TABLE OF CONTENTS

• 1. Safety Instructions
  • 1.1 Symbols used in this manual
  • 1.2 Save these instructions 
  • 1.3 WARNING: Risk of electric shock 
  • 1.4 WARNING: Accumulation of gases 
  • 1.5 CAUTION 
  • 1.6 Charging station safety precautions 
  • 1.7 Safety Labels on the packaging 
• 2. Introduction 
  • 2.1 Important information
  • 2.2 Scope of the Document 
  • 2.3 Product Introduction 
  • 2.4 Product Specification 
  • 2.5 List of Tools 
• 3. Product Features 
  • 3.1 Product Parts 
  • 3.2 Nameplate 
• 4. Transport and Storage
  • 4.1 Storage 
  • 4.2 Transport 
  • 4.3 Packed Product Handling 
  • 4.4 Packaging Removal 
  • 4.5 Supplied Components 
• 5. Product Handling
  • 5.1 Handling with a forklift
• 6. Preparation for Installation
  • 6.1 Safety precautions
  • 6.2 Plan installation 
  • 6.3 Select location 
  • 6.4 Parking space placement 
  • 6.5 Cooling
  • 6.6 Clearance
  • 6.7 Foundations
  • 6.8 Implantation plan
  • 6.9 Route power supply cables
  • 6.10 Protection against electric shock and short circuits
  • 6.11 Electrical requirements
    • 6.11.1 Upstream requirements
    • 6.11.2 Grounding Instructions
• 7. Install Morek DC180kW & DC120kW 
  • 7.1 Handling
  • 7.2 Open the door of Morek DC180kW & DC120kW 
  • 7.3 Remove the left and right plinth and the wooden pallet
  • 7.4 Placing
  • 7.5 Remove the lower plastic cover 
  • 7.6 Electrical Connections
• 8. Commissioning
  • 8.1 Operation of power on the charging station 
  • 8.2 Preparation for Power on
  • 8.3 Power on the charging station 
• 9. Use of Morek DC180kW & DC120kW 
• 10. Decommissioning
• 11. Preventative Maintenance

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 DC180kW & DC120kW 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 DC180kW & DC120kW 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 DC180kW & DC120kW 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 DC180kW & DC120kW installation.

© 2023 Morek - all rights reserved. No part of this document may be modified, reproduced, processed, or distributed in any form or by any means, without the prior written permission of Morek. 

2.3 Product Introduction 

Morek DC180kW & DC120kW 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 [HERE]

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 DC180kW & DC120kW 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 of at least 250A for 120kW and a rated current of at least 350A for 180kW . 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. Product Handling

5.1 Handling with a forklift

Morek DC180kW & DC120kW  can be handled using a forklift. 

6. Preparation for Installation

The following recommendations are intended as a guide to help you prepare for the installation of Morek DC180kW & DC120kW charging station.

6.1 Safety precautions

You must read and observe the Safety instructions on page 4 at the beginning of this manual before you install, service, or use Morek DC180kW & DC120kW charging station. The installer must ensure that the charging station is installed in accordance with the relevant country-specific standards and local regulations.

6.2 Plan 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 DC180kW & DC120kW  charging station (for network sharing), it is necessary to install an Ethernet network.

6.3 Select 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.

Note: 

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

6.4 Parking space placement 

To achieve the maximum cable length, it is recommended to place Morek DC180kW & DC120kW 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.

6.5 Cooling

The air inlet is located on the right door of the cabinet, and the air outlet is located on the left door of the cabinet. 

6.6 Clearance

6.7 Foundations

Observe the following rules regarding the foundations:

• Foundations must be carried out in accordance with local regulations. 
• Concrete characteristics must be calculated based on the technical data of the charging station. 
• The concrete should be frost-proof. 
• Thickness of the foundations must be calculated in accordance with the weight of the system and the installation site. 23 / 48 
• The foundation must be flat and leveled. 
• A slope deviation to the left/right or front/back may cause infiltration of water and damage the charging station. 
• Foundations must be under the ground. 
• Charger must be installed on the ground.

6.8 Implantation plan

Prepare the foundations according to the diagram below: 

6.9 Route power supply cables

Prepare the cable and use standardized cable only. For AC cable, we suggest using cable size 3*95+2*50mm² for DC120kW, and 3*185+2*95mm² for DC180kW. 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. 

6.10 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 each CCS2 outlet
• Surge protector 
• MCB for AC Input 
• RCD (Residual Current Device) on 12 Vdc power supply 

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.

6.11 Electrical requirements

6.11.1 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. 

6.11.2 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.

7. Install Morek DC180kW & DC120kW 

7.1 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.

7.2 Open the door of Morek DC180kW & DC120kW 

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.

7.3 Remove the left and right plinth and the wooden pallet

Tool: Phillips screwdriver 

1.    Locate the left and right plinth.

2.    Loosen 2pcs of M6 nuts on each side.

3.    Remove the left and right plinth.

4.    Remove the 4pcs of M12 nuts (fixing the wooden pallet) and spacers on both sides.

5.    Remove the wooden pallet.

7.4 Placing

When the installation area is prepared, you can install and connect the charging station. 

1.    Use a crane to hoist the charging station and place it on the treated foundation, make sure that the φ15 mounting hole reserved on the charging station is aligned with the M12 expansion bolt on the foundation, and tighten it with a wrench.

2.    After the cabinet is installed, shake the cabinet from different directions, and you should not feel any obvious looseness or shaking. 

3.    Install the left and right plinth at the bottom of the charging station.

7.5 Remove the lower plastic cover 

Tool: Phillips screwdriver 

1.    Locate the lower plastic cover.

2.    Loosen the 3pcs M4 nuts that hold the plastic cover.

3.    Remove the plastic cover

7.6 Electrical Connections

Cable connection

1.    Open the front door

2.    Take live lines, neutral line and earth line from outside to inside through protecting holes on the bottom of equipment cabinet.

3.    Connect earth line to PE strip. Connect 3 live lines and 1neutral line to L1\L2\L3\N screws. Follow the instruction as showing below.

4.    Seal the protecting holes to prevent the enter of foreign matter by using fireproofing mud.

8. 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.

8.1 Operation of power 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. 

8.2 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 two charging gun heads. 

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).

8.3 Power on the charging station 

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

2.    Connect the circuit breakers Q3 and Q4 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.

9. Use of Morek DC180kW & DC120kW 

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.

10. 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.

11. Preventative Maintenance

For safe operation of the charger and to ensure a continuous and adequate level of service for users, regular maintenance and control of the equipment is required. 

In addition to these regular maintenance operations, in case a fault or suspected fault, a corrective maintenance operation must be performed. 

Below is the recommended preventive maintenance plan. If the operating environment is harsh (such as sandy environment, dusty environment, etc.), please shorten the maintenance cycle as appropriate. 

Accident handling 

Catastrophic accidents include charging equipment failures caused by lightning strikes, flooding, earthquakes, fires and other disasters. For disasters that may seriously affect safety, prevention should be the priority. At the same time, the charging station should have countermeasures and corresponding manpower and material resources to deal with these disasters, and should have emergency management regulations and major accident repair procedures.

It is recommended that when there is water immersion near the charging device, all switches inside the charging station should be disconnected, and the upstream power supply switch of the charging station should be disconnected to ensure the safety of personnel and prevent electric shock. The power module can be pulled out to minimize losses.

Note: 

When the high-voltage power distribution of the upstream transformer of the charging equipment is cut off, the MCCB Q1 in the charging equipment should be disconnected immediately to prevent the voltage shock causing damage to the charging equipment after the high-voltage power distribution of the upstream transformer is restored. damage. Please wait for the high voltage distribution of the upstream transformer to be restored before restoring the power supply to the charging equipment

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