug B – Type 2

8. Electromagnets

9. Base

8

4

3 1 5 6 7

2

9

2

3 PRODUCT OVERVIEW

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

1. Rear Beacon Plug B (H1)

2. CCL1 Device (U1)

3. Plug A – Meter (AN1)

4. Plug B – Meter (AN2)

5. Plug A – Mode 3 (AM3-1)

6. Plug B – Mode 3 (AM3-2)

7. RFID Reader (B3)

8. LCD Display (H3)

9. Type 2 socket (B2)

10. Heater (R1)

11. MCB Power Supply (Q3)

12. WGS-20 (T3)

13. Power Supply (G1)

14. AC Power terminals

15. Thermostat (G3)

16. Tamper switch (S1)

17. Plug A – Contactor (K1)

18. Plug B – Contactor (K2)

19. Relay power supply (K3)

20. Plug A – MCB (Q1)

21. Plug B – MCB (Q2)

22. Type 2 socket (B1)

23. Plug A – Relay

electromagnet (K7)

24. Plug B – Relay
electromagnet Plug B (K8)

25. CBS-4C RCD (AF1)

26. Beacon led driver (X2.1)

27. Rear beacon Plug A (H2)

28. Beacon led driver

(X1.1)

1 2 4 5 6 7 9

12

13

16

20

21

22

23

24

25

27

17

18 3 19

14 8 10

11

26

28

15

4 COMPONENT PARTS LOCATION

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CIRCONTROL, S.A. – Innovació, 3 – 08232 – Viladecavalls (Barcelona)

INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

Units specified in mm

5 PRODUCT DIMENSIONS

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

Material

Qty

Picture

“L Threaded

bar

4
M12 Nuts

8

Center

template

1

Main fixing

structure unit

1

6 INSTALLATION

6.1 PREREQUISITES

Bellow material list is attached with the unit for foundation and installation purpose.

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

Units specified in mm

6.2 FOUNDATION DRAWING

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

STEP

ACTION

1

The four “L” threaded bars must be placed and cemented underground in
the foundation place as shows bellow figure.

Drawing foundation dimensions are minimum recommended to fix post
to the ground, please consider hardness ground conditions.

6.3 FOUNDATION PROCEDURE

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

2

Once the four “L” threaded bars are undergrounded, the metal template must
be mounted, as shown in the image, in order to get the bars completely
aligned.

3

When dry, remove the template, and keep the four nuts that must be
lowered close to the floor level.

4

Insert the main fixing structure through the lower holes.

ATTENTION!! : Be careful with the position of the base (BACK & FRONT)

due is not symmetrical.

FRONT VIEW

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

5

Connections wires must be introduced and fixed as shown in the back view
image.

6

Adjust the lower four nuts, you can properly level the main structure.

BACK VIEW

Wire Input

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

7

1. Tight strongly with the appropriate tools, the upper nuts.

2. Check main fixing structure unit has not inclination using a level tool.

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

8

Disassembly the metal plate from the housing removing the 6 screw.

9

Once the base is tightened, introduce the housing as shown.

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

10

1. Insert the connection wires through supplied the metal plate.

2. Assembly metal plate screwing with 6 supplied screws and keep
original position for all screws.

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

11

Assembly cable glands (not supplied) in pre-holes position.

12

Assembly supplied cover with 2 screws.

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

STEP

ACTION

1

After unpack main body, remove 8 screws from rear cover.

2

Assembly main body with two covers plates and the four M8 supplied screws
as shown below.

ATTENTION: Do not trap connection wires with main body.

6.4 ASSEMBLY MAIN BODY

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

3

Install tamper switch and adjust its position with the two screws.

After assembly, check tamper position and adjust push button to position 1

Tamper possible positions

1. Maintenance position

2. Open cover (Alarm on)

3. Normal function

3 2 1

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

4

The unit is ready to electrical connections described in section nº 8.
It is recommended to keep a distance of approximately 40cm of electric wires

before cutting.

5

Proceed with input connections, please see section 8.

40cm

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

STEP

ACTION

1

Locate Control module CCL1 on top of the charge point.

2

SIM card holder is located at the right side of the CCL1 device.

7 INSERT THE SIM CARD (FOR 3G MODELS)

Please, follow bellow procedure to insert SIM card in CCL1 integrated modem.

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

3

The SIM card and its contacts can be easily damaged by scratches or

bending, so be careful when handling, inserting or removing the card.

1. Insert the SIM card with the contact surface facing down.

2. The image below shows how it should be done.

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

CCL1 Device

8 ETHERNET CONNECTION

Charge station can be configured and monitored to establish owner preferences or
specific setup using integrated Ethernet communication port installed at the top of the
unit of the main controller named as CCL1 device.

This unit is shipped from the factory with default network setting of “DHCP enabled”. It
means that the charge station will try to obtain an IP address from a DHCP server
available on the network.

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

25mm

2

25mm

2

25mm

2

25mm

2

25mm

2

L1
L2
L3

9 ELECTRICAL INSTALLATION

- Connect to the 400V AC Three-phase as shown.

- Do not forget to connect the ground cable to the ground terminal.

Recommended cable section is 25 mm

2

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

STEP

ACTION

1

For the closure of the rear cover the following M8x20 Allen screws & rings are
supplied. The two upper screws, with a standard flat ring must be used for the
two holes at top of the cover; the six screws equipped with a special sealing
ring, must be placed for the holes at the sides.

In order to keep the optimal sealing,
must be done alternating from left to
right and from up to down screws.

10 CLOSING THE UNIT

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

11 UNIT VERIFICATION

Once all installation procedure has been performed, check points below:

1. Check each plug is in proper conditions before start operation.

2. Check no abnormal noise appears while unit is charging.

3. Check all beacons indicators are lighting.

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INSTALLATION MANUAL –CCL-PT3 SMART & CCL-PT3 SMART 3G–

CCL-PT3-SMART

AC INPUT

AC Power supply

3P + N + PE

AC Voltage

400VAC +/- 10%

Nominal input current

64 A

Nominal input power

44kW

Frequency

50 / 60 Hz

OUTPUT

PLUG A

PLUG B

Charge system

Mode 3

Mode 3

Sockets/ Plugs

Type 2

Type 2

Lock system

Yes

Maximum output power

22kW

22kW

Maximum output current

32A

32A

Output voltage range

400V

AC

(3P + N + PE)

ELECTRICAL PROTECTIONS

Overcurrent protections

MCB

Safety protection

RCD 30mA auto recovery (class A)

ENERGY METERS

Accuracy class in active energy

Class B – EN50470-3

Accuracy class in reactive energy

Class 2 – EN62053-23

Meter standards

EN62052-11, EN62053-21, EN62053-23, EN61010-1

NETWORK

Ethernet

10/100BaseTX

GENERAL

Enclosure rating

IP54 / IK10

Enclosure material

Stainless steel

Operating temperature

-30 to +45ºC

Operating humidity

To 95% RH Non-condensing

RFID system

ISO / IEC14443A / B

Display

LCD Backlight double line text

Power limit control

Mode 3 PWM control according ISO / IEC 61851-1

Interface protocol

OCPP / XML

Net weight

65Kg

OPTIONAL DEVICES

Mobile communications

3G / GPRS

RCD protection

RCD class B

Overvoltage protection

Transient surge protector

12 TECHNICAL DATA

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C / Innovació, 3

Pol. Ind. Can Mitjans

08232 - Viladecavalls

Barcelona - Spain

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