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Related Manuals for Autel MaxiCharger DC HiPower
Summary of Contents for Autel MaxiCharger DC HiPower
- Page 1 MaxiCharger DC HiPower Installation Manual Version 1.0 UL Model...
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Page 2: Copyright Information
Autel will not be liable for any direct damages or for any special, incidental, or indirect damages or for any economic consequential damages (including the loss of profits). -
Page 3: Table Of Contents
CONTENTS 1 Using This Manual .................... 1 1.1 Signal Word ............................1 1.2 Target Group ............................1 1.3 Revision History ..........................2 1.4 Terminology ............................2 2 Safety ........................ 3 2.1 Safety Warnings ..........................3 2.2 Owner Responsibilities ........................4 2.3 Installation Engineer Qualifications .................... - Page 4 5.2 Installing the Dispenser ........................29 5.2.1 Before Installing ........................29 5.2.2 Installing the Dispenser......................30 5.2.3 Installing the Cable Management System (CMS) ..............34 5.3 Electrical Installation........................38 5.3.1 Connecting the AC Input Cable ....................38 5.3.2 Connecting the DC Output Cable .................... 40 5.3.3 Connecting the PE Cable ......................
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Page 5: Using This Manual
Using This Manual This manual describes the installation of the MaxiCharger DC HiPower. Prior to installation, read through this manual to become familiar with the instructions of this MaxiCharger to ensure a successful installation and smooth operations. Signal Word DANGER Indicates an imminently hazardous situation with a high risk level which, if the danger is not avoided, will cause death or serious injury. -
Page 6: Revision History
Revision History Version Date Descriptions V1.0 2023.09.15 Initial version Terminology Term Definition Alternating current Combined Charging System, a standard charging method for electric vehicles Charging Control Unit: a control unit used to communicate with the BMS (Battery Management System) and control the power delivery to the EV Abbreviation of CHArge de MOve, a standard charging method for electric CHAdeMO vehicles... -
Page 7: Safety
Safety The safety messages herein cover situations of which Autel is aware. Autel cannot know, evaluate or advise you as to all of the possible hazards. You must be certain that any condition or service procedure encountered does not jeopardize your personal safety. -
Page 8: Owner Responsibilities
Protect the MaxiCharger with safety devices and measures that the local rules specify. Installation personnel must have the correct protective equipment such as protective clothing, safety gloves, safety shoes, and safety glasses. Owner Responsibilities The owner runs the MaxiCharger for commercial or business use or has authorized a third party to use it. -
Page 9: Signs On The Maxicharger
These measures may include firewall building, authentication methods, data encryption, and anti-virus programs installation, etc. Autel is not liable for damages and/or losses pertaining to the security breaches described above. -
Page 10: General Introduction
When you need power now, this future-ready innovative design delivers up to 640kW and is perfect for fleet applications and highways service centers. Faster charging means less time waiting and an enhancing user experience. The MaxiCharger DC HiPower is the unrivaled EV charger solution for people and business where time is the most value asset. -
Page 11: Product Overview
Product Overview Power Cabinet 1. Lifting Hole 2. Antenna 3. Vent 4. Handle Lock (Install lifting eye bolts) 7. Bracket 5. Front Cabinet Mounting 6. Front Base Cover 8. LED Indicator Door Location 9. Emergency Stop 10. Grounding Bar 11. Side Base Cover Button... - Page 12 Table 3-1 Power Cabinet Indicator Descriptions Color Description The power cabinet is in stand-by mode. Illuminating Green A charge session has started. Flashing Blue Flashing Yellow The power cabinet is upgrading. Illuminating Red An error has occurred.
- Page 13 Dispenser 1. Lifting Hole 2. Cabinet Front Door 3. 15.6” Touchscreen 4. Operation Button (Install lifting eye bolts) 5. POS Device (Optional) 6. LED Indicator 7. Cable Exit 8. Meter (Optional) 9. Emergency Stop 10. Handle Lock 11. Holster Indicator 12.
- Page 14 The dispenser is upgrading. Flashing Yellow NOTICE Autel can deliver the MaxiCharger with different payment terminals. The available options vary depending on the region of the installation. Consult Autel’s customer service to obtain more information about the different payment options.
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Page 15: Principle Diagram
Principle Diagram... -
Page 16: Preparation
Preparation General installation procedure: Ensure the installation site is ready and you have all the parts and tools described in the sections below. Lay the cables as described. Install the power cabinet. Install the dispenser and cable management system (CMS). Complete the wiring. - Page 17 Build the concrete foundation as described in 4.1.3 Preparing the Foundation. NOTICE While Autel tests the MaxiCharger with a majority of upcoming vehicles, we cannot guarantee the port locations of future vehicles and cannot warrant the configurations proposed will work for all vehicles.
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Page 18: 4.1.2 Space Requirements
4.1.2 Space Requirements The MaxiCharger requires the installation space as described below to ensure the normal operation and airflow around the MaxiCharger. Power Cabinet Table 4-1 Power Cabinet Space Requirements Specification Parameter inch 66.9 1700 19.7 19.7 23.6 19.7 1050 33.5 1050... - Page 19 Dispenser...
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Page 20: 4.1.3 Preparing The Foundation
4.1.3 Preparing the Foundation Power Cabinet Prepare the cable well and foundation as recommended below: Table 4-2 Power Cabinet Foundation Specifications Specification Parameter inch 78.7 2000 51.2 1300 13.8 51.2 1300 24.4 13.4 11.8... - Page 21 Dispenser The recommended foundation dimensions are as the following:...
- Page 22 Table 4-3 Dispenser Foundation Specifications Specification Parameter inch 30.7 130.5 20.4 163.5 20.5 153.5 NOTICE Embed four M12 threaded studs when pouring the concrete into the foundation. The threaded stud should be 1.2-1.4” (30-35 mm) above the surface.
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Page 23: Cable Connection
Cable Connection Ensure to consult the above electrical design diagram when preparing the cables. The DC power cable to be used should be able to withstand at least 1000 V and required safe ampere capacity, as the maximum DC voltage is 950 VDC. ... -
Page 24: Cable Specifications
4.2.1 Cable Specifications Prepare the DC and AC cables as recommended below: Cable Cable Type Cross Section Cable Lug Pics Connection See the Connect power Galvanized flat corresponding cabinet/dispenser steel for grounding to the earth grounding description for reference AC Input 1： L1/L2/L3: 300 Kcmil x 2 PE: 300 Kcmil... -
Page 25: Cable Laying
4.2.2 Cable Laying Route the cable through the pre-embedded conduit, with one end connected to the power cabinet and the other to the dispenser. All the cables to the dispenser enter from the bottom opening. See the cable opening layout for the power cabinet: Number Description ... -
Page 26: Recommended Tools
Recommended Tools The following tools are recommended when installing the MaxiCharger. Ensure you have these tools readily available prior to installation. Hoisting equipment Pencil Tape measure Brush Twin-step ladder Power drill Drill bit (5/16”) ... -
Page 27: Unpacking
If the sensors demonstrate over 30° of tilt or total overturn, note on bill of lading and inspect the product. If the Shockwatch displays red, contact Autel customer service and the delivery personnel, and then inspect the product for any damage. Do not accept the delivery until the inspection is complete and no damage is found. -
Page 28: Installation
Installation Installing the Power Cabinet 5.1.1 Before Installing Prior to installation, check the following: The installation site is prepared. The appropriate wiring, circuit protection, and metering is in place at the installation site. A grounding conductor that complies with local codes is properly grounded to earth. ... -
Page 29: Installing The Power Cabinet
5.1.2 Installing the Power Cabinet STEP 1 Unscrew the screws using a 1/5” socket wrench to remove the front, rear, and two side base covers. Set them aside. STEP 2 Remove the eight M12 screws at the bottom of the cabinet using a 1/2” socket wrench to detach it from the pallet. - Page 30 STEP 3 Install and tighten the four M24 lifting eye bolts onto the top of the cabinet. Then hoist the cabinet onto the installation site. WARNING Risk of pinching or crushing. Heavy Equipment. Ensure that the hoisting equipment can lift the cabinet safely. ...
- Page 31 STEP 4 Place four mounting brackets to the four corners of the charger, aligning with the mounting holes. Then mark the four anchoring holes on the foundation. Remove the brackets. STEP 5 Drill four holes measuring 5/8” (16 mm) in diameter and 3.15” (80 mm) in depth into the concrete.
- Page 32 STEP 6 Install the mounting bracket by inserting two M12 x 30 screws into the holes. Tighten the screws to 406 in-lb. (46 Nm) using a 1/2” socket wrench. Reinstall and tighten the gaskets and nuts to secure the cabinet onto the foundation. STEP 7 Prepare a ground plate to connect the cabinet to Ground.
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Page 33: Installing The Dispenser
Installing the Dispenser 5.2.1 Before Installing Prior to installation, check the following: The installation site is prepared. The appropriate service wiring, circuit protection, and metering is in place at the installation site. A grounding conductor that complies with local codes is properly grounded to earth. ... -
Page 34: Installing The Dispenser
5.2.2 Installing the Dispenser STEP 1 Remove the four screws using a 5/32” socket wrench to remove the base covers on both sides. STEP 2 Remove the four M12 nuts and gaskets at the bottom using a 1/2” socket wrench to detach the dispenser from the pallet. - Page 35 STEP 3 Install and tighten four M12 lifting eye bolts on the top of the dispenser. Then hoist the dispenser to the installation site. WARNING Risk of pinching or crushing. Heavy Equipment. Ensure that the hoisting equipment can lift the dispenser safely. ...
- Page 36 STEP 4 Lower the dispenser onto the foundation, aligning it with the four threaded studs. Then remove the four lifting eye bolts. STEP 5 Reinstall and tighten the four M12 nuts and gaskets using a 1/2” socket wrench to secure the dispenser to the foundation.
- Page 37 STEP 6 Prepare a ground plate to connect the dispenser to Ground from the rear. The dimensions of the threaded holes are 5/16” (8 mm) in diameter and 3/5” (15 mm) in depth.
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Page 38: Installing The Cable Management System (Cms)
5.2.3 Installing the Cable Management System (CMS) NOTICE This installation may require the assistance of two adults and a twin-step ladder. STEP 1 Attach the CMS mounting base onto the top of the dispenser, aligning it with the four mounting holes. Insert four M12 x 30 screws into the holes and tighten them using a 1/2”... - Page 39 STEP 3 Attach the CMS onto its mounting base, aligning the CMS’s four mounting holes with the threaded studs of the base. STEP 4 Extend the two arms until all four mounting holes are visible. Then screw four flat gaskets, spring washers, and M8 hex nuts into the four threaded studs sequentially.
- Page 40 STEP 5 Reinstall the cover onto the top of the dispenser. STEP 6 Remove the two silicone covers from the arms. Then put a #5 hex key into the hole to hold the bolt while removing the M10 nuts and washers using a monkey wrench. Set them aside. STEP 7 Place the M10 nuts and washers that were removed from the previous step into the groove of the cable bracket.
- Page 41 STEP 8 1. Mark the cable hanging point — 5 feet from the cable exit. 2. Wrap three rounds of the adhesive tape around the approximate locations according to the diagram, ensuring the charging cable will not move randomly. 3. Place the charging cable into the cable bracket according to the marked position. Then attach the other cable bracket and insert two M5 x 8 and M5 x 10 screws.
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Page 42: Electrical Installation
Electrical Installation DANGER Ensure the upstream breakers are turned off throughout the installation. Wear protective personal equipment. WARNING Ensure to refer to the Cable Connection diagram prior to/during the installation. 5.3.1 Connecting the AC Input Cable STEP 1 1. - Page 43 STEP 2 Remove the four nuts and gaskets using a 3/16” socket wrench to remove the cable cover plates. Set them aside. STEP 3 Connect the AC input cable as shown below or refer to the label instructions in the power cabinet. Use a 2/5”...
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Page 44: Connecting The Dc Output Cable
5.3.2 Connecting the DC Output Cable To the Power Cabinet: STEP 1 1. Use the cabinet door key to open the rear doors. Then manually loosen the four screws to remove the metal plates. Set them aside. 2. Follow the Step 2 above to remove the cable cover plates at the bottom. Set them aside. - Page 45 STEP 2 Connect the DC output cable to the power cabinet as shown below or refer to the label instructions in the power cabinet. Use a 2/5” socket wrench to tighten the M10 x 30 screws to 230 in-lb.
- Page 46 To the Dispenser: STEP 1 1. Use the key to open the dispenser’s front door. 2. Unscrew the two M5 x 12 screws using a 3/16” socket wrench to remove the insulation barrier from the dispenser. Set them aside. STEP 2 Connect the DC output cable to the dispenser as shown below or refer to the label instructions in the power cabinet.
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Page 47: Connecting The Pe Cable
5.3.3 Connecting the PE Cable Use the M8 x 20 screws to connect the PE cables to the power cabinet and two dispensers. Tighten the screws using a 5/16” socket wrench. NOTICE Refer to 4.2.1 Cable Specifications to prepare the PE cables. Ensure the local rules are followed. -
Page 48: Connecting The Ac Auxiliary Power Cable
5.3.4 Connecting the AC Auxiliary Power Cable STEP 1 Locate the dispenser power on the rear side of the power cabinet. STEP 2 Connect the wires as shown below. - Page 49 STEP 3 1. Locate the XT terminal block in the dispenser. 2. Use a flathead screwdriver to hold the release button above the connector hole and push the wires into the holes.
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Page 50: Connecting The Ethernet Cable
5.3.5 Connecting the Ethernet Cable STEP 1 Connect the Ethernet cable to the Ethernet port located on the rear side of the power cabinet. STEP 2 Rotate the dust cover to reveal the Ethernet port and connect the Ethernet cable. -
Page 51: Finish Installation
Finish Installation For the Power Cabinet: 1. After all the wires are connected and the screws are tightened properly, reinstall the four cable cover plates and organize the wires. Then use fireproof mortar to seal any gaps. 2. Reinstall the two metal plates on the rear of the cabinet. 3. -
Page 52: Technical Specifications
Technical Specifications Power Cabinet Specifications AC Input 3P + PE, no neutral Earthing System Input Voltage 3-phase 480 VAC ± 10% (2 routes) Input Frequency 60 Hz >= 0.99 Power Factor Harmonic Distortion (THDi) < 5% (> 2% normal load) General Characteristics Max. -
Page 53: Dispenser Specifications
Certification and Standards UL 2202, UL 2231-1, UL 2231-2, Safety Standards NEC Article 625, CSA C22.2 No. 107.1-16 CSA, FCC part 15 Class A Certification 24 months, warranty extension possible Warranty Dispenser Specifications DC Output Connection Mode 4: CCS1 Charging Mode 480 kW Output 1 Power Output 1 Voltage... - Page 54 81.7” x 22.8” x 12.6” (2075 x 580 x 320 mm) 15.6-inch LCD touchscreen Touchscreen 16.4 feet (5 m) Cable Length User Interface Status Indication Autel Charger app User Interface Autel Config app Connectivity Ethernet OCPP 1.6J (OCPP 2.0.1 optional) Communication Protocol...
- Page 55 www.autelenergy.com...
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