Yet another CU, RCD/RCBO, AVR, SPD, Line Conditioner Post

[mistaphix]

Thanks again to the moderators and contributors to this forum, regardless of my experience, there is no way I'd attempt this in Thailand without the valuable insights and advice offered here.

 

Initial Query: Do we need a line conditioner or something for these Batteries and Chargers (4 in total - 220V/7amp each)
Initial Consultation: Well, lets regress, the little beach shack your operating out of has no Ground to the original Breaker Box (CU) and all this commercial and domestic equipment tripping these power strips every day is an issue, see the melted plastic behind that old knife switch... your getting little tingles from the coffee machine. 
2nd Onsite Visit: We ordered 4 more batteries and chargers...
Subsequent Consultations and Evaluation led to ditching the plan of a little CU with a RCD and a SPD and 2 duplex outlets connected to either a MCB in the existing box with a new ground rod somewhere (see separate post) or 15m of THW 1x10 from the existing 60a knife switch out front.
I'll let the pics do most of talking along with a blow by blow and ensuing questions for this post
A. 'Borrowed' one of the two ground cables doing nothing but collecting oxide by the incoming pole. To it, connected 20m of THW 1x16 with a heavy duty copper cable to cable 2 bolt joiner. Some Hi-Voltage Splice Tape and liberal amount of vinyl insulation tape.
B. Added another 60amp Knife Switch along with a new enclosure (Question 1. below) and mated the two flimsy Chang switches with same materials as mentioned above.
C. Took L & N along for the 15m journey along the side of the shack with their long lost brother G/E via 3way rack & insulators. Note: PEA are doing major upgrades in the area which inspired me along with the fear of melted conduit dripping onto the neighbours breezeway.
D. New Haco 12 way CU (really wanted plastic split box, but not one supplier on Samui had either) populated with: 1 x Haco R7-263/30 - 2P 63a and 5 x Haco H7-16/1C - 1P 16am (4 x 14a circuits for the 8 chargers + 1 for other sensitive gear in the room. Opted for DIN as per Crossy advice on bigger selection of SPD (DSqaure Solution was nearly triple price)
E. Installed 4 x panasonic duplex outlets (best build quality ive used for the price point) and 4 circuits of VAF 2 x 2.5. Any suggestions of different brand/spec for a duplex 16-20a
F. Took some average pics and came here to the Mount Olympus of Fire before I finish Stage 1 of version 3 (This is a prototype install, which will have to be replicated a number of times for each property that take on this very cool new water toy (world first)

So the questions are:
Q1. Incoming: The 2 bolt cable joiner was, I think the only option for connecting the existing Ground to the new extension, any other suggestions?
But using same in the incoming enclosure just doesn't feel or look right. I did buy 3 poles of modular DIN 100a busbar, not super heavy duty, but I thought it might be adequate when used with ring terminals soldered on to the 16mm. Plans are to change the 2 x 60am Chang Throw Switches with a pair of no-fuse breakers 1 x 60a for the old CU + 100a for the new CU. Any suggestions on Switch/Breaker/Joiner etc for the incoming box, bearing in mind there is nothing else before or after the 15/45 Meter.
Before:

 

 

After:

Q2. New CU: Do I need to install a 63a Main Breaker before the RCD to use this setup now?
Stage 2 plan is to add another CU under this one for all the leaky and trippy appliance circuits starting with a 80/100a Main Breaker (2 deep freezers, 3 commercial + domestic fridges, coffee machine etc etc)
Q3. The expensive/specialised/sensitive Charger & Battery Combos need/want/require ultimate protection from all the fire demons. Over/Under Voltage Cutoff is fine, as protection is more important than continuous supply. Haco supplier can order the SPD I (naively/lack of choice) selected (Haco S7-40C/1C)  - Any other suggestions for Surge/Lightening Protection? And most important question, What else can I add to this setup to ensure that the potential for damage is at its least likely?
Adjustable? Voltage Regulator/Line Conditioner - DIN Mount is desirable or a standalone wall box before the CU would be ok. MOV's into each outlet?

Any brand/items that are readily available in Thailand, Chinese items that need replacing every week, will not cut it.
And finally, anybody know where in Thailand I can source Legrand Pass & Seymour wiring devices and accessories?

 

 

 

[Crossy]

I'm not convinced that "borrowing" the PEA ground was the best decision, you want the shortest ground run possible from your surge protection. May be wise to add another rod or two at the consumer unit.

 

The bolt connectors work well, best to crimp the ring terminals rather than solder, but what you have should be OK. The ideal solution would be Henley Blocks http://www.cef.co.uk/catalogue/categories/junction-boxes-henley-blocks but good luck finding them here

 

Replacing the Chang units with 2-pole MCBs is a good idea. But 100A + 60A on a 15/45?? I would make them both 63A unless you plan on upgrading the supply. Do be sensible with your breaker sizes, you want them to open when they're supposed to.

 

If you have the breakers instead of the Chang units, no need for a front-end MCB in the CU.

 

Are your chargers Class-II (double-insulated) or do they require a ground? What is their input voltage range?

 

I would put a nice big surge arrestor in the CU, with a short run to a decent ground rod. Then some of the little 8kA beasties inside each outlet (there are links in many of my threads).

 

Get a decent under/over trip, it will likely need a contactor (relay) to handle those chargers.

 

Even with the best in surge protection I would also pull the plugs on everything at close of business each day and if there's lightning in the area.

 

The Kymera looks enormous fun.

 

I'll add some links to assorted kit when I get back from a site visit.

 

 

 

 

[mistaphix]

Thanks Crossy,

 

Yes borrowing the PEA ground was more of a convenience until a better plan for install can be concocted. The property is literally on the beach with the new CU in a room facing the ocean. The ground (tidal sand) is only a 4-5m run of cable, refer to my first post:
 

Its pretty much sand until the Soi... Before jackhammering up the neighbours breezeway in search of some 'earth' I opted for the PEA pinch to get this charging station online.

Terminal / Connector Tips noted, will look into ordering the Henley blocks or similar. May have to put in a small incoming CU with a 100a Main Breaker (Stage 3 - upgrade the supply and meter 30/100 or juggle it all onto 2x63a to feed the old and new CU + another new CU for the leaky stuff. I've may have bloated the amperage tally, the max total is 203a for the whole premises including 8 of theses chargers. 

 

Am downgrading existing breakers to what they should be and the chargers are on 16a (speculated to be max draw at 7a each x two per circuit)

Chargers are not Class 2 and Im pretty sure these chinese masterpieces should be properly grounded. 

 

 

Charger Specs: this is all i have at the moment (plus a nearly useless schematic) 

 

 

And yes, Surge Arrestor and Under/Over is what i need to procure next. As mentioned, this whole thing is Prototype/Version 1 of a system that will get replicated and installed at subsequent locations, so I am looking for correct/adequate/available/elegant solutions. 

Many thanks and bring the family for some quiet water sports.

 

[johng]

2 hours ago, mistaphix said:

correct/adequate/available/elegant solutions. 

 

2 hours ago, mistaphix said:

for some quiet water sports

why not just close the bathroom door