ABB DuraStation EVSE Charging Station Installation Instructions

g

EV Charging Station --

Installation Instructions --

DuraStation™ EVSE CHARGING STATION

INSTALLATION INSTRUCTIONS

WALL-MOUNT

POLE-MOUNT

Rev. 2

9/2016

PEDESTAL

DEH41709

BACK TO BACK

1 of 22

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Table of Contents

1.

Important Safety and Grounding Instructions ................................................................................................. 3

1.1

Safety and Compliance ........................................................................................................................... 3

1.2

Grounding Instructions ........................................................................................................................... 3

2.

Installation Instruction ................................................................................................................................... 3

2.1

Before Installing ..................................................................................................................................... 3

2.2

Safety Requirements .............................................................................................................................. 3

2.3

Installation Overview and Specifications ................................................................................................. 3

2.4

Pedestal ..................................................................................................................................................5

2.5

Back To Back ......................................................................................................................................... 10

2.6

Wall-Mounted ....................................................................................................................................... 15

2.7

Pole-Mounted ....................................................................................................................................... 19

2.8

Replacement Part Installation ........................................................... Error! Bookmark not defined.

2.8.1

VFD .............................................................................................. Error! Bookmark not defined.

2.8.2

Charging Cord .............................................................................. Error! Bookmark not defined.

2.8.3

Holding Socket ............................................................................. Error! Bookmark not defined.

2.8.4

Service Door ................................................................................. Error! Bookmark not defined.

2.9

Wiring Diagram ................................................................................ Error! Bookmark not defined.

3.

User Manual ............................................................................................ Error! Bookmark not defined.

3.1

Receiving ......................................................................................... Error! Bookmark not defined.

3.2

Basic User Instructions ..................................................................... Error! Bookmark not defined.

3.3

Technical Data ................................................................................. Error! Bookmark not defined.

3.3.1

Display fault messages ................................................................. Error! Bookmark not defined.

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1.

Important Safety and Grounding Instructions

1.1

Safety and Compliance

This document provides instructions for installation of EV Charging Station products listed in Table 8 in

Section 3.3, and should not be used for any other product. Before installing the EVSE (Electric Vehicle

Supply Equipment), you should review this manual carefully and consult with a licensed contractor, licensed electrician, or trained installation expert to ensure compliance with local building codes, climate conditions, safety standards and state and local electrical codes.

The EVSE should be installed only by a licensed contractor, and/or a licensed electrician in accordance with all applicable state, local and national electrical codes and standards. The EVSE should be inspected by a qualified installer prior to initial use. Under no circumstances will compliance with the information in this manual relieve the user of his/her responsibility to comply with all applicable codes or safety standards.

1.2

Grounding Instructions

The EVSE must be connected to a grounded, metal, permanent wiring system, or an equipment grounding conductor. This should be run with circuit conductors and connected to the equipment grounding bar or lead on the EVSE. Connections to the EVSE shall comply with all applicable electrical codes and ordinances.

2.

Installation Instruction

2.1

Before Installing

Before any installation work is performed, study all drawings furnished by the supplier for the particular installation.

These include arrangement drawings (front, end, and plan views), connections to the equipment that may be required to meet any local codes (such as mats, screens, or railings) is not furnished.

2.2

Safety Requirements

• Eye protection with appropriate glasses (especially when using the electrical drill).

• In the installation be sure to not connect directly to power distribution network cables without additional protection.

• Ensure that at all times when working, no power is connected.

• Use appropriate tools for each function (the appropriate bit to the material to work).

• Turn off the machine (better unplugged) for a bit change or cleaning.

• Keep in mind the general security requirements common to all electrical appliances (not to put them near sources of heat or humidity, do not pull the cable, etc).

2.3

Installation Overview and Specifications

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This document describes how to install any EVSE charging station family.

It includes step-by-step instructions for installing the body assembly for the following stations:

• Pedestal

• Back to Back

• Wall- Mounted

• Pole-Mounted

EVSE Torque Specification Table

Rev. 2

9/2016

- Table 1 -

Tools

Type

Slotted Screwdriver

Phillips Screwdriver

3/16” or ¼”

#2

Characteristics

Socket

Electric Drill

Socket sizes: 7/16”, ¾”

Used in the wall mounted and pole mounted installations

Wire stripper, hammer, and wall anchors

- Table 2 -

WARNING : Make sure power to the EVSE is shut off before performing any task

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2.4

Pedestal

Bill of materials

ITEM

1

2

3

4

5

6

7

DESCRIPTION

Kiosk Pedestal Unit

Base Mounting Assembly

Kiosk Skirting

Base Mounting Template, NEMA 3R

Hex Nut, ½” SS

Washer, Plain, ½” dia. SS

Lock Washer, External Tooth, ½” SS

- Table 3 -

Rev. 2

9/2016

DEH41709

QTY

1

1

1

1

12

4

8

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Procedure

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The conduits must extend minimum 5” above the concrete floor, or according to local codes.

Install mounting template securely over these conduits.

CONDUITS

KIOSK SKIRT

WASHER

Figure 2: Pedestal Base Installation

Rev. 2

9/2016


Adjust nuts to position height, position mounting template, and pour concrete to level shown in

Figure 3. Do not cover the nuts with concrete. Verify that the final surface is completely smooth. The

Mounting template is for concrete installation only, and requires removal after concrete is poured.

Install nuts and washers, after lowering skirt over matching threaded rods over the nuts.

Use the bottom nuts for leveling the skirt. Torque nuts per specification Table 1.

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Ensure the body casing is firmly aligned to the bottom surface and that no movement (rocking) can take place, even when significant pressure is applied.

Open the door with the corresponding key by the door latch.

Insert the Kiosk from top and Install nuts, star washers, and flat washers, after lowering skirt over matching threaded rods as shown in Figure 4.


Torque all the nuts as per the torque specification in Table 1.

Connect the different wires to the power circuit: Pull lines into the body assembly and connect to the fuse block as illustrated in Figure 5.

Ground wire is connected to a ground bar prepared for that connection, as illustrated in Figure 5.

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Fuse Block

Ground Bar

Incoming Power

Figure 5: Power Wire and Ground Wire Connections for Pedestal

Rev. 2

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DEH41709

Fuse Block

Ground Bar

Incoming Power Cables

Connect at Bottom

Terminals of Fuse Block

Ground Wire Connects to

Ground Bars

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2.5

Back To Back

Bill of materials

ITEM

1

2

3

4

5

6

7

DESCRIPTION

Kiosk Pedestal Unit

Base Mounting Assembly

Kiosk Skirting

Base Mounting Template, NEMA 3R

Hex Nut, ½” SS

Washer, Plain, ½” dia. SS

Lock Washer, External Tooth, ½” SS

- Table 4 -

Rev. 2

9/2016

DEH41709

QTY

1

1

1

1

12

4

8

10 of 22

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Procedure

Rev. 2

9/2016

Figure 7: Exploded double pedestal base assembly

Locate area for pedestal location.

Maintain the alignment of the base as shown in Figure 7.


IMPORTANT: EV Charging Station is rated for 120V or 208-240V power only. The EVSE must be connected to a grounded, metal, permanent wiring system, or an equipment grounding conductor.

This should be run with circuit conductors and connected to the equipment grounding bar or lead on the EVSE. Connections to the EVSE shall comply with all applicable electrical codes and ordinances.

The conduits must extend minimum 5” above the concrete floor, or according to local codes.

Install mounting template securely over these conduits.

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CONDUITS

KIOSK SKIRT

Figure 8: Double pedestal base assembly

WASHER

Rev. 2

9/2016

Figure 9: Double pedestal base assembly

Adjust nuts to position height, position mounting template, and pour concrete to level shown in

Figure 9. Do not cover the nuts with concrete. Verify that the final surface is completely smooth. The mounting template is for concrete installation only, and requires removal after concrete is poured.

Install nuts and washers, after lowering skirt over matching threaded rods over the nuts.

Use the bottom nuts for leveling the skirt. Torque nuts per specification Table 1.

Open the door with the corresponding key by the door latch.

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Insert the Kiosk from top and Install nuts, star washers, and flat washers, after lowering skirt over matching threaded rods as shown in Figure 10.

Figure 10: Double Pedestal Base Installation




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Fuse Blocks

Ground Bars

Fuse Blocks

Incoming Power


Connect at Bottom

Terminals of Fuse Blocks

Ground Wires Connect to

Ground Bars

Ground Bars

Figure 11: Power Wire and Ground Wire Connections for Double Pedestal

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2.6

Wall-Mounted

Bill of materials

ITEM

1

DESCRIPTION

Kiosk Unit

CHARACTERISTICS

Wall mounted enclosure

2

3

Wall Bracket Assembly

Hex. Nuts ¼”-20

(4) ¼”-20 Weld Stud

Zinc Plated Steel, Flanged

Locknut

4

5

6

7

Anchor Bolt, 3/8-16

Sealing Washer, ¼” dia.

Washer plain, 1” dia.

Conduit Hub, ¾”

Drill ½” dia. hole

Seals ¼” studs

Included with 3/8” Anchor Bolt

Attach to ¾” conduits/enclosure

- Table 5 -

QTY

1

1

4

4

4

4

2

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Procedure


Drill 6 holes in the wall, as illustrated in Figure 13. Use the supplied template to ensure correct alignment.

IMPORTANT: Exercise extreme caution when drilling holes in the wall. Make sure there are no electrical cables.

Figure 13: Wall-Mount Bracket Holes

Figure 14: Wall-Mount Bracket

IMPORTANT: The maximum height above the surface should be set to meet any local or national requirements for persons with disabilities. It is recommended that the lowest part of the socketoutlet, shall be located at a height between 16” and 60” above ground level.

Using the 6 installer-supplied lag screws and anchors, fasten the wall base bracket to the wall.

Supply (2) ¾” conduits as per bracket drawing dimensions, and connect supplied ¾” conduit hubs to conduits. Ensure that conduit hubs seal against wall-mount enclosure per following section view.

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Install the kiosk wall mounted unit in the wall base bracket, using the nuts, star washers, flat washers, and nuts as indicated in Figure 15.

CONCRETE ANCHOR

WALL-MOUNT BRACKET

3/8-16 NUT

WALL-MOUNT

UNIT

(2) ¾” CONDUITS

Rev. 2

9/2016

¼-20 HEX NUT, ¼: SEALING WASHER

¾” CONDUIT HUB

Figure 15: Wall-Mount Installation, Exploded View

IMPORTANT: EV Charging Station is rated for 120 or 208-240V power only. The EVSE must be connected to a grounded, metal, permanent wiring system, or an equipment grounding conductor.


The cables must extend 16” to 24” above the wall surface, or according to local codes.



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In case of RFID sensor the communication cable is connected to the Ethernet connector on the controller, just like the pedestal example as shown in Figure 6.

.

Ground Bar

Fuse Block


Connect at Terminals of

Fuse Block

Ground Wire Connects to

Ground Bar

Rev. 2

9/2016

Figure 16: Power Wire and Ground Wire Connections for Wall Mount

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Figure 17: Wall-Mount Conduit Installation

Default Fitting Locations

2.7

Pole-Mounted

Bill of materials

Figure 18: Wall-Mount Conduit Installation

– Alternate Knockouts on Bottom of Unit

ITEM

1

2

3

4

5

6

DESCRIPTION

Kiosk Unit

Pole-bracket Assembly

Band Clamp

Hex. Nuts ¼-20

Sealing Washers, ¼”

Conduit Hub, ¾”

CHARACTERISTICS

Pole-Mounted

Bracket & ¾” Banding

¾” Stainless Steel Clamp

Supplied with EVSE unit

Seals ¼” studs

Attach to ¾” conduits/enclosure

QTY

1

1

2

4

4

2

- Table 6 -

Procedure


Drill the different holes in the pole to accommodate the two couplings and the two screws for the base-mounting fixation.

IMPORTANT: Exercise extreme caution when drilling holes in the pole. Make sure there are no electrical cables.

Insert the coupler into the hole and hold the body assembly in place using a temporary strap.

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IMPORTANT: The maximum height above the surface should be set to meet any local or national requirements for persons with disabilities. It is recommended that the lowest part of the socketoutlet, shall be located at a height between 36” and 48” above ground level.

Figure 19: Pole Mount Installation, Critical Dimensions

Strap the body assembly to the pole using (¾”), (0.030”) stainless steel banding.

IMPORTANT: You must use a high tension-banding tool to install bands.

Install the kiosk pole mounted unit , using the nuts, star washers, and flat washers nuts as indicated in the following picture. Torque all the nuts as per the torque specification in Table 1.

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Figure 20: Default Pole-Mount Installation, Exploded View

Rev. 2

9/2016

Figure 21: Pole-Mount Conduit Using Side

Fittings Installations

Figure 22: Alternate Pole-Mount Conduit

Installation Using Bottom Knockouts

IMPORTANT: EV Charging Station is rated for 120V or 208-240V power only. The EVSE must be connected to a grounded, metal, permanent wiring system, or an equipment grounding conductor.


The cables must extend 16” to 24” above the pole surface, or according to local codes.

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Connect the different wires to the power circuit: Pull lines into the body assembly and connect to the fuse block as illustrated in Figure 16 (same as wall mounted unit).

Ground wire is connected to a ground bar prepared for that connection, as illustrated in Figure 16

(same as wall-mounted unit).

* SAVE THESE INSTRUCTIONS*

The instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred to the GE company.

GE Industrial Solutions

41 Woodford Ave.

Plainville, CT 06062 www.geindustrial.com

Rev. 2

9/2016

DEH41709 22 of 22

ABB DuraStation EVSE Charging Station Installation Instructions

DuraStation™ EVSE CHARGING STATION

INSTALLATION INSTRUCTIONS

1.

Important Safety and Grounding Instructions

1.1

Safety and Compliance

1.2

Grounding Instructions

2.

Installation Instruction

2.1

Before Installing

2.2

Safety Requirements

2.3

Installation Overview and Specifications

2.4

Pedestal

2.5

Back To Back

2.6

Wall-Mounted

2.7

Pole-Mounted

* SAVE THESE INSTRUCTIONS*

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