Leviton Evr-Green DC Installation Manual
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Leviton Evr-Green DC Installation Manual

Electric vehicle charging station for public use
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Evr-Green DC
Electric Vehicle Charging Station for Public Use
CAT. NO: CPDCF
Installation Guide
for Standalone and Paired Stations
Express 250
DC Fast Charging Station

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Summary of Contents for Leviton Evr-Green DC

  • Page 1 ® Evr-Green DC Electric Vehicle Charging Station for Public Use CAT. NO: CPDCF Installation Guide for Standalone and Paired Stations Express 250 DC Fast Charging Station...
  • Page 2 IMPORTANT SAFETY INSTRUCTIONS: SAVE THESE INSTRUCTIONS WARNING: 1. Read and follow all warnings and instructions before installing and operating the ChargePoint® Charging Station. Install and operate only as instructed. Failure to do so may lead to death, injury, or property damage, and will void the Limited Warranty. 2.
  • Page 3 Copyright and Trademarks ©2013-2019 ChargePoint, Inc. All rights reserved. This material is protected by the copyright laws of the United States and other countries. It may not be modified, reproduced or distributed without the prior, express written consent of ChargePoint, Inc. CHARGEPOINT is a U.S. and European Union registered trademark and service mark of ChargePoint, Inc.

  • Page 5: Table Of Contents

    Contents Prepare for Installation ........1 Check Site Readiness.

  • Page 7: Prepare For Installation

    Prepare for Installation ® This document describes how to install a ChargePoint Express 250 DC fast charging station. An Express 250 can be installed to operate by itself (called “Standalone”) or to share power with one other Express 250 for higher throughput (called “Paired”). You must be a licensed electrician and complete an online training course to Important: become a ChargePoint certified installer.

  • Page 8: Check Site Readiness

    Do not use power tools during installation or servicing. Over-torquing can CAUTION: damage the equipment. For all charging station specifications other than dimensions and weights, refer to the Express Note: 250 Data Sheet found online at chargepoint.com/support/guides. For assistance, go to chargepoint.com/support and find your region’s technical support number.
  • Page 9 Prepare for Installation Before beginning work, check that the site meets these civil and mechanical requirements outlined below, as illustrated in the following image. Measurements are in mm (in): • The concrete pad is ready and the concrete is fully cured and level. •...
  • Page 10 • Enough space is available around the installation pad to use a forklift and other lifting equipment, unpack crates, remove packing materials, and allow two people to freely move throughout the area. Remove any concrete that is not level with the rest of the surface, or you Important: cannot level the Express 250.

  • Page 11: Check Express 250 Shipping Crates

    Prepare for Installation Paired only: Outdoor rated Ethernet Cat5e or Cat6 cable, without terminations, is pulled • between the two stations with 3050 mm (10 ft) of service loop at each end. For any questions about site specifications, refer to the Express 250 Data Sheet and Express 250 Site Design Guide.
  • Page 12 Express 250 Charging Station Crate Leave components in the shipping crate until needed. When removing, protect Important: them from damage (such as scratches) by placing them flat on a blanket or tarp, face up. Do not stand up cover panels, as they may be knocked or blown over. Cover charging connectors to prevent damage or ingress.
  • Page 13 Prepare for Installation ChargePoint also provides a tool kit (not shown): • T20 Torx security driver • T25 Torx security driver • T27 Torx security driver • Wago driver • Coolant funnel • 2.5 cm x 183 cm (1 in x 6 ft) lifting straps •...

  • Page 14: Bring Tools And Materials

    Bring Tools and Materials In addition to the tools and materials provided by ChargePoint in product crates, an approved installer needs: • Lifting equipment (forklift or crane) • Lockout/tag out equipment • Step ladder • Cut-resistant gloves • Safety glasses •...
  • Page 15 Prepare for Installation If this is a Paired installation, the certified installer also needs these tools and materials: • Cable puller or fish tape (if not already completed on site) • DC conductors (x4): Voltage Rating Temperature Rating Maximum Conductor Size for Terminals Insulation Type EU non-armored: 90°C...
  • Page 16 • DC cable lug crimper and die that is compatible with lug size and brand (NOTE: The lug die and crimp tool must match the lug manufacturer. Always review the lug manufacturer’s instructions for compatibility) • Multimeter with toner attachment, such as Fluke 117 or similar •...

  • Page 17: Secure Anchors And Ac Wiring

    Secure Anchors and AC Wiring This section describes how to receive and anchor a new Express 250 charging station, and wire the AC conductors. These steps are the same for both Standalone and Paired installations. Prepare the Express 250 for Mounting The Express 250 is equipped with both forklift handles and crane lift guides to move and Note: mount the Express 250.
  • Page 18 Remove the plastic caps from all mounting bolts on the concrete installation pad. Use a wire brush to clean out threads if any concrete is on the upper bolts. Place a leveling nut and washer on each of the four corner bolts.
  • Page 19 Secure Anchors and AC Wiring If the crate is horizontal: Thread the lifting straps through the 25 mm (1 in) lifting holes in the left and right skids of the crate (a). Fasten the other ends of the straps to an appropriately- rated forklift or crane.

  • Page 20: Mount And Secure The Express 250

    Mount and Secure the Express 250 While the Express 250 is elevated, use a 24 mm (15/16 in) hex wrench to remove the bolts and wooden stands from the bottom of the charging station. Lift the Express 250 over the mounting bolts on the installation pad, ensuring the bolts align with the corresponding holes in the bottom of the Express 250.
  • Page 21 Secure Anchors and AC Wiring Tighten the final top nut by hand. Torque all top nuts to 94.9 Nm (70 ft-lbs). For easier access to the nuts, Note: press down on the Power Module yellow release latch and slide the tray out.

  • Page 22: Connect The Ac Wiring

    Connect the AC Wiring Before performing this procedure, disconnect the power to the DANGER: RISK OF SHOCK. Express 250 at the service panel. Keep power off for this circuit until all cover panels are correctly reinstalled and the work scope is completed. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR LOSS OF LIFE.
  • Page 23 Secure Anchors and AC Wiring For North America and other regions using conduit: Use a T25 Torx to loosen the two M5 screws attaching the rodent guard bracket to the charging station. Route the AC wiring bundle through the larger rodent bracket grommet and the ferrite stack.
  • Page 24 Complete installation of the cable gland. Once secure, tighten the T25 screws on the adjustable rodent guard bracket to secure it in place. Multiple screw holes are available to fasten the bracket at different heights. Strip each wire end 25 mm (1 in). Stripping the wire less CAUTION: than 25 mm (1 in) can prevent the...
  • Page 25 Secure Anchors and AC Wiring Ensure the L1, L2, and L3 cables are installed in the correct order. Incorrect Important: installation creates a phase rotation error later in the process. Phase rotation must be counter-clockwise. Inspect the wiring and Wago terminals before proceeding: Ensure no copper is exposed below the terminal.
  • Page 26 Install the AC wiring cover. Tilt the narrow end of the cover under the side panel. Slide the tabs near the bottom of the cover into the slots on the Express 250. Squeeze the sides of the wiring cover as you guide these tabs into the slots. Slide the wiring cover upward until the tabs click into place.

  • Page 27: Pair The Charging Stations

    Pair the Charging Stations This section describes the steps needed to install labels, connect the DC conductors, and connect Ethernet communication if the charging station is being paired. If the Express 250 is being installed as a Standalone station, skip this section and continue to Install Cover Panels (page 29).

  • Page 28: Install Dc Cables

    Disconnect numbers must be written in permanent marker. Normal ballpoint Important: pen ink does not stay legible on the label. Install DC Cables The wiring on the DC side (the right side of the charging station) is only connected for Paired installations.
  • Page 29 Pair the Charging Stations Be sure to connect positive to positive, and negative to negative, on the same CAUTION: wire. Do not reverse the polarity. If not already done, pull DC conductors through the DC conduit and Ethernet wire through the communications conduit in the installation pad, as described in the Express 250 Site Design Guide.
  • Page 30 For the UK and other regions using armored cable: Install the included small grommet into the smaller bracket hole, to protect the Ethernet wiring from the edges of the metal bracket. Do not install the larger grommet, to prevent interference with the cable gland. Use the smallest cable gland appropriate for the DC conductor size.

  • Page 31: Install The Ethernet Wiring

    Pair the Charging Stations B lugs on the top B1 terminal blocks. Fasten each lug in this order: terminal block, lug, M6 flat washer, M6 Belleville washer with the cup facing the station, 10 mm M6 nut. Use a 10 mm (3/8 in) nut driver to torque DC lugs to 5.5 Nm (48.7 in-lbs). Mark all DC connections with a paint pen.
  • Page 32 Route the Ethernet wire across the charging station from right to left between the auxiliary power supply and the contactor assembly. Zip tie the Ethernet wire to the existing cable bundle at each corner (c). Route the Ethernet wire down behind the touchscreen adjustment bar.
  • Page 33 Pair the Charging Stations Strip the end of the Ethernet insulation. Crimp the Ethernet wire in a straight-through pattern into RJ45 connectors at both ends. Note the location of Pin 1 relative to the clip in the image, and the order of the blue and green wires in the pattern.
  • Page 34 Use the duct seal compound included in the crate to completely seal all DC openings against pest ingress: The inside of the conduit opening Within the rodent guard bracket openings for wiring, to pad any sharp edges and block ingress Around the edges of the rodent guard bracket where it will meet the extrusion The conduit opening must be sealed to...

  • Page 35: Install Cover Panels

    Install Cover Panels This section describes how to correctly attach all cover panels. This is required to prevent any electrical shock hazard before powering on the charging station. These steps are the same for both Standalone and Paired installations. Install the Left Extrusion At the bottom right corner of the Express 250, press and hold the yellow release latch while pulling the Power Module tray out of the station.
  • Page 36 Using one hand, hold the extrusion and loosely secure the top two captive screws using the supplied T25 Torx driver. The step ladder is needed to reach the Note: top screws. The top and middle screws are Note: asymmetrical. Use the supplied T25 Torx driver to loosely secure the bottom two screws next.

  • Page 37: Connect The Right Extrusion's Holster Light Cables

    Install Cover Panels Use the supplied T25 Torx driver to loosely secure the middle two screws, just above the Power Module mechanism. Access to the middle screws is easier with the Note: Power Module mechanism handle in the closed (down) position. Tighten all left extrusion screws.

  • Page 38: Install The Right Extrusion

    Connect the shortest cable to the top holster. Connect the next-longest cable to the bottom holster. If there is a third, longer cable, bundle it to avoid Note: pinch points during installation. The third cable is not currently used. Check that these connections are Important: correctly seated, or the system will not operate.
  • Page 39 Install Cover Panels Using one hand, hold the extrusion and loosely secure the top two captive screws using the supplied T25 Torx driver. The step ladder is needed to reach the Note: top screws. The top and middle screws are Note: asymmetrical.
  • Page 40 Use the supplied T25 Torx driver to loosely secure the middle two screws, just above the Power Module mechanism. Access to the middle screws is easier Note: with the Power Module mechanism handle in the closed (down) position. Tighten all right extrusion screws. Secure each holster to the frame using a T25 Torx to fasten a supplied rubberized washer and M5 shoulder screw.

  • Page 41: Install The Power Modules And Emi Shields

    Install Cover Panels Install the Power Modules and EMI Shields Power Modules are 45 kg (98.5 lb) each. Two people are needed to install or CAUTION: replace a Power Module. Always rest a Power Module flat on the ground until it is being installed. Power CAUTION: Modules are not stable in any other position.
  • Page 42 If only one Power Module is being Note: installed, it must be installed in the rear holder (b). Repeat the step for the second Power Module if applicable. Lift each Power Module to the upright position one at a time. If not already done, remove the safety caps from the coolant ports.
  • Page 43 Install Cover Panels Using two hands, squeeze the Power Module mechanism’s release bar against the flange. Raise the bar to fully raise the Power Module mechanism upward to the lock position. This ensures enough clearance for the Power Modules to slide under the mechanism.
  • Page 44 Using two hands, squeeze the Power Module mechanism’s release bar and lower it halfway to check alignment with the ports and guide posts. Lower the Power Module mechanism until you hear a click as the mechanism locks into place. Ensure the mechanism is fully engaged with all Power Module connectors.
  • Page 45 Install Cover Panels Position the rear EMI shield (a) over the closed Power Module holder, the drain hose, and the cooling controller cover (b). Ensure the cutout on the long edge is on the right side, leaving the sensor wire clear. If the top edge of the EMI shield CAUTION: risks contact with the wiring below the...

  • Page 46: Fill The Coolant Reservoir

    Use isopropyl wipes to clean the frame grounding locations and both sides of front EMI shield tabs. Remove the two T25 screws and washers that align with the top front EMI shield tabs (g). Position the front EMI shield (e) over the closed Power Module holder, ensuring the bottom cut-out is positioned over the yellow release latch (f).
  • Page 47 Install Cover Panels Attach the quick connect line on the left side of the coolant reservoir. Using a step ladder if needed, unscrew the reservoir cap. Use the funnel to fill the reservoir to the marked Max line with coolant. Replace the reservoir cap.

  • Page 48: Install The Rear Cover Panels

    Install the Rear Cover Panels When installing the rear panels, take special care to ensure that each panel is Important: correctly positioned. Failure to do so can prevent station operation. Small gauge wiring routed on the sides of the frame could be sheared if caught Important: by panel tabs.
  • Page 49 Install Cover Panels Using two hands, align the guide tabs on the panel to the matching slots on the enclosure frame. Squeeze the sides of the panel inward to fit the tabs into place in the C-channel, inside the watertight gasket. Carefully push the panel down. Newer cover panels do not have signs on Note: the rear panels, only the front panels.

  • Page 50: Install The Front Cover Panels

    Using a T25 Torx, tighten the two hidden captive screws located in the panel’s vents, 2 squares up and 2 squares over from each bottom corner. Use the T25 Torx driver to tighten the top two screws. Install the Front Cover Panels Align the guide tabs on the front bottom panel to the matching slots on the Express 250’s frame, and slide the panel down carefully.
  • Page 51 Install Cover Panels On the middle vent panel, route both proximity wires under the sheet metal edge, to hang in front of the panel on the right side (as you face the front of the charging station). Align the guide tabs on the middle vent panel to the corresponding slots on the Express 250’s frame.
  • Page 52 With hand pressure, swing the touchscreen down. Loosen both retention knobs (a), allowing the touchscreen beam (b) to slide up vertically. Re-tighten the knobs at the highest position. Tilt the bottom of the touchscreen inside the slot in the middle vent panel, aligning the notch in the center of the bottom edge (c) to the guide ridge inside the panel slot.

  • Page 53: Install The Led Display And Area Light Bar

    Install Cover Panels Install the LED Display and Area Light Bar Unpack the LED display from its shipping box. While holding the LED display near the opening at the top of the Express 250, connect its five cables to their corresponding connectors on the back of the display (each connector is keyed to fit only into its matching port): Communications cable (USB-A) Holster light cable...
  • Page 54 Angle the top edge of the LED display under the light bar on the Express 250. Starting at the top, align and slide the LED display guide tabs into the corresponding slots. Ensure the lower sign is correctly captured by the bottom edge of the LED display. Push the bottom into place until firmly seated.

  • Page 55: Complete The Installation

    Complete the Installation After an Express 250 charging station (or pair of stations) has been successfully installed, follow the instructions in this section to complete the installation. You need: • A smartphone or laptop with a QR-code scanner, camera, and Internet connection. These are required to access the pinpointing dashboard at m.chargepoint.com.

  • Page 56: Complete The Installation Wizard: Paired Installations

    The next Installation Wizard test determines whether all cover panels are correctly installed and fully seated. Check the lower right corner of the screen for any error messages. If panel errors appear, match the panel letters to this illustration. Front bottom panel Middle vent panel Front top panel LED display...
  • Page 57 Complete the Installation properly. Power on both Express 250 charging stations at the breaker panel. If the stations do not power on and begin their configuration automatically after a couple of minutes, go to chargepoint.com/support and find your region’s technical support number. Identify the two stations you are installing or updating.

  • Page 58: Pinpoint The Station(S)

    Confirm you have all required materials to continue activation, and select Yes. If the Ethernet connection is detected, the Installation Wizard runs the paired connectivity check in the background and displays a notice if all tests have succeeded. If the Installation Wizard Ethernet test initially fails, it asks you to select Standalone or Paired configuration.

  • Page 59: Run A Test Charging Session

    Complete the Installation Run a Test Charging Session Before leaving the installation site, follow these steps to ensure the Express 250 is fully operational: Connect the charging cable to a vehicle. Use your ChargePoint card to start a charging session. The Express 250 displays instructions on how to plug in a vehicle.

  • Page 61: Appendix A Removing The Express 200 Adapter

    Removing the Express 200 Adapter If you are installing an Express 250 to replace an existing Express 200, remove the Express 200 by reversing the instructions provided in the CPE200 Installation Guide. You must also uninstall the Express 200 adapter as described in this appendix.
  • Page 63 Limited Warranty Information and Disclaimer The Limited Warranty you received with your Charging Station is subject to certain exceptions and exclusions. For example, your use of, installation of, or modification to, the ChargePoint® Charging Station in a manner in which the ChargePoint®...
  • Page 64 Visit our Website at: Leviton Manufacturing Co., Inc. 201 N Service Rd, Melville, NY 11747 www.leviton.com/evrgreen Telephone: 1-800-323-8920 • FAX: 1-800-832-9538 email: commercial@leviton.com Tech Line: 1-800-824-3005 (M-F 8AM-10PM; Sat 9AM-7PM; Sun 9AM-5PM) Q-1450-INSTALL © 2022 Leviton Manufacturing Co., Inc. All rights reserved. 052422...

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