Safety

Installation

Safety

Safety

Risks and Hazards

Electrical Shock Hazard

NOTICE

Wet Conditions

Installing any components in wet conditions can cause damage to the machine.

  1. Before opening charger cabinet or the charge post, always use waterproof protective shelter or similar structure against rain and moisture.

Installation and use of the machine must follow the instructions that are given in the international standards regarding the installation and use of the machine type in question. Always follow also local rules and legislation regarding the installation and use of high-voltage units.

To minimize risk:

  • Before cable installation, check that the circuit breaker or switch of the supply cable is mechanically locked to OFF and main power switch of the Charging Power Unit is OFF.

  • Double check and meter voltage on each phase versus PE.

  • Confirm that level is 0 V.

  • Make sure that installation is not energized.

Fire Hazard

In Case of Fire

NOTE

It is important to follow local laws and regulations.

  1. 1.
    Stop the charging session if possible.
  2. 2.
    Remove the charging connector from the machine.
  3. 3.
    Use fire extinguishers suitable for electric equipments (CO2 extinguishers) to extinguish the fire.
  4. 4.
    Contact the local authorities.

Actions After Fire

  1. 1.
    Contact Epiroc before starting any maintenance work on the charging station.

    NOTE

    Epiroc does a critical failure analysis before maintenance work can be carried out on the charging station.

Safety Precautions

Safety Messages in Publications

Safety messages in publications declare hazards and the related measures to avoid the hazards in that particular situation. Safety messages contain signal words (Danger, Warning, Caution, and Notice) that relate to the consequences of those specific hazards. The information in safety messages must be obeyed.

Safety messages consist of:

  • A signal word to determine the degree of the hazard.

  • A type of hazard states the potential source of a hazard. For example: Moving parts, Hot surface, and so on.

  • The consequence of the hazard, if not avoided.

  • A method to avoid the hazard.

The following are examples of safety message structures.

DANGER

Hazard

The signal word "DANGER" indicates a hazardous situation which will result in death or serious injury if not avoided.

  1. The method to avoid the hazard is written here.

WARNING

Hazard

The signal word "WARNING" indicates a hazardous situation which could result in death or serious injury if not avoided.

  1. The method to avoid the hazard is written here.

CAUTION

Hazard

The signal word "CAUTION" indicates a hazardous situation which could result in minor or moderate injury if not avoided.

  1. The method to avoid the hazard is written here.

NOTICE

Hazard

The signal word "NOTICE" contains information that is not related to bodily injury yet considered important. In a "NOTICE" the damage is related to machines, components, or systems.

  1. The method to avoid the hazard is written here.

Safety Precautions When Working With Battery Chargers

NOTICE

Damage to the Battery Charger

Incorrect handling of the battery charge can cause damage to the equipment and or to the machine being charged.

  1. Changes or modifications to the charging equipment, unless agreed upon with Epiroc are prohibited and voids the warranty.

  2. Only use spare parts approved by Epiroc.

  3. Do not repeatedly transport the battery charger in a vehicle.

  4. The environment of the battery charger must conform with its IP classification. Do not expose the charging unit to high temperatures.

  5. Do not turn off the battery charger or disconnect its power supply during charging.

  6. Keep the battery charger stop switch in ON position. Only turn the equipment stop switch to OFF position if the charging unit malfunctions, if the charging session does not start after several attempts, or if there is another unrecognized error. To reset the charging unit, disconnect its power supply.

  7. Do not use the top handles to lift the battery charger off the ground. The top handles are for moving the battery charger on its wheels.

  8. Be careful when you move the battery charger, its center of gravity is high and it weighs 120–135 kg depending on the configuration.

  9. During charging, do not wind the cables around the battery charger. Straighten tight loops in the cables

  10. Do not put the vehicle connector on the ground. Put the connector in its holder after charging. The vehicle connector pins do not have voltage when the device is not charging.

WARNING

Risk of Electrocution

Not following the safety precautions while working with battery chargers can cause fire accident, serious injury, or death.

  1. After you disconnect the power supply, wait at least minimum two minutes for the capacitors of the power module to discharge before you continue. Before you start work, measure the voltage of the electrical circuits to make sure that no dangerous voltage remains.

  2. Obey the general and local safety regulations and procedures.

  3. Only certified maintenance personnel are allowed to do the service and maintenance task of battery charger.

  4. Disconnect the battery charger from the main power supply when energy isolation is necessary. The battery charger is still connected to the main power supply even if the battery charger power-switch is in OFF position.

  5. Turn the battery charger power-switch to OFF position and disconnect the main power supply if there is a risk of electrocution due to damaged cables.

  6. Always connect the battery charger to properly grounded electric network.

  7. Do not use the battery charger if the cables and machine connectors are damaged.

  8. The battery charger is intended for machines that do not require ventilation during charging.

  9. Do not open or remove any panel from the battery charger if you are not a certified maintenance personnel.

  10. Do not use running water or pressure washing equipment to clean the battery charger. Use a pH neutral detergent if necessary.

  11. The battery chargers must not be exposed to high temperatures as it may damage the equipment.

  12. The airflow to and from the battery charger must be unrestricted.

Warning Signs

Image

Description

Dangerous voltage.

Incorrect handling can be fatal.

Only qualified and authorized service technicians are permitted to work on the electrical system.

Machine Safety

  • Machine manufactures adopt standards and use high-quality components to make sure that charging and operating machine is safe.

  • During charging session, Vehicle Management System (VMS) prevents machine to start and move, make sure that charging session block off some of the functions of the machine.

  • Drive train cables of the machine are colored in orange (high DC voltage).

  • If communication between machine and charging station is not available (modulated CCS1/CCS2 or CAN-bus), charging session is not possible

See Reference Machine Documentation

User manual

Charging Station Safety

  • Mechanical design is according to IK08 and it withstands heavy use.

  • Electrical safety internal over leak DC current monitoring is according to IEC 61851-21-2.

  • Overcurrent protection is EMC Class A.

  • Continuous overheating monitoring and automated power management.

  • Power grid conditions are also monitored for over and under voltages.

  • Monitor the charging DC voltage; over and under voltages.

NOTE

Only authorized electrician is allowed to carry out any electrical work on the charging station.

Power Supply Safety

  • Electrification of the operating site must follow the instructions given in the international standards regarding the installation and use of the machine type in question.

  • Always follow the local rules and legislation regarding the installation and use of high-voltage units.

  • Power supply source must meet the selected maximum current level.

Personal Protection

Read the following steps carefully before installation or maintenance work.

  • Qualified electricians must do electrical installation and maintenance work for the charging system.

  • Always use the following Personal Protection Equipment (PPE) when working with or near the battery chargers:

    • Protective footwear

    • Safety helmet

    • Protective gloves

    • Safety clothing

    • Eye protection

    • Hearing protection

  • Keep installation report filled and keep it for the future reference.

  • The electrification supervisor must have a permit to start the electrical installation.

  • Optional charge posts can be installed either using a flat surface installation KIT (standard) or on a concrete foundation (optional).

  • Main power switch of charger cabinet must be kept at Off until all cables are connected to all charge posts and to charger cabinet terminals. Follow charge post installation guide.

Environmental Protection

Environmental Guidelines

  • The device is installed in a location whereas the ingress protection (IP) classification and ambient operating conditions are within the limits to that of the device.

  • Do not expose the device to high temperatures, as it damages the device.

  • If possible, put the charging station in such a location that protects it from direct sunlight to prevent overheating and aging of the technical parts.

  • Make sure that operators and maintenance personnel are adequately trained.

  • Use biologically-degradable fluids and lubricants when refilling the systems. Contact Epiroc for more information. See https://www.epiroc.com

Owners Responsibility during Disposal of the Battery

The product labeled with this symbol is in compliance with the WEEE – 2012/19/EU Directive on waste electrical and electronic equipment.

Always follow local environmental regulations for disposing of waste and for recycling.

Under no circumstances dispose of this product or its parts as part of household waste.

A worn out battery charger must be handled and disposed of in such a way that maximizes the percentage of recyclable material. The negative impact on the environment must be as low as possible. If the end user has inadequate knowledge about disposal, a locally-authorized disposal company must be hired.

The following points must be considered during disposal of the battery chargers:

  • All steel structures, copper, and aluminum found in electrical cables can be recycled.

  • Make sure that fluids are drained and filters are removed and handled in accordance with local regulations.

  • Most plastic parts are recyclable. Check the material type and date marked on each plastic part to determine if that part can be recycled.

  • Rubber parts are not considered as hazardous waste and can be disposed of according to local environmental regulations. Hoses must be cleaned before they can be disposed of.

  • Electrical components, such as batteries and circuit boards, must be taken to an approved electrical recycling facility.