DC30kW Charger Installation Manual

Modified on Fri, 13 Dec, 2024 at 3:43 PM

TABLE OF CONTENTS

1. Safety Instructions
2. Introduction
3. Product Features
- 3.1 Product Parts
- 3.2 Nameplate
4. Transport and Storage
5. Preparation for Installation
6. Install Morek DC 30KW
7. Commissioning
- 7.1 Preparation for Power on
- 7.2 power on the charging station
8. Use of Morek DC30kW
9. Decommissioning

1. Safety Instructions

Read and observe the following safety precautions before you install, service or user your Morek charging station. The installer must ensure that the charging station is installed in accordance with the relevant country-specific standards and local regulations.

1.1 Symbols used in this manual

1.2 Save these instructions

This manual contains important instructions for Morek DC30kW Charging Station that need to be followed during installation, operation and maintenance of the unit.

1.3 WARNING: Risk of electric shock

Switch off input power to your charging station before you install or service the charging station. Keep the power off until the charging station is fully installed with its covers secured.
In the event of danger and/or an accident, a certified electrician must immediately disconnect the charging station from the electrical supply.
Do not operate the charging station if it is physically damaged or if the charging cable has cracks, excessive wear, or other visible damage. Contact Morek or your distributor if you suspect that the charging station is damaged.
Do not direct powerful jets of water toward or onto the charging station. Never operate it with wet hands. Do not put the EV charging plug into any liquid.
Do not place fingers or other objects inside the charging port or plug port.
Read the user instructions delivered with your Morek charging station and the User Manual for your electric vehicle before charging.

1.4 WARNING: Accumulation of gases

Some electric vehicles require an external ventilation system to prevent the accumulation of hazardous or explosive gases when charging indoors. Refer to your vehicle User Manual to check if your vehicle releases hazardous or explosive gases when charging.

1.5 CAUTION

Use this charging station to charge compatible electric vehicles only. Refer to your vehicle user manual to check if your vehicle is compatible.
This charging station may affect implanted electronic medical devices. Before you charge your vehicle, consult the supplier of the electronic medical device to determine if it can be affected by charging effects.
This charging station contains no user-serviceable parts. The user must not attempt to service, repair, or relocate the charging station. Contact Morek or your distributor for more information.
Make sure that the charging cable cannot be damaged (kinked, jammed, or driven over) and that the plug(s) do not come into contact with heat sources, dirt, or water.
Only use the charging station under the specified operating conditions.
Do not use explosives or flammable substances near the charging station.
If you are unsure about how to use a charging station, ask for help.
Do not allow children to operate a charging station. Adult supervision is required when children are near a charging station that is in use.
Adapters, conversion adapters, or cord extensions must never be used on this charging station.

1.6 Charging station safety precautions

CAUTION:

Do not open the charging station doors when:

It is raining, snowing.
The charging station is exposed to direct sunlight.
Weather conditions are wet (fog, ...).

Failure to follow these instructions can result in danger to the user and may void the warranty and liability.

This device contains components that can be damaged or destroyed by electrostatic discharge.

When handling this device, observe the necessary safety measures regarding electrostatic discharge (ESD) according to EN61340-5-1 and 61340-5-2.
This charging station must be stored and transported according to the specifications described in this manual.
Even if the charging station can be used by a non-qualified person, the charging station may only be installed, commissioned, serviced, relocated, repaired and decommissioned by qualified persons. Failure to follow these instructions can result in danger to the user and may void the warranty and liability.
Modification of the product is prohibited. It can result in danger to the user and may void the warranty and liability.
This charging station contains no user-serviceable parts. The user must not attempt to service, repair, or relocate the charging station. Contact Morek or your distributor for more information.
Make sure that the charging cable cannot be damaged (kinked, jammed, or driven over) and that the plug(s) do not come into contact with heat sources, dirt, or water.
Only use the charging station under the specified operating conditions.
Do not use explosives or flammable substances near the charging station.
Do not use peripherals, consumables or accessories that do not conform or are unsuitable for the charging station.
Do not use anti-graffiti treatment that may damage the charging station.
Do not modify the features of the charging station (data settings, cabling, …).
This charging station must be protected against animals, object intrusion or water ingress even if they do not alter charging station operation.

Failure to follow these instructions will result in damage to the charging station.

1.7 Safety Labels on the packaging

2. Introduction

This Installation and User Manual outlines the installation requirements and steps for Morek DC30kW charging station, as well as how to use the station.

CAUTION:

This equipment is not intended for use in residential environments and may not provide adequate protection to radio reception in such environments.

2.1 Important information

The document is produced for information purposes only and does not constitute an offer binding upon Morek. Morek has compiled the contents of this document to the best of its knowledge. No express or implied warranty is given for the completeness, accuracy, reliability, or fitness for particular purpose of its content and the products and services presented therein. Specifications and performance data contain average values within existing specification tolerances and are subject to change without prior notice. Prior to ordering, always contact Morek for the latest information and specification. Morek explicitly waives liability for any direct or indirect damage, in the broadest sense, arising from or related to the use and/or interpretation of this document. ©Morek. All rights reserved.

2.2 Scope of the Document

Keep this manual for the entire lifetime of Morek DC30kW charging Station.

CAUTION:

This manual is intended as a resource for qualified personnel with experience in working on High Voltage projects who are capable of identifying the requirements and taking all necessary precautions to safely complete a Morek DC 30KW installation.

2.3 Product Introduction

Morek DC 30kW EV charging station optimizes the use of space with it's reduced depth and ability to be mounted either on a pole or a wall. 7" Touch screen ensures smooth interaction between the User and the device.

2.4 Product Specification

Specifications are listed in a separate article: DC30kW Charger

2.5 List of Tools

CAUTION:

Some operations described in this manual may require a ladder or a stepladder. Refer to your local regulation regarding the working height and relevant safety instructions.

Below is the list of the tools required (not included) to install Morek DC30kW charging station:

Needle nose pliers
Utility knife
Phillips screwdriver
M12*100 expansion screw
Percussion drill + φ12 drill
Afterburner lever
13# ratchet wrench
18# ratchet wrench

The connecting point of the EV supply equipment shall be protected by an RCD having a rated residual operating current not exceeding 30 mA,RCD(s) protecting connecting points shall be at least type A, Rated voltage 400V, rated current at least 80A. You need to add AC molded case circuit breaker with leakage protection function in the front of single equipment.

3. Product Features

3.1 Product Parts

3.2 Nameplate

The nameplate is located at the bottom of the left side.

4. Transport and Storage

4.1 Storage

WARNING:

Condensation inside the cabinet damages the charger.

Only transport and store the charging station in its original packaging. No liability can be accepted for damage incurred when the product is transported in non-standard packaging.
Store the charging station away from exposure to the sun and in a dry environment in the temperature range stated in the specifications.
Disconnect input power before removing the charging station for storage or relocation.

Failure to follow these instructions will result in waiver of warranty and product damage.

4.2 Transport

WARNING:

Damaged product.

After any transportation, make a detailed visual inspection of the charger with its packaging opened. Reject the product if there is any visible damage. Make all damage claims to the transport operator immediately and also immediately inform the sender regarding transport insurance.

Failure to follow these instructions can result in death, serious injury or equipment damage.

Visual inspection

Check if:

The exterior packaging has been damaged.
The exterior panels of the charger are damaged (shock, scratch, ...).
The doors are working properly.
The interior of the charger is clean and undamaged

4.3 Packed Product Handling

1. Handling with a forklift

Handle the packed product with a forklift (No more than 3 units on the pallet).

2. Manual Materials handling

Two persons are required to move one cabinet at a time.

4.4 Packaging Removal

CAUTION:

Some operations described in this manual may require a ladder or a stepladder.

Refer to your local regulation regarding the working height and relevant safety instructions.

1. Remove the metal clips that hold the wooden package.

Tools: needle-nose piler and an iron crowbar.

2. Put them aside.

3. Remove the roof cover.

4. Remove the left and right side covers.

5. Remove the front and back covers.

6. Remove the wrapping film wrapped around the cabinet.

7. Remove the PE plastic bag over the cabinet.

8. Remove the EPE cushioning blocks around the cabinet.

4.5 Supplied Components

The packaging includes the following components:

Charging station
Accessories

5. Preparation for Installation

The following recommendations are intended as a guide to help you prepare for the installation of Morek DC30kW charging station.

5.1 Safety precautions

You must read and observe the Safety instructions on page 3 at the beginning of this manual before you install, service, or use Morek DC30kW charging station. The installer must ensure that the charging station is installed in accordance with the relevant country specific standards and local regulations.

5.2 Plan the installation

Calculate the existing electrical load to determine the maximum operating current for the charging station installation.
Calculate the distance from the local power supply panel to the charging station installation to find the voltage drop. Local regulations may apply and can vary depending upon the region or country.
Obtain all necessary permits from the local authority that has jurisdiction.
PE grounding connectors must be not spliced.
Refer to local regulations, maximum current and voltage drop to select the conductor sizes.
Use the correct tools and ensure sufficient material resources and protection measures.
Make sure that there is good cellular reception where the charging station will be installed.
Prepare the installation areas with the correct power wiring and data cabling.
Prepare the upstream electric switchboard according to local regulations and Morek recommendations

Ethernet network

To connect several Morek DC30kW charging station (for network sharing), it is necessary to install an Ethernet network

5.3 Select the location

The charger is intended for outdoor or indoor areas.

Position the charging station, where possible, in surroundings where it is not exposed to extreme sunlight and vulnerable to external damage.

The charger is intended for location in a non-restricted area.

5.4 Parking space placement

To achieve the maximum cable length, it is recommended to place Morek DC 30KW as described below.

Note:

Leave adequate free space in front of the charging station to ensure that users can interact with the touchscreen and other interfaces safely and comfortably.
Leave at least 600 mm on both side of the charger in order to ensure the connector is accessible.

Note:

Bollards should not interfere with the clearance around the charger.

5.5 Cooling

The air inlet is located at the bottom of the cabinet, and the air outlet is located on the left side of the cabinet.

Note:

In locations with harsh weather conditions (high temperatures, snow, strong sun conditions,...), it is recommended to ensure additional protection such as canopy or roof protection.

5.6 Implantation plan

5.6.1 Column installation

The opening size of the equipment is shown in the figure:

5.6.2 Wall mount installation

The opening size of the equipment is shown in the figure:

Explanation:

1. The installation position of the charging pile shall be determined according to the site

2. M8 stainless steel expansion bolt (length not less than 60mm), it must be perpendicular to the foundation surface, and ensure that 3 to 4 silk teeth are exposed after the nut is tightened.

3. All dimensions in the figure are in mm.

4. Matters not mentioned in the drawing shall be carried out according to the current national norms.

5. The distance between the front door of the equipment and the obstacle is not less than 0.8m, and the distance between the left and right sides and the wall is not less than 0.8m.

5.7 Route power supply cables

Prepare the cable and use standardized cable only.For AC cable, For AC cable, we suggest using cable size is 3*25+2*16mm².AC cable size depends on system configuration and local regulations. Refer to electrical installation drawings or discuss with electrical designer for further information.

Note:

Adaptors or conversion adapters are not allowed to be used. Cord extension sets are not allowed to be used.

5.8 Protection against electric shock and short circuits

Protection against electric shock

The charging station contains the following devices to protect against electric shock:

IMD (Insulation Monitoring Device). On outlet CCS2.
Surge protector
MCB for AC Input
Leakage protection device for AC input

The following device is not included in the unit and must be installed in the switchboard upstream:

Refer to local regulations, maximum current and voltage drop to select the device against electric shock in switchboard upstream.

Short circuit protection

The charging station contains the following devices to protect against short circuit:

CCS2 outlet is protected by fuse.

5.9 Electrical requirements

5.9.1 Upstream requirements

Charging station

Electrical connection must be carried out by a professional electrician according to the local regulations.

Charging station must be connected to an electrical network with the following characteristics:

3 Phases (3P + PE +N*) (*Neutral required in case of AC socket).
400 Vac +/- 10%
50/60 Hz

The main switch disconnector, located upstream of the charger power supply, must be rated by the installer.

Refer to local regulations, maximum current and voltage drop to select the upstream protection.

Note:

A RCD 30mA type A is required as minimum.

5.9.2 Grounding Instructions

Observe the following rules for the grounding instructions:

Ground impedance must be lower than 20 ohms in dry conditions where the charging station is installed.

6. Install Morek DC 30KW

6.1 Handling

WARNING:

Always transport the charger in an upright position.
Do not manipulate the charger when it is connected to the power supply.
Do not use a crane type hoist that is unable to support the weight of the charger.
The center of gravity of the charger is high, take care when handling.
Do not place your hand underneath the charger or inside the feet through the side openings.
The charger must be protected against overturning. This protection must be maintained until final mounting.

6.2 Installing a cabinet

Wall-mounted installation

1. Mark the center position of each mounting hole on the wall according to the wall-mounted construction drawing of a 30kW cabinet.

2. Use a φ12 drill bit to drill a 45mm deep mounting hole at the marked point, remove dust from the hole, and insert an expansion tube (M8*60) into the mounting hole.

3. Install cabinet mounting ears on the wall according to the holes, and secure them using the nuts delivered with expansion bolts.

4. Lift the 30kW wall hanging cabinet, align the upper and lower projecting parts of the cabinet with the long holes above the mounting ears on the wall, and place the cabinet into the mounting ears.

5. Open the cabinet door and install the M6 bolts and washers in the accessories to the place marked with anti-theft screws.

Vertical column installation

1. Mark the center of each mounting hole on the concrete floor according to the opening size of the 30kW vertical column base.

2. The embedded M10*100 bolts should be perpendicular to the foundation surface and the exposed length should be 30mm.

3. If an expansion screw is used, drill a diameter of 70mm deep into a hole with a drill bit of 12mm diameter at the marked point.

4. Remove dust from the hole, insert an expansion tube (M10*100mm) into the hole, and secure it with M10 nuts.

After the cabinet is installed, shake the cabinet from different directions. No obvious loosening or shaking should be felt.

6.3 Opening the door of Morek DC30kW

CAUTION:

When opening the door, please follow the instruction next to the door lock.

Failure to follow this instruction will result in visible damage to the product.

Tool: Door Key

Locate the handle:

Open the door:

1. Use the key to open the lock.

2. Pull out the handle.

3. Turn the handle clockwise.

4. Open the door.

6.4 Electrical Connections

The steps to connect the cable are as follows:

1. Open the front door of the cabinet.

2. Ensure that the front switch of the cable is powered off to prevent electric shock.

3. Securely connect one end of the grounding cable to the grounding copper bar.

4. Connect AC input three-phase cables L1, L2 and L3 to input copper bars A, B and C respectively; the N wire is connected to the N wire copper bar.

6.5 Check after Installation

1. Sealing

According to the requirements of the design and protection level, After the AC cable is installed, lock the cable lock to prevent dust or bugs from entering.

2. Cleanup

Clean up the sundries inside the cabinet and around the cabinet, such as cables, binding tapes, screws, etc. Do not leave installation tools on site or in the cabinet.

3. Final check

Check whether the base is firmly installed.

Check whether the electrical connections and cables are correct and complete, the connections are tight, and whether the grounding is reliable.

Check appearance, marking, cleanliness.

7. Commissioning

DANGER:

Risk of electric shock.

Before commissioning or servicing, switch off the power at the main breaker and switch off the MCB in AC power supply system.

Powering on the charging station

During operation, pay attention to the danger of high voltage to avoid personal injury and property damage. The system must be well grounded before power-on. An installation check must be carried out before commissioning. Confirm that the main AC input switch Q1 and circuit breakers Q3 are disconnected, and the charging gun head is on the cabinet body, and ensure that all devices are installed in place.

7.1 Preparation for Power on

1. Make sure that the upstream power supply switch of the charging system is disconnected.

2. Use a multimeter to confirm that there is no short circuit between the AC input L1\L2\L3\N\PE.

3. Use a multimeter to measure and confirm that there is no short circuit between DC+\DC- \PE of the charging gun head.

4. Turn on the upstream power supply switch of the system.

5. Use a multimeter to measure that the three-phase input power supply voltage in the charging system cabinet is within the allowable working voltage range of the system (323VAC ~ 460VAC).

7.2 power on the charging station

1. Connect the AC input general MCB Q1 of the charging system.

2. Connect the circuit breakers Q3 of the front cabinet door of the charging system, and close the front door.

3. After 2s, the system will automatically pull in the AC input contactor after the system self-check is passed, and the power module is electrified.

8. Use of Morek DC30kW

The charger can be used by ordinary people (no special qualification or training is needed).

The owner of the charging station shall provide to the customer with all the procedure, security and warning related information.

Because of Firmware development, some UI elements might change. For up to date usage and configuration instructions, check DC Charger User Interface Guide.

WARNING:

Do not operate the charging station if it is physically damaged or if the charging cable has cracks, excessive wear, or other visible damage. Contact Morek or your distributor if you suspect that the charging station is damaged.
Do not direct powerful jets of water toward or onto the charging station. Never operate it with wet hands. Do not put the EV charging plug into any liquid.
Do not place fingers or other objects inside the charging port or plug port.
Read the user instructions supplied with your Morek charging station and the User Manual for your electric vehicle before charging.
Make sure that the charging cable cannot become damaged (kinked, jammed, or driven over) and that the plug(s) do not come into contact with heat sources, dirt, or water.
When the cable is connected on the charging station, do not leave the cable lying around on the floor.

9. Decommissioning

Remove and dispose of the charging station in accordance with applicable local disposal regulations.

DANGER:

Risk of electric shock.

Before the charging station is removed, switch off all power at the power supply cabinet. Secure the power supply cabinet and put up warning signs to prevent accidental supply of power.

To remove Morek DC 30KW charging station, follow the installation steps listed above in reverse order.

Dispose of the charging station in a responsible manner.

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If you encounter any issues or have questions, please Submit a ticket.