Leviton CPDCF Installation Manual Download Page 5

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Contents

Prepare for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Check Site Readiness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Check Express 250 Shipping Crates . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bring Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Secure Anchors and AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Prepare the Express 250 for Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . 11
Mount and Secure the Express 250. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Connect the AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3 Pair the Charging Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Install New Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install DC Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install the Ethernet Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4 Install Cover Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5 Complete the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Complete the Installation Wizard: Standalone Installations . . . . . . . 49
Complete the Installation Wizard: Paired Installations. . . . . . . . . . . . 50
Pinpoint the Station(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Run a Test Charging Session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Appendix A Removing the Express 200 Adapter . . . . . . . . . . . . . . . . . 55

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11/18/2019 3:37:40 PM

Summary of Contents for CPDCF

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: ...se 3 Always ground the ChargePoint charging station Failure to ground the charging station can lead to risk of electrocution or fire The charging station must be connected to a grounded metal permanen...

Page 3: ...t Inc CHARGEPOINT is a U S and European Union registered trademark and service mark of ChargePoint Inc and cannot be used without the prior written consent of ChargePoint Symbols Used in This Document...

Page 4: ...iv...

Page 5: ...ll Cover Panels 29 Install the Left Extrusion 29 Connect the Right Extrusion s Holster Light Cables 31 Install the Right Extrusion 32 Install the Power Modules and EMI Shields 35 Fill the Coolant Rese...

Page 6: ...vi...

Page 7: ...or chargepoint com eu installers Document Content Audiences Express 250 Data Sheet Full station specifications Site designer installer and station owner Express 250 Site Design Guide Civil mechanical...

Page 8: ...ht DC wiring and Ethernet communication c CAUTION Do not use power tools during installation or servicing Over torquing can damage the equipment Important Always ensure that the installation complies...

Page 9: ...e DC conduit max 76 2 mm 3 in trade size and Ethernet conduit max 19 1 mm in size are positioned correctly in the CMT and cut down to 76 2 mm 3 in above grade The service clearance of open space not n...

Page 10: ...ellular signal detection device such as a Snyper Octopus or similar to ensure the signal is 85 dBm or better Note that these numbers are negative so 70 dBm is stronger than 85 dBm and 90 dBm is weaker...

Page 11: ...n geographic areas that experience frequent thunderstorms supplemental surge protection must be installed at the service panel Contents Max Shipped Dimensions Max Shipped Weight Express 250 Charging S...

Page 12: ...lds x2 not shown Propylene glycol coolant the coolant label references its Safety Data Sheet if needed Ethernet connector that accommodates up to 6 mm 0 24 in OD jacketed Cat5e or Cat6 cable for Paire...

Page 13: ...ds one Power Module each It also contains a fastener kit that includes Ground stud brackets x2 M5x6 mounting screws x8 These brackets are only needed for Power Module replacements in older stations Ne...

Page 14: ...river 5 mm 3 16 in hex driver 2 Phillips screwdriver with long handle Cellular signal detection device such as a Snyper Octopus or similar Standard electrical equipment such as wire cutter wire stripp...

Page 15: ...examples for reference Leave 61 cm 2 ft of each conductor above grade at each end DC lugs x4 lug specifications are Silver plated copper compression lug 2 hole specified for North America tin plated i...

Page 16: ...such as Fluke 117 or similar Ethernet wiring for DC Minimum of CAT5e or better Outdoor or plenum rated wiring Maximum run length of 100 m 328 ft Leave 3 2 m 10 5 ft of wire above grade at each end Fie...

Page 17: ...und maximum 160 mm 6 3 in If the site is using armored cable strip the outer jacket to within the same height 2 Ensure no bell ends are left on any conduit after all wires are pulled Bell ends can int...

Page 18: ...vel 7 Retrieve the lifting straps from either the toolkit or the main crate If there is no separate toolkit rest the crate in a stable position and unlatch the lid Retrieve the lifting straps just ins...

Page 19: ...Loosen but do not remove the wingnuts holding the boards that secure the charging station base Slide the support boards away from the charging station 14 Using either a forklift or crane remove the E...

Page 20: ...the rails is to ensure the Express 250 is installed a minimum height from the concrete allowing the front and rear panels to sit flush with the concrete surface 4 Install a washer and nut onto each of...

Page 21: ...e tightening of the nuts did not cause the Express 250 to shift Make any adjustments to ensure the Express 250 is level while all nuts are tightly secured 10 Use the supplied T27 Torx driver to remove...

Page 22: ...nnect the power to the 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 INSTRUC...

Page 23: ...iple screw holes are available to fasten the bracket at different heights e Skip to step 7 6 For the UK and other regions using armored cable a Use a T25 Torx to loosen the two M5 screws attaching the...

Page 24: ...ool into the Wago port a and rotate the tool firmly counter clockwise 90o to open the connector b Lock the connector in the open position by firmly pressing the orange button below it b c Insert the w...

Page 25: ...conduit Only one wire is shown in the example Shunt wires are interchangeable Release the terminal tab and confirm each wire is held securely by performing a pull push test 12 Use cable ties to bundle...

Page 26: ...of the cover under the side panel b 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 c Slide...

Page 27: ...tations to be paired For each pair check site plans to see which charging station is designated Station 1 and which is Station 2 If the plans do not define it designate them now 4 Affix the AC disconn...

Page 28: ...1 B1 on one end and Station 2 A on the other end Station 1 B1 on one end and Station 2 A on the other end Important Disconnect numbers must be written in permanent marker Normal ballpoint pen ink doe...

Page 29: ...r bracket hole Note If the cable bend radius does not allow them to thread through the rodent guard bracket use a T25 Torx to temporarily remove the bracket from the charging station Immediately reins...

Page 30: ...h Use a T25 Torx to loosen the two M5 screws attaching the rodent guard bracket to the charging station Slide the bracket down to leave no gap above the conduit openings i Complete installation of th...

Page 31: ...teps for Station 2 Install the Ethernet Wiring 1 Measure the length needed to extend the Ethernet wiring from the conduit opening up the side of the frame and into the Express 250 s Station Management...

Page 32: ...e at each corner c 4 Route the Ethernet wire down behind the touchscreen adjustment bar 5 With hand pressure swing the bottom of the touchscreen out to a 45 degree angle d 6 Re measure the distance to...

Page 33: ...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 9 Test the Ethernet wire for functionality 10 Plug the Ethernet wire into the Eth...

Page 34: ...dent guard bracket openings for wiring to pad any sharp edges and block ingress c Around the edges of the rodent guard bracket where it will meet the extrusion 12 Install the DC wiring cover on the le...

Page 35: ...ight corner of the Express 250 press and hold the yellow release latch while pulling the Power Module tray out of the station 2 Carefully lift the charging cables connectors out of the Power Module tr...

Page 36: ...d T25 Torx driver Note The step ladder is needed to reach the top screws Note The top and middle screws are asymmetrical 5 Use the supplied T25 Torx driver to loosely secure the bottom two screws next...

Page 37: ...ip mounted to one of the holsters top or bottom holster varies by product version 2 Remove the P clip hardware from the extrusion holster Generation 1 attached with screw use a T25 Torx driver to remo...

Page 38: ...round cable lug P clip with light power cable routed through M5 T25 screw head Generation 2 holster stud P clip with light power cable routed through nut Torque the nut to 5 5 Nm 48 7 in lbs Install t...

Page 39: ...the supplied T25 Torx driver Note The step ladder is needed to reach the top screws Note The top and middle screws are asymmetrical 3 Use the supplied T25 Torx driver to loosely secure the bottom two...

Page 40: ...to the middle screws is easier with the Power Module mechanism handle in the closed down position 5 Tighten all right extrusion screws 6 Secure each holster to the frame using a T25 Torx to fasten a s...

Page 41: ...andles and gently slide it into its holder with its connections facing outward a Once the Power Module is positioned partially inside its holder fold the handles down to slide it in completely CAUTION...

Page 42: ...f applicable 4 Lift each Power Module to the upright position one at a time 5 If not already done remove the safety caps from the coolant ports 6 With hand pressure swing the bottom of the touchscreen...

Page 43: ...he 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 8 At the bottom right of the Express 250 p...

Page 44: ...er Module connectors The ridges on the Power Module s top edge should not be visible If the mechanism does not engage raise it again and push the Power Modules to the back of the station to realign th...

Page 45: ...clean the frame grounding locations and both sides of the rear EMI shield tabs 15 Reinstall the T20 screws with an M5 flat washer from the installation kit to secure the top tabs of the shield on eac...

Page 46: ...r to attach the front EMI shield to each middle and bottom grounding location on the front of the frame h Torque to 4 Nm 35 in lbs Fill the Coolant Reservoir The Express 250 is shipped with an empty c...

Page 47: ...side of the coolant reservoir 3 Using a step ladder if needed unscrew the reservoir cap 4 Use the funnel to fill the reservoir to the marked Max line with coolant 5 Replace the reservoir cap 6 Cut and...

Page 48: ...tight gasket Carefully push the panel down Note The charging station has guide marks on the frame to show initial and final cover locations Important When installing the rear panels take special care...

Page 49: ...ewer cover panels do not have signs on the rear panels only the front panels 3 Using two hands hold the top rear panel at an angle and slide into place beginning with the top edge Squeeze the sides of...

Page 50: ...corner 6 Use the T25 Torx driver to tighten the top two screws Install the Front Cover Panels 1 Align the guide tabs on the front bottom panel to the matching slots on the Express 250 s frame and slid...

Page 51: ...d as you carefully push the middle panel down until it is fully seated 4 Remove the packaging tape and material from the touchscreen 5 Connect the proximity sensor wires on the middle vent panel to th...

Page 52: ...hten the knobs to secure it 10 Use a T25 Torx driver an M5 screw and an M5 washer to attach each end of the touchscreen ground strap to the frame d Torque to 4 Nm 35 in lbs 11 Using two hands align th...

Page 53: ...cables to their corresponding connectors on the back of the display each connector is keyed to fit only into its matching port a Communications cable USB A b Holster light cable c Area light cable x2...

Page 54: ...d hold it in place with enough force to compress the gaskets 6 Use the supplied T25 Torx driver to tighten the two captive screws on the bottom edge of the area light bar 7 Unwrap the charging cable c...

Page 55: ...e parking space where the Express 250 is installed Complete the Installation Wizard Standalone Installations Follow the steps in this section if you are installing a Standalone charging station For Pa...

Page 56: ...Yes 6 Skip the next section and continue with Pinpoint the Station s page 52 Complete the Installation Wizard Paired Installations Follow the steps in this section if you are installing Paired chargi...

Page 57: ...match the panel letters to this illustration a Front bottom panel b Middle vent panel c Front top panel d LED display e Area light bar f Rear bottom panel g Rear middle panel h Rear top panel i Left...

Page 58: ...t com 2 Log into the ChargePoint mobile site from your smart phone with your installer credentials 3 Scan the QR code on the screen with your phone Enter the activation password and touch Next 4 Confi...

Page 59: ...he Express 250 operates correctly and no errors are displayed the installation is complete If the Express 250 does not power up or fails to begin a charging session confirm the wiring is properly conn...

Page 60: ...54...

Page 61: ...o remove the L shaped wiring cover 3 Remove the conduit shield from the wiring cover by holding down the conduit connector release ring while pulling the conduit shield 4 Remove the Express 200 adapte...

Page 62: ...56...

Page 63: ...Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial envi...

Page 64: ...747 Telephone 1 800 323 8920 FAX 1 800 832 9538 Tech Line 1 800 824 3005 M F 8AM 10PM Sat 9AM 7PM Sun 9AM 5PM 2022 Leviton Manufacturing Co Inc All rights reserved Visit our Website at www leviton com...

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