Ultracharger 500S Installation Guide

BP Chargemaster ULTRACHARGER
500S
Electric Vehicle Rapid Charging Unit
Installation Guide

VERSION 1.03 – SEPTEMBER 2016

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 Ultracharger 500S Installation Guide

CHAdeMO outlet
Combined Charging
System (CCS) outlet

AC outlet

RFID Card Reader

Touch Screen
Colour display

Emergency Stop
Button

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 Ultracharger 500S Installation Guide

TABLE OF CONTENTS
Safety Information 4
Overview of the Ultracharger unit 5
1. INSTALLATION REQUIREMENTS 7
2. SITE PREPARATION 7
3. UNIT PREPARATION 7
4. CONNECTION 8
5. EARTHING REQUIREMENT 8
6. POWERING UP 8
7. SYSTEM CHECKS 10
8. APPENDIX 10

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Safety Information

 Warning: Protective earth – To protect against electrical shock if there is a fault, the
earth terminal must be connected to earth before operating the equipment
 Switch main power off before connecting or disconnecting the device.
 The main power must be turned off before connecting or disconnecting wires to the
terminals
 Dangerous voltage present for at least 5 minutes after disconnecting all sources of
power
 Warning: Electric hazard - Make sure there is not any voltage in the input terminals,
in the outputs and in the power module bus-bars
 Please note that the enclosure and devices inside it may become very hot
depending on the ambient temperature and load applied to the power supply. Risk
of burns!
 Do not introduce any objects into the unit!
 Warning: Explosion Hazard - Do not disconnect equipment unless the power has
been switched off or the area is known to be non-hazardous

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 Ultracharger 500S Installation Guide

Overview of the Ultracharger unit

Introduction
Electric vehicle users may want to recharge the vehicle battery more quickly than
can be achieved using a regular domestic or lower power charging system. The
Ultracharger from BP Chargemaster provides such a solution by permitting EV
charging at power levels up to 50kW, depending on the option selected and
various other parameters e.g. residual remaining battery charge, battery
temperature, electrical supply etc. This should allow compatible electric vehicles
to recharge 80% of its battery in less than 30 minutes.

Furthermore the Ultracharger provides EV charging by three different industry

standard systems, namely Combined Charging System (widely known as CCS or
Combo), CHAdeMO and AC (also known as Type 2 or Mennekes). Currently the
Ultracharger only permits using one of the three systems at any one time.

Description and layout

A – CCS charging cable and plug

B – CHAdeMO charging cable and plug

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C – AC charging cable and plug

D – Emergency stop button
E – RFID tag reader panel
F – Touch-screen user interface

G – Rear exhaust vent

H – Rear inlet vent and filter panel
I – ‘Above ground’ installation mains cable entry point

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1. INSTALLATION REQUIREMENTS
The completed installation must be compliant with both BS7671 – IET Wiring
Regulations 17th Edition (BS7671:2008 incorporating amendment number 3:2015) and
IET Code of Practice for Electric Vehicle Charging Equipment Installation 2nd Edition.
Installers are expected to hold up to date copies of these publications.
Prior to commencing installation a risk assessment should be carried out, as detailed in
Annexes D1 and E1 of the IET Code of Practice for Electric vehicle Charging Equipment
Installation 2nd Edition.

2. SITE PREPARATION
The 500S Ultracharger shall be installed on a firm, level and horizontal concrete cube
approximately 800mm x 800m x 800mm conforming to BS/EN206-1 and BS8500. The
base shall be strong enough to support the weight of the Ultracharger unit
(approximately 180 kg). Detailed drawings of the floor space required and drilling
positions for the ground anchors can be found in the Appendix – Figures 2 & 3.
The incoming mains cable should be ducted to enter the Ultracharger through the
provided aperture in the base plate of the unit when the Ultracharger is lowered into
position. Electrical supply to the unit is by 5 x 25mm² mains cable for a cable run of no
more than 10m. For cable run lengths longer than 10m please consult BS7671 ”IET
Wiring Regulations for Electrical Installations” for further information. The cable should
be additionally protected by a 4-pole 100A Curve ‘C’ 15kA MCB and a 4-pole 125A Type
‘A’ 300mA RCB, usually placed at the supply end.

3. UNIT PREPARATION
The Ultracharger can be hoisted into position by means of 4 x M12 eyebolts (not
supplied). Access is gained by removing the lid panel as follows;
a) Remove the Ultracharger from the shipping packaging and stand it upright near
to where the unit is to be sited
b) Remove the CHAdeMO and AC cables from their docks on the right-hand side of
the unit
c) Carefully place the cables and plugs on the ground
d) Open the front outer door of the unit by unlocking the two latches on the left-hand
side of the door.
e) Remove the 2 x M5 screws in the underside of the front of the lid panel
f) Gently slide the lid panel rearwards approximately 30-40mm until the tongue on
the underside of the lid disengages from the top of the cabinet
g) Lift the lid panel vertically off the unit and place it carefully nearby taking care not
to damage it
The four M12 button head screws and rubber washers (NB – DO NOT DISPOSE!) can
now be temporarily replaced with four M12 eyebolts and the Ultracharger can be
carefully moved into place.

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Once in position, remove the eyebolts and replace the four M12 screws and washers.
The lid can then be replaced following the reverse of the directions above.
The Ultracharger is secured to the ground by M12 ground anchors in four positions (see
Appendix – Figure 3). In order to reduce corrosion issues, it is recommended that
stainless steel fixings are used where possible.

4. CONNECTION
Once the Ultracharger has been secured, the mains supply cable terminals can be
accessed by removing the kick panel at the base of the frame below the inner door. This
is fixed using 2 x M5 screws on the left-hand side of the kick panel.
The supply cable should be cut and prepared so that each of the cores can be inserted
vertically into the corresponding holes on the pass-through terminals. Each of the inner
cores should be stripped to expose a conductor length of 19mm and finished with a
ferrule. Once inserted, the cables can be secured by tightening the cable clamp screws
(minimum torque 4Nm, maximum torque 4.5Nm).
Having secured the supply cables, the kick panel and screws can be replaced.

5. EARTHING REQUIREMENTS
An independent earth connection must be utilised. The method of earthing shall comply
with the requirements of:

 BS7671 – IET Wiring Regulations 17th Edition (BS7671:2008 incorporating

amendment number 3:2015)
 IET Code Of Practice for Electric Vehicle Charging Equipment Installation 2nd Edition
particularly:
o Section 5.2 – Protection against electric shock
o Section 5.3.3 – Converting to a TT system
o Section 7.3 – Earthing and protective equipotential bonding requirements
o Section 8.2 - Earthing and protective equipotential bonding requirements
Refer to the IET Code of Practice for Electric Vehicle Charging Equipment Installation
2nd Edition for detailed guidance on earthing arrangements. Sections 3.3, 5.2, 5.3, 7.3
and 8.2 apply.
The measured resistance of the earth electrode shall not exceed 100 Ω.

6. POWERING UP
Once the unit is fixed in position and the main supply cable is properly connected,
switching on the power to the unit can be done as follows;
a) Open the front outer door (if not open already)
b) Override the safety interlock microswitch on the inside of the outer door
c) Carefully open the inner door using the triangular ‘Double Bit 5’ key on the two
latches

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 Ultracharger 500S Installation Guide

d) Locate the Front DIN Rail assembly (on the right-hand side of the interior)

Figure 5.1 Schematic of internal components - front elevation

e) Switch on the components in the following order (see Figure 5.1 above);
i. SPD Backing MCB
ii. Power Stage RCB
iii. AC/DC Power Module MCB
iv. AC Charger Power MCB
v. Control Stage and Fans RCCB
vi. Control Stage and Fans MCB
f) The unit should now have power and the display screen and fans should now be
running
g) The inner door can now be closed and the latches shut

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 Ultracharger 500S Installation Guide

h) The outer door can be closed and locked, taking care that the safety interlock
microswitch override is removed and the switch closes when the door is closed
i) The CHAdeMO and AC charging cables can now the returned to their relevant docks
on the right-hand side of the unit

7. SYSTEM CHECKS

a) Measure voltage in the Mains Input Terminal Block:

i. Voltage between phases: 400Vac ± 10 %
ii. Voltage between phase and neutral: 230Vac ± 10 %
b) Measure voltage in right side of the AC/DC Power module MCB:
i. Voltage between phases: 400Vac ± 10 %
c) Measure voltage in the right side of the AC Charger Output Contactor
i. Voltage between phases: 400Vac ± 10 %
ii. Voltage between phase and neutral: 230Vac ± 10 %
d) Measure Voltage in the GUI, UxB and Fans 12 VDC PSU
i. Voltage in the input between phase and neutral: 230Vac ± 10 %
ii. Voltage in the output between V+ and V-: 12.3Vdc ± 1 %
e) When door is open, first an “Emergency Stop” and thereafter an “Unit out of service”
messages shall be displayed on the screen and LEDs illuminate red.
f) Close the door and wait until “OK” button is displayed, then acknowledge the error
message by pressing the “OK” button, then 3 initial rotating screens should be
displayed and LEDs illuminate blue.
g) When door is closed and the Emergency Stop button is pressed, an “Emergency
Stop” message shall be displayed on the screen and LEDs illuminate red
h) When door is closed and Emergency Stop button is reset, wait until “OK” button is
displayed, then acknowledge the error message by pressing the “OK” button, then 3
initial rotating screens should be displayed and LEDs illuminate blue.

8. APPENDIX

Figure 7.1 External dimensions of the Ultracharger 500S

Figure 7.2 Plan view of the footprint of the Ultracharger 500S
Figure 7.3 Baseplate dimensions and ground anchor fixing points
Table 7.1 Ultracharger 500S Incoming Power Requirements

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Figure 7.1 Ultracharger 500S external dimensions

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 Ultracharger 500S Installation Guide

Figure 7.2 Plan view of Ultracharger 500S footprint

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Figure 7.3 Base plate dimensions and fixing points

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3 x 400/480VAC 3Ph+N+E
Voltage
Voltage Range 360Vac to 508VAC
Frequency 45Hz to 65Hz

Maximum Input Current 78A per phase (@400VAC)

Power factor >0.98

Efficiency >94%

Earth Leakage Current 3.5mA (max)

To be compliant with local regulations
Earthing Scheme
(usually TT)
Table 7.1 Ultracharger 500S Incoming Power Requirements

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