Installation
Indicative Cable Diagram for Charging System
A | Installation kit |
B | Concrete foundation |
C | Concrete foundation |
D | DC supply cable (ground assembly) |
E | AC supply cable |
Charging Site Definitions | Description | Quantity |
|---|---|---|
Distribution board | 3-Phase circuit breaker | 1 |
3-Phase fuse | 3 | |
AC Supply cable, 160 KW | 3-Phase cable | 1 |
DC Supply cable (Ground assembly) | 1 or 2 x MCMK 4 x 35 mm2 or 16 mm2 | |
DC Control cable | 7 x 1.5 mm2 | 1 |
Ethernet control cable | Supercat ETH-6 shielded | 1 |
NOTE
External cables that are AC supply cable, DC supply cable, control cable, ethernet cables are not under scope of standard delivery. These cable are to be arranged by customer locally.
NOTE
AC and DC Cable sizing must be selected according to local installation rules depending on both site and system configuration.
NOTE
Concrete foundation parts that are shown are indicative only, not available by delivery scope.
Follow local rules on electrical installations and manufacturer installation safety instructions. Sizing of the cables must follow local rules and must be adopted for different installation type, for example, surface and underground installation may different local rules.
Always follow guidelines provided by cable manufacturer.
Each cabinet has its own AC supply cable and appropriate terminal blocks inside the cabinet.
Charging Power Unit Installation
Each charger cabinet utilizes four power modules that each has charging power up to 40 kW. Charger cabinet supplies DC current through charging cables directly to each charge post. Recommended maximum DC cabling between charger cabinet and charge post is up to 50 meters.
Charging Power Unit cabinet can be installed on a flat surface such as concrete floor or concrete foundation.
It can also be installed on steel foundation (Optional part) or on the floor of a container or alike.
If there is container installation, air circulation must be natural or forced to keep ambient temperature within limits.
Install Charging Power Unit (CPU)
- 1.Inspect the charger cabinet and frame are proper after transportation.
- 2.Remove the bottom cover.
- 3.Transport the cabinet on a palette with tilt up to 6 degrees.
- 4.Support the cabinet with a belt or rope of the mast of the fork truck to prevent it from falling.
- 5.Mark the holes to the surface 940 x 608 mm (37 x 23.93 in.) crossing four outer anchors. Four inner anchors are 340 mm (13.38 in.) from outer holes.
- 6.Drill the holes and install M12 anchors and follow mechanical or chemical anchor installation instructions.
NOTE
Use epoxy for installation of M12 anchors. Epoxy is not included on delivery.
- 7.Install the steel foundation to the floor.
- 8.Open the cabinet doors.
- 9.Loosen the screws to remove bottom section of the CPU base cover plate and control module.
- 10.Gently slide off the module from the charger cabinet.
NOTE
Place the module on a clean cardboard surface.
- 11.Lift the cabinet on its position with fork truck. Guide the cables through the bottom and support them through the front open.
- 12.If there is a container, gently insert the charger cabinet inside a shipping container.
NOTE
Auxiliary arrangement can be necessary for cooling and proper ventilation when the cabinet is installed inside a container.
- 13.Open the charger cabinet doors to fasten the charger cabinet with anchors to the steel foundation or to the foundation surface.
NOTE
For charger-160MV and charger-400, a total of eight anchors must be used.
NOTE
For Charger 200, a total of four anchors must be used.
- 14.It is recommended that AC supply cable enters the cabinet from the left or bottom left of the left cabinet section. DC cabling must be located to the right or back side of the charger cabinet.
NOTE
Do not cross AC and DC cabling to prevent extra EMC.
- 15.Cooling air inlets are at the front door and outlet is on the top of the charger cabinet. If there is a container installation, in which the container doors are closed during charging, forced ventilation must be installed to prevent high ambient temperature.
- 16.Install the fixing anchors of the charger cabinet and tighten torque to 30 Nm (22.13 lbf.ft).
NOTE
If there is concrete floor installation, epoxy gets hard in 0.5 – 5 hr depending on conditions. Follow mechanical or chemical anchor installation instructions.
Installing the Steel Base (Charger 200)
WARNING
Heavy Equipment
Working with heavy components can cause crushing injury.
Do not stand near the heavy component being lifted.
Use adequate lifting devices and supports.
CAUTION
Fall Over
Heavy equipment fall over can cause severe injury
Use all lifting lugs of the unit when you lift it. Keep the Minimum angle of slings 60°.
Maintain high center of gravity. Make sure that the cabinet does not fall over.
NOTICE
Precautions
One cabinet with four power modules weighs approximately 400 kg. Use appropriate lifting device operated by qualified professionals.
Make sure that the installation surface is solid and as level as possible.
Make sure that the door of the unit has space to open when the unit is in position.
NOTE
Identify the cable routes and open the knock-out holes in the steel base. Use cable bushings or smooth the sharp edges of the knock-out holes to protect the cables from damage.
- 1.Drill the fixing holes into the installation surface.
- 2.Make sure that the installation surface is solid and as level as possible.
- 3.Place the steel base and align the holes.
- 4.Install the two M6 bolts (A) to attach the seam with panels.
- 5.Install the bolts (B) to attach the steel base with surface.
NOTE
The bolts that are used for installing the steel base to the installation surface are not included in the delivery.
- 6.Lift and place the charging power unit on the steel base.
NOTE
Make sure that the steel base is in horizontal position.
- 7.Install the charging power unit to the steel frame using four M12 bolts (C).
- 8.Torque the bolts loosely until all the bolts are placed.
NOTE
If the charging power unit does not align correctly with the steel base, adjust the steel base as needed.
- 9.Torque the bolts tightly.
Installing the Steel Base (Charger 400 / Charger 160MV)
WARNING
Heavy Equipment
Working with heavy components can cause crushing injury.
Do not stand near the heavy component being lifted.
Use adequate lifting devices and supports.
CAUTION
Fall Over
Heavy equipment fall over can cause severe injury
Use all lifting lugs of the unit when you lift it. Keep the Minimum angle of slings 60°.
Maintain high center of gravity. Make sure that the cabinet does not fall over.
NOTICE
Precautions
One cabinet with four power modules weighs approximately 400 kg. Use appropriate lifting device operated by qualified professionals.
Make sure that the installation surface is solid and as level as possible.
Make sure that the door of the unit has space to open when the unit is in position.
NOTE
Identify the cable routes and open the knock-out holes in the steel base. Use cable bushings or smooth the sharp edges of the knock-out holes to protect the cables from damage.
- 1.Drill the fixing holes into the installation surface.
- 2.Make sure that the installation surface is solid and as level as possible.
- 3.Assemble the side panels on steel base and align the holes.
- 4.Install the two M6 bolts (A) and nuts to attach the seam with panels.
- 5.Use the correct number of side panels for installation, two for a double cabinet and three for a triple cabinet.
- 6.Assemble the end panels on steel base and align the holes.
NOTE
The middle panels are optional.
- 7.Install the M6 bolts (B) to attach the end panels with seam.
- 8.Install the bolts (C) to attach the steel base with surface.
NOTE
The bolts that are used for installing the steel base to the installation surface are not included in the delivery.
- 9.Lift and place the charging power unit on the steel base.
NOTE
Make sure that the steel base is in horizontal position.
- 10.Install the charging power unit to the steel frame using four M12 bolts (D) per cabinet.
- 11.Torque the bolts loosely until all the bolts are placed.
NOTE
If the charging power unit does not align correctly with the steel base, adjust the steel base as needed.
- 12.Torque the bolts tightly.
Installing the Steel Base (Triple / Charger 600)
WARNING
Heavy Equipment
Working with heavy components can cause crushing injury.
Do not stand near the heavy component being lifted.
Use adequate lifting devices and supports.
CAUTION
Fall Over
Heavy equipment fall over can cause severe injury
Use all lifting lugs of the unit when you lift it. Keep the Minimum angle of slings 60°.
Maintain high center of gravity. Make sure that the cabinet does not fall over.
NOTICE
Precautions
One cabinet with four power modules weighs approximately 400 kg. Use appropriate lifting device operated by qualified professionals.
Make sure that the installation surface is solid and as level as possible.
Make sure that the door of the unit has space to open when the unit is in position.
NOTE
Identify the cable routes and open the knock-out holes in the steel base. Use cable bushings or smooth the sharp edges of the knock-out holes to protect the cables from damage.
- 1.Drill the fixing holes into the installation surface.
- 2.Make sure that the installation surface is solid and as level as possible.
- 3.Assemble the side panels on steel base and align the holes.
- 4.Install the two M6 bolts (A) and nuts to attach the seam with panels.
- 5.Use the correct number of side panels for installation, two for a double cabinet and three for a triple cabinet.
- 6.Assemble the end panels on steel base and align the holes.
NOTE
The middle panels are optional.
- 7.Install the M6 bolts (B) to attach the end panels with seam.
- 8.Install the bolts (C) to attach the steel base with surface.
NOTE
The bolts that are used for installing the steel base to the installation surface are not included in the delivery.
- 9.Lift and place the charging power unit on the steel base.
NOTE
Make sure that the steel base is in horizontal position.
- 10.Install the charging power unit to the steel frame using four M12 bolts (D) per cabinet.
- 11.Torque the bolts loosely until all the bolts are placed.
NOTE
If the charging power unit does not align correctly with the steel base, adjust the steel base as needed.
- 12.Torque the bolts tightly.
Cabinet Foot Print and Fixing Points
NOTE
Use four M12 anchor bolts or equivalent per cabinet.
Foot Print of Charger 200
mm | in. | |
|---|---|---|
A | 520 | 20.47 |
B | 702 | 27.63 |
C | 91 | 3.58 |
D | 40 | 1.57 |
E | 600 | 23.62 |
F | 520 | 20.47 |
G | 13.5 | 0.53 |
Footprint for Charger 160 MV and Charger 400 Cabinets
mm | in. | |
|---|---|---|
A | 690 | 27.16 |
B | 608 | 23.93 |
C | 562 | 22.12 |
D | 510 | 20.07 |
E | 31 | 1.22 |
F | 1182 | 46.53 |
G | 1046 | 41.18 |
H | 940 | 37.00 |
J | 340 | 13.38 |
K | 20 | 0.78 |
Foot Print of Charger 600
mm | in. | |
|---|---|---|
A | 155 | 6.10 |
B | 495 | 19.48 |
C | 755 | 29.72 |
D | 1095 | 43.11 |
E | 1355 | 53.34 |
F | 1695 | 66.73 |
G | 1850 | 72.83 |
H | 72 | 2.83 |
J | 680 | 26.77 |
K | 825 | 32.48 |
L | 12 X 13.5 | 0.47 X 0.13 |
Preparation for Cable Connection
NOTE
Make sure to place the components on clean and flat surface.
- 1.Remove the screws on the power module (A).
- 2.Roll the module on the shelve slides and remove it.
WARNING
Heavy Equipment
Equipment weighs approximately 43 kg (95 lb), depending on the current setup. Accidental movement of the heavy equipment can cause serious personal injury.
Use caution when moving the equipment.
- 3.Remove the screws on the dynamic module (B).
- 4.Pull out the dynamic module (B).
- 5.Remove the screws on the control module (C).
- 6.Pull out the control module (C).
- 7.Loosen the front screws of the front plate (D).
- 8.Remove the front plate (D).
- 9.Install the cables inside the cabinets.
Install DC Cable, Control Cable, and Ethernet Cable
A | CT B |
B | CT A |
C | GND |
D | + 24V |
E | ETH |
F | Charge post control cable |
G | GND |
H | GND |
J | +24 V |
K | +24V |
L | 1.-2.-3.-4 CT A (5) |
M | CT 1-8 |
Install DC Cable
- 1.Remove the back plate of the control unit and turn it slightly up to make more space for connecting the cables to the terminals.
- 2.Cable connection to RJ-45 connector can be made according to RJ-45 connection standard T-568B.
- 3.Stripe the DC mains leads and connect the DC mains leads (+plus and – minus) to output terminal blocks, Out1 – Out4 (C).
NOTE
Based on the numbers of charge post to be connected to the power cabinet, refer the installation circuit diagram for proper installation.
- 4.Tighten the DC cable terminal screws to 10 Nm (7.38 lbf.ft).
Install Ethernet Cable
NOTE
Based on the numbers of charge post to be connected to the power cabinet, refer the installation circuit diagram for proper installation.
- 1.Suitable cable type must be used at installation conditions.
NOTE
Indicative recommended cable type is SuperCat6 or similar.
- 2.Both ends (cabinet and charge post sides) of the Ethernet cable must be connected same way.
- 3.Ethernet connectors are included in the cabinet delivery, where ethernet cables are designed to connect (DIN-rail ethernet extension connectors).
- 4.Connectors are in a plastic bag and fastened to power module handle inside cabinet door. No special tools are needed to install the connectors.
- 5.Place the connector to the DIN-rail at the back side of the cabinet when ethernet cable is connected to connector.
- 6.From this connector ethernet cable should continue to the control module front panel.
NOTE
Ethernet cables can be connected to any of the eight available ports on the control modules.
NOTE
Lubricate ethernet cable connector with electric contact grease before connecting to the ethernet port.
Install Control Cable
Install AC - Supply Cable (Charger 200)
NOTE
Cable size must be selected as per installed power and local regulation.
- 1.Install and connect the AC cables PE (A), L1 (B), L2 (C), and L3 (D).
NOTE
PE conductor must be installed to PE potential balance bar on the left side of the bottom wall of the cabinet.
- 2.Tighten the AC cable terminal screws to 40 Nm (29.5 lbf.ft).
Install - AC Cable for Multivoltage Charger
NOTE
AC cabling between transformer and charger cabinet is installed in the factory.
- 1.For multivoltage cabinet, AC supply cables are installed and connected to the transformer.
- 2.Depending upon the input voltage, connect the AC cables to the appropriate tapping on the transformer.
Install the Cover
- 1.Install the back plate of control unit to its original location in the reverse order again.
- 2.Install the power module of bottom section, dynamic module, control module (B), and base cover plate (C) again using screws.
- 3.Connect all RJ-45 cables (A) to RJ-45 sockets on the front plate of control module. The cables can be connected to any of the ports.
- 4.Install the bottom cover of the cabinet.
Install Charge Post
A | 400 mm (15.74 in.) |
B | 200 mm (7.87 in.) |
C | LMN=2 R |
D | R=10 x DC Cable diameter |
Install Charge Post
Charge posts must be installed to meet the cable bending radius, check limit from cable specifications.
NOTE
Follow mechanical or chemical anchor installation instructions.
- 1.Measure the distance of 240 mm (9.45 in.) on the sides of (A) and (B) to drill the holes.
- 2.Install with M16 anchors. Follow anchor manufacturers guidelines.
NOTE
M16 anchors is not included on delivery.
- 3.Remove the charge post from the palette.
- 4.Install the mains lead and stripe it.
- 5.Open the frame and pull the cables through the bottom.
NOTE
Cable groove is at the back.
- 6.Install the charge post and tighten the bolts (C) to 40 Nm (29.5 lbf.ft).
NOTE
Epoxy gets hard in 0.5 – 5 hr depending on conditions.
- 7.Check and tighten the frame sliders to 25 Nm (18.4 lbf.ft).
Connect the Cables
- 1.Install the charging cable inside the supporting springs.
NOTE
End of the charging cable that is to be connected to terminals has a white marking on the isolation surface. It indicates the correct length of cable to be pulled through the spring.
- 2.Put the cables and spring on the holder and turn to left or right on the front side of the charge post.
- 3.Tighten the cable holder ring on the bottom of the holder.
NOTE
Make sure that the cable double-membrane seals are firm on the holes. Use appropriate sealing aid to fill any openings.
- 4.Connect first PE part of the DC mains lead to PE on the charge post terminal block.
NOTE
Make sure to connect the DC charging cables to the terminals on appropriate polarity.
- 5.Connect all DC charging cables to the left side of the terminal block.
- 6.Torque tighten the DC cable (A) and PE terminal screws to 20 Nm (14.8 lbf.ft) tightness.
- 7.Connect the DC mains leads to the right side of terminal block on appropriate polarity.
- 8.Torque tighten the terminal screws to 20 Nm (14.8 lbf.ft) tightness, cross-check tightness on terminal screws on both sides.
Control Cable Connection
NOTE
For more information on installation diagram contact Epiroc.
A | CT B |
B | CT A |
C | GND (0V) |
D | +24V |
Install Liquid Cooled Satellite Post
NOTICE
Prerequisites
This task requires two people.
The Liquid Cooled Satellite weighs approximately 150 kg. Use suitable lifting device operated by qualified personnel.
Do not exceed the bending radius of the cable specified by the cable manufacturer.
NOTE
Use five M16 anchor bolts or equivalent per liquid cooled satellite installation flange.
- 1.Make sure that the installation flange is securely attached to the liquid cooled satellite.
- 2.Make sure that the front panel has enough space to open when liquid cooled satellite is installed.
- 3.Make sure that the bending radius of the cables is not exceeded when liquid cooled satellite is installed.
- 4.Route the cables to the liquid cooled satellite frame with the user interface.
NOTE
To make cable routing easier, strap the power and control cables together with electric tape or equivalent.
- 5.Drill the fixing holes as specified in Cabinet Foot Print and Fixing Points.
- 6.Install the fixing anchors in place. If necessary, use epoxy or equivalent to fasten them.
- 7.Make sure that the installation level is horizontal. If necessary, use washers.
- 8.If the cables are surface-installed, make an opening in the collar on the bottom of liquid cooled satellite for routing the cables.
- 9.The collar is plastic. Use a suitable tool such as a hole saw.
- 10.To make installing the cables easier, extend the opening to the bottom edge of the collar.
Opening in liquid cooled satellite collar for surface-installed cables - 11.Remove the three security T30H screws to open the front panel of the liquid cooled satellite.
- 12.Secure the front panel in the open position using duct tape or an equivalent material.
- 13.Lift the liquid cooled satellite into the installation position.
- 14.Route the cables through the installation flange before setting the unit in place.
- 15.Install the liquid cooled satellite on the fixing anchors or into the concrete element.
NOTE
Make sure that the unit is horizontally level after installation.
- 16.If using a concrete base, fill it with granular clay or an equivalent material once the installation is complete.
- 17.Connect all the charging cables to satellite.
Install Wall Charge Post
DANGER
High Voltage
High voltage installation can cause severe injury or death.
Make sure that the units are correctly isolated when necessary during installation, service, or maintenance work.
Know and obey general and local safety regulations and procedures.
Use adequate personal protection equipment (PPE).
NOTE
The Control Unit frame weighs approximately 12.5 kg without the charging cable.
NOTE
Do not exceed the bending radius of the cable.
- 1.Unlock and open the door of the charging power unit.
- 2.Set the miniature circuit breaker (MCB) for control voltage (B) and the main switch (A) to the OFF position in each cabinet.
- 3.Disconnect the AC power supply to the unit from the main supply point (C).
- 4.Complete the Lockout-Tagout procedure.
WARNING
Risk of Electric Shock
High-voltage electricity can cause severe damage or death.
After you disconnect the power supply, wait a minimum of two minutes for the capacitors of the power modules to discharge before you continue.
Before you start work, measure the voltage of the electrical circuits to make sure that no dangerous voltage remains.
- 5.Drill the fixing holes (D) 350 x 350 mm.
- 6.Open the control unit door and align the fixing holes.
- 7.Install the screws (E) into place. If necessary, use appropriate washers.
NOTE
Make sure that the installation level is horizontal.
NOTE
Use 6 mm fixing screws wall-mounted installations. Use 8 mm fixing screws for more challenging installations.
- 8.Route the charging cable into the unit, make sure that the wires reach the terminals.
- 9.Securely tighten the cable bushing.
- 10.Connect the charging cable wires to the terminals.
- 11.Tighten each screw terminal to the correct torque.
6–25 mm2: 12 Nm
35–95 mm2: 22 Nm
NOTE
Do not exceed the bending radius of the cable.
- 12.Route the supply cable into the unit and connect the wires to the terminals.
- 13.Tighten each screw terminal to the correct torque.
6–25 mm2: 12 Nm
35–95 mm2: 22 Nm
NOTE
Do not exceed the bending radius of the cable.
- 14.Route the control cable into the unit and connect the wires to the terminals.
NOTE
Do not exceed the bending radius of the cable.
- 15.Close the Control Unit door.
- 16.Connect the AC power supply to the unit from the main supply point (C).
- 17.Set the miniature circuit breaker (MCB) for control voltage (B) and the main switch (A) to the ON position in each cabinet.
- 18.Lock the doors of the unit.
Connecting the DC Input Power Cables to Liquid Cooled
NOTE
The liquid cooled satellite is delivered with the charging cable already installed.
Connect the DC input power cables from the Power Unit to the copper terminal bars of the liquid cooled satellite with cable lugs and M10 screws. Leave a minimum of 8 mm between the cable lugs. Connect the protective earth wire to the liquid cooled satellite's installation flange with a wire clamp.
Be careful not to damage the coolant hoses when you connect the power cables. The coolant hoses are routed to the frame with the liquid cooling unit from below the power cable terminal blocks.
The frame with the liquid cooling unit does not need any installation work. Make sure that there are no leaks and that the expansion tank in the liquid cooling unit is 1/3 full before you start operation.
The coolant system has a liquid level sensor that gives an alarm on the user interface screen when the system is powered on if the level of coolant is below the limit.
Liquid Cooled Satellite with One CCS Connector
NOTE
Grounding of the ethernet shield at one end only, charging power unit or satellite.
A | Configuration tag (right vehicle connector) |
B | CT A line signal wires (CT B not connected) |
C | Vehicle connector signal wires |
D | Charging cable |
E | PE wire connected to installation flange with wire clamp |
F | Communication cable |
G | DC output power cables + PE |
H | Configuration tag (right vehicle connector) |
Connecting the DC Input Power Cables to Wall Charge Post
Wall Charge Post with One CCS Connector
NOTE
Grounding of the Ethernet shield at one end only, either at the charging power unit or Control Unit.
A | Terminal block for power cable PE |
B | Fuse terminal block (24 VDC, 2 A) |
C | Charging cable Phoenix Connector |
D | DC+ terminal (X2+) |
E | DC-terminal (X2-) |
F | DC Voltage measurement fuses (1000 VDC) |
G | Voltage and insulation monitor (A019) |
H | Ethernet terminal |
J | Control cable auxiliary power wires (+24 V) |
K | Control cable ground wire |
L | Control cable (CT A) |
M | Equipment stop button |
N | Equipment stop button communication cable |
P | DC power charging cable (machine connector) |
Q | DC power cable from cabinet |
R | Control cable |
S | Equipment stop button cable |
T | Communication cable |