150kW Integrated DC charger

Installation Manual
Ver.1.0

Jiangsu Wanbang Dehe New Energy Technology Co.,Ltd.

 Content
1. General ..................................................................................................................................................... 4
1.1 Purpose of document ..................................................................................................................... 4
1.3 Definition of warning symbols ........................................................................................................ 4
2. Preparation before installation ................................................................................................................. 5
2.1 General construction tools ............................................................................................................. 5
2.2 Construction materials ................................................................................................................... 6
2.2.1 Copper bush ........................................................................................................................ 6
2.2.2 Other materials.................................................................................................................... 6
2.3 Installer requirements .................................................................................................................... 6
2.4 Handover of construction drawings ............................................................................................... 7
2.5 Inspection of electric power cables ................................................................................................ 7
2.6 Requirements for cement base ...................................................................................................... 7
2.7 Equipment spacing requirements .................................................................................................. 9
2.8 Current and distribution capacity requirements .......................................................................... 10
2.9 Grounding/insulation resistance requirements ........................................................................... 10
3. Installation procedure ............................................................................................................................ 11
3.1 Unpacking and unpacking inspection ........................................................................................... 11
3.1.1 Equipment unpacking drawing and attachment list .......................................................... 11
3.1.2Inspection of unpacking ..................................................................................................... 11
3.1.3 Notes for unpacking .......................................................................................................... 11
3.3 Electricity wiring diagram of charger............................................................................................ 12
3.4 Fire-proof mud seal ...................................................................................................................... 13
4. Post-installation inspection .................................................................................................................... 14
4.1 Installation wiring inspection ....................................................................................................... 14
4.1.1 Equipment and equipment fixation inspection ................................................................. 14
4.1.2 Cable laying and connection inspection ............................................................................ 14
4.2 Check before power-on ................................................................................................................ 14
4.3 Check on power-on ...................................................................................................................... 14
5. Installation environment ........................................................................................................................ 15
6. Completion data ..................................................................................................................................... 15

Installation manual Jiang Su Wanbang Dehe New Energy Technology Co.,Ltd.

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Figure catalogue
Figure 1 Top view of cement foundation of charger ..................................................................................8
Figure 2 three views of installation and construction ................................................................................8
Figure 3 Charger maintenance distance diagram .......................................................................................9
Figure 4 Single or back-to-back parking spaces distance requirements ..................................................9
Figure 5 Multiple adjacent parking spaces distance requirements ..........................................................10
Figure 6 Schematic diagram of front and rear sealing plates of charger..................................................12
Figure 7 three effect diagram of charging pile installation base ..............................................................12
Figure 8 Terminal wiring diagram .............................................................................................................13
Figure 9 before the fire mud is sealed......................................................................................................13
Figure 10 after the fire mud is sealed ......................................................................................................14

Installation manual Jiang Su Wanbang Dehe New Energy Technology Co.,Ltd.

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1. General
1.1 Purpose of document

This document aims to guide construction personnel to complete the on-site installation of the 150kW
Integrated DC charger
1.2 Scope of application
1.2.1 This manual applies to following charging equipment：
150kW Integrated DC charger
1.2.2 This manual is for the following people:
Installer of 150kW Integrated DC charger
1.3 Definition of warning symbols

Table1 Definition of warning symbol

No. Symbol Content
“Electrical hazard” symbol indicates danger
Failure to pay attention to the procedures, practices or improper implementation
may cause installer injuries and death. Only after the conditions referred to are
1
fully understood and fulfilled, the operation accompanied the "electrical hazard"
symbol can be performed.

"Be careful" symbol indicates danger

Failure to pay attention to the procedures, practices or improper implementation
may cause product damaged or destroyed. Only after the conditions referred to are
2
fully understood and fulfilled, the operation accompanied the "be careful" symbol
can be performed.

“Prompt” indicates usage tips or useful information

3 Tips and useful information are marked with “prompt”. It does not contain
information to warn about dangerous or harmful functions.
This symbol is located on the product, in the instruction manual, or on the
packaging. It indicates that electrical and electronic equipment and its accessories
should be separately disposed from ordinary household waste.
4
Materials can be reused according to this symbol. You can make a huge
contribution to environmental protection by reusing old equipment, materials, or
other forms of reuse.

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2. Preparation before installation
2.1 General construction tools

Table 2 General construction tools

No. Category Name Uses Picture

Cable preparation Stripping of

1 Electrician knife
tools insulation sheath

Wire stripping Stripping of

2 Installation tools
pliers insulation layer

Wire pressing
3 Installation tools Terminal bonding
pliers

Percussion Component
4 Installation tools
drilling installation

Electric air pick

5 Installation tools Notching
machine

6 Installation tools Cutting machine Tube Cutting

Thermal shrinkage
7 Installation tools Heat gun of insulating
materials

8 Installation tools Fuse machine Welded PE pipe

Hexagon socket Install and remove

9 Installation tools
wrench (set) screw
Open End
Install and remove
10 Installation tools Wrenches (set
nut
includes No.13)

Polishing of
11 Installation tools Angle grinder
materials

Measuring Horizontal
12 Laser level meter
instrument measurement

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 Measuring Horizontal
13 Horizontal rule
instrument measurement

Measuring Measure voltage,

14 Multimeter
instrument current, etc.

Place the
15 Assistive devices Insulation mat
disassembled parts

Transportation
16 Means of transport Forklift truck
equipment

2.2 Construction materials

2.2.1 Copper bush

(1) 150 square cable Corresponding terminal: DT-150 copper terminal.
(2) 70 square cable Corresponding terminal: DT- 70 copper terminal.
2.2.2 Other materials
(1) Several fire-proof mud
(2) Heat shrinkable tube, insulating tape and other auxiliary materials
2.3 Installer requirements

(1) Entering the construction site shall comply with the construction site safety management regulations.
(2) Entering the construction site must wear a safety helmet (fasten your jaw strap, and the helmet is intact),
do not wear unsafe clothes such as loose clothing, slippers, etc. It is strictly forbidden to drink to work and
smoke at the construction site.
(3) Operators at high altitude must wear safety helmets, hang up safety belts, wear non-slip shoes, and fasten
labor tools.
(4) If the work site is dusty or has spray paint work, protective masks must be worn.
(5) Do not enter dangerous areas such as the hoisting area and below the vertical operation to prevent
objects from striking.
(6) Keep as far away as possible from various mechanical equipment, electrical circuits, and prevent
mechanical and electrical injuries.
(7) Those who use mobile power tools must master their use skills and precautions. Wear insulated shoes and
insulated gloves as much as possible. The metal case must be grounded or zero - protected.
(8) Temporary on-site electricity, electricity box should be kept intact, damaged electrical components must
be replaced in time.
(9) Rubber cable shall be used for the temporary electric wires on the site. No plastic splines are allowed. No

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wires shall be directly inserted into the socket.
(10) Try to avoid working with electricity.
(11) Enter the edge of foundation pits, roofs, and other openings, and concentrate to prevent falls from
falling.
(12) Pay attention to the ground environmental conditions such as nails and steel bars, and prevent sticking,
bumping, hanging, falling and other injuries.
(13) The on-site construction protective facilities, safety signs, warning signs, etc. cannot be removed without
authorization.
(14) Strengthen on-site maintenance of construction equipment to maintain intact rate, and prohibit
operation with problems and overloading.
2.4 Handover of construction drawings

After the installer arrives at the site, first ask the store staff for a drawing of the installation location of
the equipment, and check that the cables and concrete foundation of each equipment meet the
requirements.
2.5 Inspection of electric power cables

180kW all-in-one type charger’s power cable to be laid is not less than YJV-0.6 / 1kV-3 * 150mm² + 2 *
70mm², and the depth of the surface of the base is about 0.5m / 1.5 feet. Please check the cable type before
installation.
2.6 Requirements for cement base

Before installing the charger, it is necessary to pour the cement foundation. The size of the cement
foundation is 800mm * 700mm * 600mm, the foundation burial depth is 400mm, and the ground height is
200mm. The top view is shown in Figure 1. The foundation inspection requirements are as follows:
(1) Pay attention to the correction level when pouring the foundation.
(2) The foundation installation is higher than the ground level, and the necessary maintenance channels
are reserved on the site depending on the specific space.
(3) The drain on the foundation surface is slightly inclined to avoid standing water.
(4) The foundation is filled with C20 concrete.
(6) A wire hole is reserved on the basis, as shown in Figure 1.
(7) Test the flatness with a spirit level after the foundation is completed.
(8) 4 M10 screws are used for fixed embedding, and they are embedded in the concrete foundation in
advance according to the positioning of the drawing, exposing 30-40mm threads on the upper surface of the
concrete foundation.
(9) The 30mm thread on the exposed surface of the concrete foundation is wrapped with adhesive tape
when pouring concrete to prevent dross between the threads used for fastening.

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 Figure 1 Top view of cement foundation of charger
The three views of installation and construction are as follows:

Figure 2 three views of installation and construction

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2.7 Equipment spacing requirements

(1) Maintenance distance requirements

When the back or side of the charging pile to be installed is near a wall or other obstacles, a certain
maintenance distance needs to be left, please refer to Figure 3 below:

Figure 3 Charger maintenance distance diagram

（2）Single or back-to-back parking spaces distance requirements
When the charger is installed in the middle of a parking space or back-to-back parking space, it is
recommended to leave a space of 1000mm / 3.3 feet between the car and the charger to facilitate the use of
the charger, as shown in Figure 4:

Figure 4 Single or back-to-back parking spaces distance requirements

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（3）Multiple adjacent parking spaces distance requirements
When the charger is installed between two parking spaces, in order to ensure sufficient inspection
distance between the car and the charger, it is recommended that the minimum distance from the bottom
center of the charging pile to the car gear is 1700mm / 5.6 feet, as shown in Figure 5:

Figure 5 Multiple adjacent parking spaces distance requirements

2.8 Current and distribution capacity requirements

If the charging pile runs at full power, the power grid capacity should meet 200kVA and the rated current
parameter is 280A. It is recommended that the parameters of the superior circuit breaker should be
Ue=400Vac, In: 400A, thermo-magnetic, Icu=Ics=40kA, 4P.
2.9 Grounding/insulation resistance requirements

(1) Check the civil grounding resistance test report to ensure that the resistance of the grounding grid
produced on site must be ≤ 4Ω.
(2) Check the civil insulation resistance test report to ensure that the insulation resistance of the cable is
≥10MΩ.

Note: the above requirements are the minimum requirements of the equipment.
The specific standards shall be subject to local laws and regulations.

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3. Installation procedure
3.1 Unpacking and unpacking inspection

3.1.1 Equipment unpacking drawing and attachment list

Table 2 Equipment unpacking diagram & List of attachments
Photo
Weight
description Accessories
name configuration Packing size (mm) (with Random file
(before list
packing)
unpacking)
Certificate
of approval，
150kW Delivery Key*6
150Kw 1130*1062*2160
Integrated 380kg inspection Rev. Stop
（mm）
DC charger report， card*2
The user
manual

3.1.2Inspection of unpacking
（1）Check the packing list number and equipment quantity.
（2）Check equipment nameplate information.
（3）Check whether the random files are complete.
（4）Check whether the spare parts and accessories are complete.
（5）Check the delivery inspection report and certificate.
（6）Check the appearance of the equipment is good, whether there is deformation, knock, stains and other
conditions.
3.1.3 Notes for unpacking
（1）The installer shall unpack the container in the presence of the owner and fill in the unpacking record in
detail. See appendix 1 for the unpacking record.
（2）After unpacking, please ask the owner's representative to confirm and sign on the equipment unpacking
record sheet.
（3）If any problem is found in the process of unpacking and acceptance of the equipment, it shall not only
record the accident, but also wait for the negotiation between the owner and the supplier.

Installation manual Jiang Su Wanbang Dehe New Energy Technology Co.,Ltd.

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3.2 Charger fixed
（1）First remove the front and rear sealing plates of the base, as shown in figure 6.

Figure 6 Schematic diagram of front and rear sealing plates of charger

（2）Use a forklift truck to fork the charging pile from the sealing plate hole and place it on the cement base.
The four hole positions should be placed on the bolt. The three-position effect diagram of the base is shown
in figure 7.

Figure 7 three effect diagram of charging pile installation base

（3）Fix the charging pile with screws.
（4）Install the base sealing plate again and fix the charger.
3.3 Electricity wiring diagram of charger

（1）Open the rear door of the equipment and introduce the power cord from the bottom of the cabinet.
（2）Connect the power cable to the terminal row as shown in Figure 8, and ensure that the copper nose
screw fastening of the wiring is not loose; When installing and connecting, avoid scratching and damage of
the cable insulation to cause short circuit.

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 Figure 8 Terminal wiring diagram
Waring: Must follow the code and correct procedures.
Failure to pay attention to the procedures, practices or improper implementation may cause
installer injuries and death.

3.4 Fire-proof mud seal

（1）Clean the dirt and debris from the entrance of the cable into the device.
（2）Block the cutout with an insulating baffle.
（3）Fill and block the inlet hole at the bottom of the equipment with Fire-proof mud (as shown in figure 9),
and make it into a regular shape.

Figure 9 before the fire mud is sealed

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 Figure 10 after the fire mud is sealed
（4）It is required to seal and compactness and smooth and clean appearance.

4. Post-installation inspection
4.1 Installation wiring inspection

4.1.1 Equipment and equipment fixation inspection

（1）The charger has a neat appearance, no knock and damage. Also, the position is consistent with the base
and firmly fixed without looseness.
（2）Equipment orientation meets installation criteria.
（3）No missing installation of equipment installation accessories.
（4）The instrument book of spirit level meets the requirements.
4.1.2 Cable laying and connection inspection
（1）Check whether the cable insulation skin is scratched or damaged.
（2）Check whether the copper nose of power cable is in compliance and whether the wiring is reliable.
（3）Check that the terminals of communication cable are correct and not loose.
（4）Check the connection of water pipe and no looseness. 。
（5）Check for hanging cable markings.
（6）Check whether the cable bending radius meets the requirements.
（8）Check whether each box leads the ground wire into the ground grid.
4.2 Check before power-on

（1）Short circuit: check the power supply line of the low voltage distribution cabinet connected to the
charging pile, and check whether there is a short circuit between the three-phase hot wire, neutral wire and
ground wire.
（2）Power supply voltage before power supply: before power supply of equipment, please check whether
the power supply voltage of plastic shell empty entering the line end of low-voltage distribution cabinet is
normal, without phase, over voltage, under voltage, phase sequence and other abnormalities
4.3 Check on power-on

（1）After confirming that the equipment wiring is complete and correct, power the equipment. The power
operation is as follows:
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 The voltage at
The voltage of
the lower end
System side charger inlet
of the outlet
circuit breaker terminal is Charger
terminal of the
for closing measured to be electrification
distribution box
operation about 400V
is about 400V
(+10%/-10%)
(+10%/-10%)

（2）Complete the overall installation.

5. Installation environment
The environmental conditions listed in the table below should be taken into consideration when selecting the
installation site of the high-power charger. The accumulation of dust or sand in the equipment may cause
premature damage to the equipment.
Table 3 Installation environment
Environmental conditions Recommended range
environment temperature -30℃ ～ 50℃

humidity 10% ~ 95%

altitude <3000m
sunshine No direct irradiation
Corrosive substance No pollutants, such as salt, acid, smoke, etc.
Insects, pests, vermin animals, No
termites
fireproofing Cabinet top, bottom no flammable
Wireless communications 4G signal is good
drainage facility Drainage facilities are good, no waterlogging
CP capacity of electric power According to the number of installation, to meet the
demand

6. Completion data

No. File name Page Document

Necessity

1 Unpacking record 1 √

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Appendix 1

Unpacking record

Name of
Date of
distribution
unpacking
store
Name of The actual The number Qualified Equipment
No. note
commodity commodity of number situation

10

Unpacking
result

Signature block Installation unit owner's unit

Installation manual Jiang Su Wanbang Dehe New Energy Technology Co.,Ltd.

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