Enel X JuicePump Installation Manual
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Enel X JuicePump Installation Manual

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Summary of Contents for Enel X JuicePump

  • Page 1 Site Installation Manual...

  • Page 2: Table Of Contents

    Contents Overview ..........................3 Purpose of this document ......................3 Disclaimer and warranty ......................3 Acronyms and abbreviations ....................3 Identifying symbols ........................4 Specifications ........................... 5 IMPORTANT SAFETY INSTRUCTIONS ................. 6 Grounding ..........................10 Wiring ............................. 10 Ratings ........................... 11 1.10 Usage limitations ........................

  • Page 3: Overview

    Purpose of this document The purpose of this document is to provide qualified electrical engineers and manufacturer- certified installers with an outline of the steps required to install a JuicePump 175-S high- power charging 175 kW site. This document is for both the single and dual cable variants of the JuicePump 175-S.

  • Page 4: Identifying Symbols

    Acronym/abbreviation Definition Power Circuit Board Power Unit User Unit Undervoltage Identifying symbols Symbol Meaning CRITICAL CAUTION RISK OF ELECTRIC SHOCK Dangerous voltage Direct Current (DC) ø Phase Symbol Alternating Current Supply Symbol 3-Phase Alternating Supply (no neutral connection) Operators Manual; Operating Installations Read Operators Manual Page 4 of 35 TRI125.INS.018.4...

  • Page 5: Specifications

    Specifications Unit Specifications • LV Distribution Board 185 kVA Output per charger • 400 V/300 A 50 Hz, 480 V/250 A 60 Hz, 600 V/200 A 60 Hz • UL-listed circuit breakers with optional under-voltage relay • Maximum available fault current of 18 kA (current limiting fuses or current limiting circuit breakers may be required to maintain limit of 18 kA) •...

  • Page 6: Important Safety Instructions

    The installation must be conducted by a manufacturer Certified technician who has completed the manufacturer’s installation training course for the JuicePump 175-S. The JuicePump 175-S fast charger system must be installed and serviced only by qualified electrical personnel (subject to local regulatory and legal requirements.)
  • Page 7 Warning! Danger due to inadequate ground conductor connection This can result in serious injury and damage to property. • This document provides guidelines for earth connections for the charger and the wiring of the system. • Connections to the battery charger shall comply with all local codes and ordinances. Warning! Cord extensions or adaptors could cause over heating serious injury or fire •...
  • Page 8 Page 8 of 35 TRI125.INS.018.4...
  • Page 9 Warning! Conduit and cabling Prior to installation of the piping and wiring, a professional review of local requirements must be performed to ensure that laws and regulations are adhered to. As a result, it may be required to deviate from the requirements of this documentation. Note: Deviations from these instructions must not reduce the effective safety and integrity of the installation and the product.

  • Page 10: Grounding

    DC copper 95 mm2 (cross section) • V90 class, rated to operate at 90°C. The manufacturer recommends the use of copper cables. Refer to the following JuicePump 175-S document for reference specifications - TRI125.INS.016 ENEL X 175-S Piping and Cabling.

  • Page 11: Ratings

    480 VAC 3~, 60 Hz, 225 A, or ø, 240 VAC, 3 A, 50/60 Hz 600 VAC 3~, 60 Hz, 200 A The JuicePump user unit must be For more information refer to the following connected to a circuit provided with datasheet: appropriate over-current protection in •...

  • Page 12: Installation Safety Considerations

    TRI125.INS.016 JuicePump RT175-S Piping and Cabling • TRI125.INS.019 JuicePump RT175-S User Unit Installation Manual • TRI125.INS.033 JuicePump RT175-S Maintenance Manual • TRI125.DTA.009 JuicePump RT175-S Datasheet (covers UU and PU) • TRI125.CHK.008 JuicePump RT175-SK System Installation Checklist • Page 12 of 35 TRI125.INS.018.4...

  • Page 13: Site Plan

    Site plan Block diagram Figure 1: Single charger block diagram Page 13 of 35 TRI125.INS.018.4...

  • Page 14: Layout

    Layout Figure 2: Site electrical layout Page 14 of 35 TRI125.INS.018.4...

  • Page 15: Resources

    Resources Tools and consumables 3.1.1 Tools • Network termination equipment • Electric hydraulic cable lug terminator • 100 m hook-up wire • 4 x 1 T (minimum) rated lifting straps • Rags • Electric caulking gun • Drill • Torque wrench •...

  • Page 16: Heavy Equipment

    Note: Due to difficulties shipping jointing compound, copper and aluminum, compound must also be installer-supplied as needed. Heavy equipment Crane – with 7 m reach, 1 T lift capacity • • Forklift • Temporary weather shelter Torques utilized during installation Equipment Thread code Position...

  • Page 17: Installation

    Note: Deviations from these instructions must not reduce the effective safety and integrity of the installation and the product. Refer to TRI125.INS.016 JuicePump RT 175-S Piping and Cabling. Site electrical design must be carried out and approved by a suitably qualified professional.

  • Page 18: Earthworks

    Caution! Risk of fire To reduce the risk of fire, connect only to a circuit provided with 320 A maximum branch circuit overcurrent protection in accordance with the National Electrical Code, ANSI/NFPA 70. 4.2.2 Optional under-voltage relay The IPU includes pre-wired terminals to allow the optional use of an under-voltage device at the upstream supply breaker.
  • Page 19 Figure 3: Maximum stacking height of similar sized boxes. Page 19 of 35 TRI125.INS.018.4...

  • Page 20: High-Power Electrical Connections

    High-power electrical connections It is critical that the high-power electrical connections are done correctly to ensure safe, compliant, and warranted performance of the charging equipment. Safety Warning! To be installed by a certified professional Only trained and competent electricians are authorized to perform this work. •...

  • Page 21: Isolated Power Unit Installation

    Isolated power unit installation 4.6.1 Access and clearance To maintain accessibility and serviceability of the unit via the cabinet doors, the front and rear of the IPU should be spaced at least 1 m from any walls. This also aids in ventilation of the units.
  • Page 22 Ensure that the cables and cable glands are sealed under the metal plate. If not, use NORFIRNO Cable Sealant to seal. • For more information, see TRI125.INS.016 JuicePump RT 175-S Piping and Cabling. Cut the mounting rods down to 50 mm above the foundation ground.
  • Page 23 4.6.3 Unbox and install the IPU Locate the IPU box that is specially marked and contains the set of lifting eyes and straps. Remove the top and side cardboard panels. Open the lifting kit and attach the M12 load-rated lifting eyes (1.2 T), lifting slings, and protective pads to the four lifting points located in each corner on top of the cabinet.
  • Page 24 Identify the DC output cables for the rectifier pack of the power unit. Note: These are contained within conduit B as shown in TRI125.INS.016 JuicePump RT 175-S Piping and Cabling. Measure, cut, and crimp with M10 cable lugs to the DC mounting points.
  • Page 25 Terminate the IPU AC link Identify the AC input cables. Note: These are contained within conduit A as shown in TRI125.INS.016 JuicePump RT 175-S Piping and Cabling. Measure, cut, and crimp with M10 cable lugs to mounting points L1, L2, and L3 on load...
  • Page 26 Figure 11: IPU earth terminals 4.6.6 Terminate earthing electrodes Caution! Earthing electrode • For EMC compliance, it is important that a local earthing electrode is used to bond the chassis of the IPU directly to ground. This may be in the form of an earth stake, or if available, can be bonded to pre-existing buried earth structures.
  • Page 27 Figure 12: IPU terminal block X1 – Red highlights showing customer field wiring. Yellow highlights show optional wiring. Page 27 of 35 TRI125.INS.018.4...
  • Page 28 Strip, bootlace (only if stranded wire; skip bootlace if solid core), and insert the wires into the field wiring terminals as follows: Terminal Wire • UU 230 VAC Neutral • UU 230 VAC Line • UU 24 V Safety Loop •...

  • Page 29: Uu Installation

    Foundation design and preparation is the responsibility of the customer. Device footprints are provided by the manufacturer for hole drilling and conduit/cable location guidance. For further details, please refer to TRI125.INS.001 JuicePump RT 175-S User Unit Installation Manual. Note: A mounting stencil may be supplied by the manufacturer at customer request.
  • Page 30 Figure 15: UU foundation preparation 4.7.2 Unboxing and craning Remove the lid and walls from the shipping box. Note: For more information, see TRI125.INS.019 JuicePump RT 175-S UU Installation Manual. Figure 16: UU lifting points (indicative) Attach lifting straps to the crane.
  • Page 31 Warning! Be aware that lifting heavy loads that are inadequately secured, could damage the product, and cause serious injury. Be careful as the unit may swing. A second operator may be required to control the user unit lift. Lower the unit to the ground in a vertical position, using the crane to keep tension. Remove the protective plastic wrapping from the lower portion of the UU.
  • Page 32 4.7.3 Terminate earthing electrode Warning! Earthing electrode • For EMC compliance, it is important that a local earthing electrode is used to bond the chassis of the UU directly to ground. This may be in the form of an earth stake, or if available, can be bonded to pre-existing buried earth structures.
  • Page 33 4.7.5 Terminate DC input cables Identify and individually feed each DC power cable through its respective gland then measure, cut, and terminate with an M10 lug. Notes: • Depending on the site design, there may be up to two DC+ and two DC- cables. To maintain device IP rating, ensure that unused holes are appropriately sealed.

  • Page 34: Site Installation Handover

    Note: Make sure that the housing is tightened in the middle and at the two end nuts to ensure a waterproof seal. Site installation handover Complete TRI125.CHK.008 JuicePump RT 175-S System Installation Checklist and attach photos of the installation. Pre-checks Check strain relief on power cables.
  • Page 35 Finalize any waste pick up and cleaning operations, and tidy up the site. Send the full report to the manufacturer and all other parties involved via TRI125.CHK.008 JuicePump RT 175-S System Installation Checklist and include the pictures to support the signed checklist.

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