13-1586 (ELEC)ELECTRIC VEHICLE
QUICK CHARGER
OWNER'S MANUAL
NSOC442D
NSOC442E
For saf+>ty, road carefully.
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS - This manual contains important instructions and safety
information for Nissan's Quick Charger Models NSQC442D and NSQC442E that shall be
followed during installation, operation, and maintenance of the unit.
- IMPORTANT — Check The Service Manual provided by manufacturer before servicing.
- The (D symbol marked on a rating label is an alternative for the word "Phase".
- The Quick Charger (QC) is designed to be operated in a maximum indoor/outdoor
environmental temperature of 104°F/40°C
- Use 2AWG, 90-C copper wire as input wire.
- Equipment shall be connected to the Star -connection (also known as Wye -connection)
-The screws of the field wiring terminal block should be tightened to a torque 'range of
135-150[in-Ib]/l 5-17[Nm].
- Use the crimping tool below for the crimping terminals of field wiring.
Manufacturer: JST Model: YPT-60N, BCT-860N, BCT-8150
m To avoid risk of fire, connect only to a circuit provided with 80
amperes maximum branch circuit over current protection in
accordance with the National Electrical Code, ANSI/NFPA 70.
GROUNDING INSTRUCTIONS - This unit must be electrically grounded for two reasons:
1)To avoid risk of electric shock and electrocution which can cause injury or
death, a grounding conductor must be run with the power feed conductors
l�WaRTJING
in accordance with the National Electrical Code. That grounding conductor
shall be connected to the unit's equipment grounding terminal.
2)For compliance with Federal Communications Commission regulations concerning
electromagnetic radiation, the unit must be connected to a ground rod as described in this
manual. The unit shall be connected to the ground rod using 2 AWG or larger wire, no more
than one meter in length. A permanent metal structure, such as a building frame or drain pipe,
that is permitted for grounding electrode in the National Electoric Code is an acceptable
substitute for a ground rod.
Grounding methods must comply with all local codes and ordinances and must employ only
copper conductors and terminal lugs.
WAThe Q
Ruuick Charger must be installed on a concrete foundation to provide a
�: stable base, to guard against water build-up and to avoid risk of fire,
electric shock and electrocution which can cause injury or death.
The Quick Charger employs parts that may produce arcs and sparks and
WARNlNQ
therefore the foundation must be 2[inches] minimum above the floor to
avoid risk of explosion and ignition due to flammable gases or vapors which
can cause injury or death.
NOTE - The height of the foundation shall be 6[inches] maximum from the finish floor drgroppd in
accordance with American with Disabilities Act regulations..:
Refer to the installation manual provided by the installation vendor for details.
- 1 - rvv 1,0 (Mar.27.2013)
Notes on installation of Nissan Quick Charger (NSQC442)
Installation must comply with local and national electrical codes.
1. Ground Rod Installation
The ground rod is installed for EMC grounding purposes only.
WARNING To avoid risk of electric shock and electrocution which can cause injury or
death, an input wire is used as a ground cable for safety ground.
1.1 Ground rod installation
Refer to Appendix 1 for ground rod location (example).
291
PLATE -BASE FRAME MTG
Front
rn
M X
O
Filter Box
Ipw�r Beds
Ground rod
` location
1.2 Ground resistance
The resistance to ground for a ground rod must comply with the National Electric
Code.
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2. Quick Charger (QC) installation
2.1 Removing the front cover
(See Service Manual)
This work must be performed by 2 persons to avoid personal injury.
WARnfInfG
The front cover weights approximately 55lbs (251(g).
When removing and installing the front cover, be careful not to pinch your
CAUTION
finger(s) and/or foot. In order to prevent injury, do not touch the edges of the
exposed portion.
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143
3 _ re .4 (Mar.27.20I3
2.2 Installing the Quick Charger (QC) on the foundation
(1) Remove the 4 bolts securing the QC to the shipping pallet.
(2) Lift and place the QC on the foundation.
When lifting and moving the QC unit body, use proper tools for the weight of the unit.
The QC weights approximately 595lbs (270K9).
Example crane
Lifting bar
Failure to lift the QC unit properly may result in personal injury or damage to
4& RN1NG
the equipment.
(3) Attach QC to foundation
The QC unit body is anchored in 4 locations.
Fix the PLATE -BASE FRAME MTG together with the QC in 4 places.
PLATE -BASE FF2AME MTG
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2.3 Connection of Ground rod and QC.
Remove the two bolts (M12-15) attached to the left and right rear terminals of the
PLATE -BASE FRAME MTG. Fasten the side of the solder less terminal of WIRE
ASSY BRAID, EARTH together with the braided line protruding from the left and right of the
charger lower portion ([1]).
Trim the length of the WIRE ASSY BRAID, EARTH to be as short as possible to reach the
ground rod clamp (If it is with a solder less terminal, cut the terminal and then use).
Connect the WIRE ASSY BRAID, EARTH to the ground rod clamp ([2]).
Refer to Appendix 2 for another example_
WIRE ASSY BRAID, EARTH x 2 (Accessory parts)
PLATE -BASE
FRAME MTG
Filter Box
lower
Front
L _ ,
rn
R Bladed line protruding
from the left and right of
the charger back lower
portion P
- -------------
Back
WIRE ASSY-
BRAID,EARTHs
rrr.rrrrrrwsrr
1]
Ground rod
emerge point
[2]
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2.4 Primary Power Wiring
Please follow proper installation procedures In order to prevent water and
CAUTION 1
dust Intrusion into the QC.
Wires should be routed underground and in metal conduit wherever there is
l ®CAUTION
`- - pedestrian traffic.
Instructions to connect the primary power to the QC unit are as per the following:
(1) Cover all cables (3 phase power cable 1-1/1-2/1-3 and ground cable) using the Flex tube
Primary power QC
- Flex tube recommendation
Brand: Sankei P/N: KUU54 (UL360)
Inner diameter 2.02in (51.3mm)
- Flex tube assembly
L IN
1 _`.A.F: ETY D PT.
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- 6 - e4� V. .0 (Mar.27.2 Y3)
(2) Insert power cables through reactors.
NOTE — the ground cable does NOT pass through the reactors
(3) Assemble power cables and crimp terminals.
(4) Attach crimp terminals onto unit terminal. Confirm power of each phase (R, S, T).
(5) Insert ground cable
(6) Strip ground cable insulation approximately 25mm-26mm (0.98 inches-1.02 inches).
(7) Fasten Lock Nut to 17Nm (12.5 lb-ft)
(8) Secure flex tube to knock -out part to prevent water intrusion.
(9) Apply cable dressing to opposite end of flex tube.
It
VWW
- Ground cable(s) wire connection procedure is as
per Appendix 3
- R38-10, Use attached crimp terminals
- Confirm power phase:
R: red S: white T. black
- Power Gables should be routed through reactors
- The grounding straps (octopus) cable.
- Ground cable should NOT be routed through
reactors
Picture shown is without the grounding strap
wires so the Reactor and ground cable routing
can be Mewed eas�ilY
7 - rev. .0 (Mar.27.2013)
2.5 Items to check after connecting the primary power cable
(1) Confirm that the tolerance of the primary power supply voltage between the measured
value and the LCD display value is within 5%. If it is not, perform calibration operation
on Printed Wiring Board1 (PWB1). (See Service Manual)
(2) Confirm that each line connection of the three -phases (R, S, and T) is correctly
installed.
(Use the phase indicator and check that the three-phase rotation is clockwise.)
The primary power supply voltage shall be within 480Vt15% AC.
The primary power voltage unbalance shall be within 3%.
CITY OF- LA QUINTA
BUIL-DINIG & SAFETY DEPT.
APPROVED
2.6 Operation check after installation (1/2)
Initial state:
(1) After the wiring from the breaker to the primary side has been checked, the voltage
check needs to be verified so that there are no problems.
(2) The power wiring has been connected and the Side Panel, Cover-Supt clamp, Plate
Assy Back (Upper), Plate Assy Back (Lower) and heat sink cover have been removed.
Check 1:
Check that the primary power supply voltage is within
AC480Vt15% by voltage tester, and the voltage
unbalance of three-phase AC is within 3%.
No
Contact service person
Yes
Check 2:
Check that each line connection of the three phases (R,
S, and T) is correct by using the indicator.
No
Fix the connection
Yes
Check 3:
Check that the tolerance of the primary power supply
voltage between the measured value and the display
value is within 5%.
J
No Calibrate PWB1.
Yes 1(See Service Manual)
I Turn ON ELC131 and ELCB2. I
Check 4:
Check that the READY, CHARGE, and ALARM lamps
all illuminated and then that all turn off after 3 seconds.
(With LCD model, check that the LCD panel illuminates
and the "Quick charger for..." screen is displayed.)
I Contact service person
Yes
Press the emergency stop SW.
Check 5:
Check that the ALARM lamp illuminates. (With LCD
model, check that 'The EMERGENCY button was
pressed..." is displayed on the LCD panel.)
No
Contact service person
Yes
Release emergency stop SW.
X Refer to recovery procedure in Service Manual
Press and hold the STOP SW (3 seconds or longer).
Check 6:
Check that the ALARM lamp turns off. (With LCD model,
check that the "Quick charger for..." screen is
displayed.)
No
Contact service person
Yes
Check 7:
Check that the fans listed below are operating as
prescribed.
- 3 boost fans:
Operate after power ON.
No
Contact service person
Yes
Turn OFF ELC131 and ELC132.
1
next section
ELCB1
ELCB2
u SAF
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rev. 1.
27.2g13) '
. J
2.7 Installing the Front Cover
See Service Manual.
When installing the Cover-Supt Clamp, jointly fasten 2 grounding wires of the charger cable.
Jointly fasten to the right side of strain relief bracket
(Grounding wire from charger cable electrically -conductive cl
Jointly fasten to the left side of strain relief bracket.
(Grounding wire from charger cable lock nut)
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_ 10 _ III �% r A (Mar2MC
2.8 Operation check after installation (2/2)
I Remove the ELCB cover. I
Turn ON ELCB1 and ELCB2. I
Check 1:
Check that the fans listed below are operating as
prescribed
- 3 heat sink fans:
Operate after power ON.
- 2 exhaust fans:
Operate after power ON
- Transformer cooling fan
Operate after power ON.
No
Contact service person
Yes
Re -tighten all screws that you installed again.
Check 2: ■
Check that all rear panel screws have been tightened and
are free of gaps, and check that there are no gaps in the
mounting surfaces. (Check visually that the spring washers
are compressed.)
No
Contact service person
Yes
Install ELCB cover.
Check 3:
Check that there is no gap between the ELCB cover and
the unit. Check that there is no gap between the breaker
window and the unit. (Check visually.)
Contact service person
Yes I '
Press the panel START SW.
Check 4:
Check that the ALARM lamp is lit. (With LCD model, check
that "Please check that the charge connector
is connected ..." is displayed on the LCD panel.
No
�ontactserviceerson
Yes
I Press and hold the panel STOP SW (3 sec. or longer). I
Check 5:
Check that the ALARM lamp turns off. (With LCD model,
check that "Quick charger for..." screen is displayed.)
Contact service person
Yes
Fonect charger connector to electric vehicle (or EV
lator).
ake sure that charger connector is locked correctly.
Press START SW
Check 6:
Confirm that charging starts.
(Check that the panel screen displays the charging status.)
N❑
Contact service person
Yes
I After 5 minutes, press the STOP SW. I
Check 7:
Confirm that CHARGE lamp turns off.
Contact service person
Yes
Disconnect the charger connector from the electric vehicle
(or EV simulator).
The operation check is completed.
2
ELCB cover
NISSAN
installation Manual
Appendix 1 — Example of ground rod location
w
Ground rod emerge
1
1
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BACK
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1
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1 rlC%4
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1
R 84"
Bolt Circle
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FRONT
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1 1 21'
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OVED
-15
- 12 - rev.1.0 (Mar.27.2013)
Pppendix 2 —Another example of ground rod connection
The grounding method depicted in the following diagram is also acceptable.
Use acorn clamps to install (2) #2 bare Cu wire from ground rod to first rear anchor bolt
and then to other rear anchor bolt as shown on diagram.
(4) Anchor Bolts
1 /2" x 12" J Hooks
Extend Thread 1" To
1 1 /2" Above Concrete
Back 0 Charg_e
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Concrete Foundation
(See Drwg. S1-3)
Front Of Charger
*Only Rear Anchor Bolts To
Be Connected To Ground Rod
(2) #2 Bare Cu
(3) Acorn Clamps
Ground Rod Embedd
In Concrete Foundat
tea LAQi+�INTA
&_ SWETY DEPT.FJOVEL
I
- 13 - rev.1.0 (Mar.27.2013)
Appendix 3 - Instructions for Connecting Conductor
■ Structure
Customer purchase parts
Knock -out parts (Provided)
■ Assembly sequence
Parts assembly should be as follows
End cap Peaking Washer Hexagon cap nut
Lock nut Sheet packing Packing Washer Hexagon cap nut
r
Main part End cap
1. Set end cap to the edge of flex tube.
2. Set all parts to edge.
3. Set end caps.
4. Set hexagon cap nut by twisting.
5. Tighten hexagon cap nut by tool.
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PIDROVE
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Tr
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-14-
rev.1.0 (Mar.27.2013)
Power Cage Clamp Rail -mounted Terminal Blocks for 35mm2
Side -entry Item No: 285-135,134,137
■ Rated
Wire Size: 6-35mm2/AWG8-2* Rated voltage: 1000V (600V UL)
Terminal block width: 16mm (0.63inches) Rated surge voltage: 8kV
Rated current: 125A (115A UL) Pollution degree: 3
* There are some cases where a wire cannot be inserted to a terminal block because of a thick
insulation or a special kind of conductor.
■ Structure
Part name and structure of terminal block
Jumper slot
Marker slot
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Removal hook
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■ Tools
Customer purchase parts
210.621TR
Supplier: WAGO Corporation
Info.us@wago.com
Part#: 210-621 TR
Operating slot
Locking button
(Color: orange)
Wire hole
■ Stripping of Wire
Strip the conductor's strip length according figure below. Frayed, twisted or bent wires area
prohibited.'
Strip Length 25mm-26mm Max external dia. 010mm
E i Y DEPT.
ED
Strip Length
twisted
- 15 - rev.1.0 (Mar.27.2013)
Wire connection
Please follow the instructions otherwise the product
CAUTION could be damaged. Note1 ).
Note1 ) Do not rotate when a 210-621TR blade is not
inserted correctly. U U
Note2 ) Do not rotate clockwisel
1. Rotate counter clockwise using a
210-621 TR blade.
2. Hold the clamp in the open position and
push an orange button.
Place stripped wire into the clamping unit up to
the stop and hold it in position.
1. Slightly rotate counter clockwise to release
the latch.
2. Rotate the 210-621 TR blade clockwise
until it stops.
CITY OF LA QUINTq
kiUILDtNG & SAFETY DEPT
APPROVED .
E ATE
-16-
rev 1.0 (Mar.27.2013)