EV-Box HomeLine Autostart Pole/Wall Mounted Single 16amp Installation Manual

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EV-Box HomeLine Autostart Pole/Wall Mounted Single 16amp Installation Manual | Manualzz

Installation Manual

EV-Box Charging Station

HomeLine Model

Table of contents

1.

Safety regulations ............................................................................................................... 3

Transportation and storage ................................................................................................................... 3

2.

Product description ............................................................................................................ 4

General ...................................................................................................................................................... 4

Online - Model with modem .................................................................................................................. 4

Safety ......................................................................................................................................................... 4

Mode 3 Controller ................................................................................................................................... 4

Operation .................................................................................................................................................. 4

3.

Control .................................................................................................................................. 5

Start charging ........................................................................................................................................... 5

Stop charging: .......................................................................................................................................... 5

LED ring indicator .................................................................................................................................... 6

4.

Installation ........................................................................................................................... 7

Safety requirements ................................................................................................................................ 7

Location ..................................................................................................................................................... 8

Connecting the power supply cable ..................................................................................................... 8

Installing the charging station ............................................................................................................... 8

Wall Mounting .......................................................................................................................................... 8

Wall plate for easier mounting .............................................................................................................. 8

Connecting the charging station ........................................................................................................... 9

Finishing Installation ............................................................................................................................... 9

Maintenance ............................................................................................................................................. 9

Product and environmental characteristics ........................................................................................ 9

5.

Installing an external modem ........................................................................................ 10

6.

Hub / Satellite connection .............................................................................................. 11

7.

Technical Specifications .................................................................................................. 12

8.

Troubleshooting ............................................................................................................. 13

9.

EU Declaration of Conformity ....................................................................................... 15

Updated: September 2015 2

1.! Safety regulations

WARNING: RISK OF ELECTRIC SHOCK.

•! Please read the documentation provided with the charging station to acquaint yourself with the safety instructions and directions before you use the charging station.

•! This charging station has been designed and tested in accordance with international standards.

•! This charging station must be used exclusively for the purpose intended.

•! These directions for use are valid for different models of the charging station. It is possible that a number of features are described that are not applicable to your charging station.

•! This charging station may only be installed, maintained and repaired by qualified personnel.

Incompetent installation or repairs may result in danger to the user.

•! Do not install a faulty charging station.

•! For instructions on installation, see Chapter 3.

•! The charging station is used in combination with a power source. Always switch off the power supply before carrying out maintenance. The charging station contains no internal components that can be maintained by the user. The “0n”/ ”Off” and “green” position of the charging station's main switch does not guarantee that the system is disconnected from the power source and does not safeguard against the voltage applied.

•! Do not switch on the product if the covers are not in place.

•! Ensure that the equipment is used under the correct operating conditions.

•! Do not use explosive or readily flammable substances in the vicinity of the charging station.

•! Persons unable to assess the dangers should not use the charging station.

•! Do not direct powerful jets of water onto the charging station, and never operate with wet hands.

•! Ensure that the charging cable is not kinked or jammed !

•! Ensure that the charging cable cannot be driven over !

•! Ensure that the charging cable cannot come into contact with heat sources.

•! Always pull on the plug's hand grip, and never on the cable.

•!

While charging the charging cable must be completely unwound and connected to the car without loops lying on top of each other! (risk of charging cable overheating).

•! In the event of danger and/or accidents, have the charging station disconnected immediately by a competent person (electrician).

Transport and storage

Ensure that the main power source has been disconnected when storing or transporting the charging station.

No liability can be accepted for damage during the transportation, if the appliance is transported in anything other than the original packaging.

Store the charging station in a dry environment. The storage temperature must be between –

25°C and +60°C.

Updated: September 2015 3

2.! Product description

General

The EV-Box charging station (Figure 1) is compatible with all mode 3 electric vehicles. The charging station is meant for both indoor and outdoor use. Usage of the charging station is allowed in an ambient temperature between -25°C and +60°C. The charging station is connected to a central system for registration of the kWh charged.

Online - Model with modem

The smart charging station is designed with an RFID card reader, a kilowatt hour meter and a GSM/GPS/GPRS modem. These components together

Figure 1 provide for the authorization and communication of the charging session procedure with the central system (BackOffice) for processing and payment of the transactions as required.

Safety

There’ s no power on the socket of the charging station as long as no plug is inserted and it has not been started up by the RFID card. In the models with BXXXXX-1100 there is a circuit breaker and a residual current device (type A - 40A-30mA) for each socket. A type B residual current device is available as an option (Table 6, Technical specifications). Models with BXXXXX-1001 do not have residual current devices or circuit breakers.

Mode 3 Controller

The Type 2 socket is connected to the Mode 3 Controller and locking module in accordance with

IEC-61851. This means that the charging station is constantly checking for the presence of a ground connection. In addition, the current is only switched on once the cable has been connected to both the charging station and the vehicle.

Operation

A charging session may be started by holding an authorized RFID card (Mifare Classic, 13.56Mhz) against the front of the charging station at the round surface showing a hand with a RFID card

(Figure 1).

Warranty

EV-Box warranties its equipment and software against errors and defects in materials and workmanship for twenty four (24) months from the date of delivery, during which time it will use its best efforts to repair the errors, if any. However, any such problems encountered out of any causes that are not attributable to EV-Box, shall be for customer’ s risk and account.

Updated: September 2015 4

3.! Control

Start charging

1.! Use your charging cable to connect the EV-Box station to your car

2.! Present your charging card (RFID Card) to the card reader.

The charging station will react with a tone. This indicates your card is being validated. It’ s possible that the LED ring will flash yellow for a couple of seconds.

3.! The transaction will start automatically (LED ring is Blue)

Stop charging:

1.! Present your charging card (RFID Card) to the card reader.

2.! The charging session stops (LED ring will be GREEN)

3.! Unplug the charge cable from the EV-Box and your car.

Charging Stations without RFID charging card / modem

For charging stations that don’ t operate with a RFID card, there will be either a key switch or with an AUTO-START. With the key switch you turn the key to start or stop the transaction and with the AUTO-START with just need to plug the charging cable to start the transaction and unplug the charging cable from the car to stop the transaction.

Updated: September 2015 5

LED ring indicator

The socket is surrounded by an LED ring. It shows the status of the appliance, so that you can see which mode the charger is in (see Chapter 7).

Green or OFF Flashing GREEN YELLOW

Stand-by or ready for use

BLUE

Your charging card is being verified

RED

Awaiting communication from your car or your car is fully charged

Flashing RED

Charging Faulted, please contact our service desk

Your charging card is not authorized to start a session

Updated: September 2015 6

4.! Installation

Safety requirements

Connecting and installing this product must be done by a qualified technician. The owner or user is responsible for the installation, operation and maintenance of the charging station, whereby both the law regarding the safety of persons, animals and property (in NL NEN

3140) must be observed, as well as the installation instructions in force in the country of use.

Read the installation instructions before you start work on the installation.

The charging station complies with Safety Class I (the charging station is supplied with a ground terminal for safety) and voltage Category III.

The incoming and/or outgoing terminals for the alternating current are fitted with an uninterruptible grounding for safety. If it is plausible that the ground safety has been damaged, the product must be taken out of operation and secured against being activated accidentally.

Ensure the correct supply voltage/power and ensure that the meter cabinet is made properly safe.

Each appliance should be protected by a residual current device Type A (>30mA/AC). The residual current device must switch off all the phases connected and the “N”. A residual current device Type B with direct current fault detection >6mA/DC is needed for certain electric cars.

Never replace a safety component by one of another type.

•! All components were correctly connected and operationally tested before dispatch of the charging station.

•! Before switching on the appliance check that the power source available corresponds to the configuration settings of the product as described in the manual and that all the cables in the charging station have been properly connected.

•! Ensure that the equipment is used under the correct operating conditions.

•! Never operate the product in wet or dusty surroundings.

•! Ensure that there is always adequate free space (at least 20cm) around the product for ventilation.

Updated: September 2015 7

Location

Position the charging station, where possible, in surroundings not subject to extreme sunlight and where damage from outside cannot occur. The charging station can be installed on the stainless steel pole/bracket supplied with the appliance. The supply cable enters through the bottom of the housing.

Connecting the power supply cable

The power supply cable is fed through a removable opening for a connection at the lower side. (figure 2) Alternatively the power supply cable can be inserted through a removable opening in the backside of the unit (figure 3).

Figure 2

Installing the charging station

•! Before starting installation switch off power supply in the distributor and in the product.

•! Secure the work environment to ensure that the power supply can’ t be switched on unintentionally.

It is important to use a separate 16A cable for the electrical distribution board, , the main power supply cable must be fitted with a MCB and RCB taking in account de-rating according to

IEC61439-2.

The minimal wire gauge of the supply line should be 4mm 2 . The correct gauge depends on the distance between charging station and meter panel. The maximum wire gauge that can be fitted is

10mm 2 .

Figure 3

Wall Mounting

•! Choose a flat vertical mounting surface, with a clearance of 20cm around the charging station for ventilation purposes. Mount the charging station on the wall with properly dimensioned mounting material suitable for > 40kg.

Check the contents of the package and all accessories for damages once the delivery is completed.

•!

Remove the cover (Figure 4), it is attached with 4 bolts at the backside of the base-unit. Mount the base-unit onto the wall.

Wall plate for easier mounting

You have the option to mount a HomeLine with the wall plate

(figure 5). It’ s an accessory that can adjust to any wall mounting situation independently of the house.

Figure 4

Figure 5

Updated: September 2015 8

Connecting charging station

1.! Run the power cable to the bottom 400mm through the M25 cable opening.

2.! Remove the cable sheath so that the cables can be connected to the main switch by a small loop. Make sure the incoming PE cable is approximately 5cm longer for the best fit.

3.! Secure the power cord into the cable opening. Apply a zip tie to the power supply line.

4.! Connect the Phase and +N + PE and clamp beside the main switch. Attach PE first!

Make sure the main supply line does not block the manual locking lever of the servo motor, mounted on the charging socket.

Finishing Installation

•! Check whether all connectors are tightly connected to the controller by firmly pressing them into position.

•! Make sure all switches are in the “ON” position.

•! Switch on the power supply.

•! Check the resistor value over ground. This should be as low as possible but not to exceed 150 Ohms.

•! Mount the cover on the casing. Be extra careful to align the cover properly to ensure that and the seals are in the right position after the cover closes. (IP54).

•! Carry out a functional test.

•! Fasten the bolts using the hex key.

Figure 6

Maintenance

Dirt on the outside of the charging station can be cleaned off using a damp soft cloth. The owner or user is responsible for the maintenance of the charging station, whereby both the law regarding the safety of persons, animals and property (in NL NEN 3140) must be observed, as well as the installation instructions in force in the country of use.

Product and environmental characteristics

The charging station has been CE-certified by the manufacturer and bears the CE logo. The relevant declaration of conformity may be obtained from the manufacturer.

The charging station complies with the RoHS Directive (RL 201//65/EU). The relevant declaration of conformity may be obtained from the manufacturer.

Electrical and electronic appliances, including accessories must be disposed of separately from the general municipal solid waste. Recycling of materials saves raw materials and energy and makes a major contribution to conserving the environment.

Updated: September 2015 9

5.! Installing an external modem

A GSM link with the charging station is essential for the appliance to work properly.

However, a good link cannot always be obtained in enclosed spaces, for instance a closed or underground car park. In cases like this, the modem can be positioned outside the charging station along with the GSM/GPS antenna and connected to the charging station. The procedure is as follows:

•! Remove the modem from the controller to which it is fixed by pinching the top points of the white feet on which it rests using pliers.

•! Remove the GPS/GSM antenna.

•! Find a suitable point where the GSM signal is well received.

•! Install 4-pole plugs on the modem and the controller. These plugs can be obtained separately.

•! Make the connection below. A 4-core RS485 cable (STP/FTP, Profibus or equivalent) should be used for this. The maximum distance between the modem and the charging station is 1,200m.

With large distances it may be necessary to install a 12V external power supply

•! Install the modem and antenna in a closed cabinet (IP54). An assembly set with all the materials needed for this (excl. cable) is available as an option.

Updated: September 2015 10

6.! Hub / Satellite connection

Up to 19 charging stations without a modem can be linked to a charging station with a modem in a Hub / Satellite connection. The advantage is for locations with a poor GSM link, making sure only a single modem can be installed externally, making it easier to control the charging stations.

The Hub / Satellite charging stations are connected in a chain. The shielded RS485 cable can be ran with the supply cable left out of sight. To prevent having cables running from one charging station to the next, this chain connection can also be made in the meter cabinet. A separate terminal box will have to be installed in the meter cabinet / supply box for making the onward connections.

•! Use a black 2-pole plug on the Satellite “S” side and a green 4-pole plug on the master “M” side of the controller. These are available as a separate set.

•! Make the connection below. The network must be set up with a cable suited to the RS485

(STP/FTP, Profibus or equivalent cable).

•! The maximum number of controllers that may be connected to a single modem is 20.

•! The network must be closed off with a terminal resistance of 120 Ω at terminals 19 and 20, where more than 6 connectors (3 double charging stations) are installed.

•! In the case of a Star or T network, reflections can occur in the cable. This method of installation is not possible for this use.

Updated: September 2015 11

7.! Technical Specifications

Below are the general specifications for the HomeLine. You can find all the technical specifications related to each articles number in the “Downloads” section of EV-Box.com

Item

Connection capacity

Output power per connector

Secondary power supply

Determining location

Communication

Temperature range

Moisture (non-regulating)

Protection class for housing

Protection class for socket

Max. Installation height

Dimensions in mm (L x W x H)

Housing

Housing (rating)

Weight

Description

1-phase or 3-phase, 50Hz, between 2.5 – 10mm2

1-phase or 3-phase, between 230V – 400V, between 16A or

32A, and 3.7kW up to 22kW

12VDC – 2.5A

GPS receiver

GSM / GPRS Modem / controller with RFID reader

- 25°C – +40°C

Max. 95%

IP54

IP54

+2,000m NAP

600 x 250 x 400 for double model / 600 x 250 x 200 for single model

Polycarbonate (Bayblend)

IK9

<5kg

Hereby you can find the explanation of our article numbers and how to interpret the technical details behind each number:

H: HomeLine

B: BusinessLine

ML: PublicLine

MB: Mast

BusinessLine

S: PublicLine (old)

1: one-phase

3: three-phase

16: 16A

32: 32A

Updated: September 2015

0: cable

1: single/wall

2: dual/pole

0: no modem

1: old modem

471002 controller

471001 S-pulse kWh meter

2: new modem

471003 controller

471011 S-bus kWh meter/wall

0: no security

1: RCB type A automatic MCB

2: RCB type A with 32A cable and automatic

MCB

3: RCB type EV,

MCB

4: Security with fuse holders and

ALS type A

0: RFID reader

1: on / off button

2: AUTOSTART controller

471020

3: Key switch

0: no cable

12: Mennekes type 2 cable linear 7 meters, red/brown

61: EV-Box type 1 cable linear 6 meters, with position 4=0

62: EV-Box type 2 cable linear 6 meter, with position 4=0

81: EV-Box type 1 cable linear 8 meters, with position 4=0

82: EV-Box type 2 cable linear 8 meter, with position 4=0

91: EV-Box type 1 spiral cable

92: EV-Box type 2 spiral cable

12

8.! Troubleshooting

EV-Box highly recommends the installation work to be done by a qualified electrician.

Problem

Charging station does not react

Charging station does not emit clear beep when it is turned on

Residual current device trips constantly

LED ring lights up constantly

One or more LED ring(s) continues to flash red in Hub / Satellite sequence

Possible cause

•!

No power to charging station

•!

Control current circuit breaker

•!

•!

•!

•!

(C6) is off

12V is not on (check lamp on

12V supply is off)

•!

Small plugs on the controller are note fully pushed in

•!

Wiring harness runs too close to the supply, with the result that the magnetic field activates the safety module of the 12V supply.

Grounding error in the charging station

Special ground resistance is needed for the car

Fault in the car or defective charging cable

•!

Residual current device and/or circuit breaker are off

•!

Crossover in Hub / Satellite connection.

•!

Charge point cannot be located.

Solution

•!

Are the residual current device and circuit breaker in the meter cabinet on? ( check by user)

•!

Is main switch in the charging station on? (if installed, must be done by electrician ).

•!

Is the supply cable entering the charging station live?

•!

Turn the charging station on again

•!

Is the control current circuit breaker (C6) on? There is a loud beep when the circuit breaker is switched on

•!

Is there 230V on the input terminals of the power supply? If this is not the case, check the circuit breaker

•!

Is there 12V on the output terminals of the power supply? If this is not the case, switch off the

C6 circuit breaker and wait two minutes before switching on again. If there is still not 12V DC on the output, then the power supply should be replaced.

•!

All plug connections, in particular to the controller

•!

Relocate wiring harness

•!

Check electrical wiring for damage. Replace damaged wiring

•!

Moisture or condensation on electrical connections. Dry the connections if necessary

•!

Replace the charging cable

•!

Measure the earth resistance and compare it with the resistance required by the supplier of the car, e.g. Renault Zoe < 150 Ohm.

•!

Switch on residual current device and/or circuit breaker

•!

Check RS485 cabling 1:1

•!

Press modem into position.

•!

Check 12V power supply to

Master.

Updated: September 2015 13

Problem

LED ring continues to light up yellow

Charging station does not start charging, LED ring flashes green for

30 seconds, followed by 10 x red.

Then LED ring green or off.

Plug does not come out of charging station

Red LED starts flashing immediately after the card is held against the reader

•!

Charging station waiting for the car

•!

Car is charged

•!

Faulty charging cable

•!

Resistance from earth too high, with certain cars this

•!

must be < 150 Ohm.

Car is on a timer

•!

Possible cause

Plug not locked

•!

Car not connected

•!

Lock in charging station blocked.

•!

Incorrect card used to stop

•!

charging (LED ring flashes purple briefly)

Unlocking pin will not lift

•!

Charging card is not authorized for charging at this charging station.

•!

There is no communication with the Back Office.

Solution

•!

Are the plugs properly inserted in the car and charging station?

( check by user)

•!

Resistance from earth correct?

(resistance measurement by electrician)

•!

Replace the charging cable (have fixed cable replaced by an electrician)

•!

Change the setting of the timer in the car. ( check by user)

•!

Is the plug pushed far enough into the charging station? ( check by user)

•!

Is the plug properly inserted in the car? ( check by user)

•!

Check the plug for damage or bent pins. ( check by user)

•!

Check whether there is something in the socket.

•!

( check by user)

•!

Check whether the wiring harness is blocking the red locking handle. ( check by electrician)

•!

Use the same card to stop charging as to start charging

•!

Push the plug further into the charging station and hold the card against the card reader again

•!

Turn residual current device in the meter cabinet off and then on again after one minute.

•!

The red handle on the lock can be turned upwards to unlock by the electrician .

•!

Check that the charging card is interoperable (use throughout the Netherlands) ( check by user)

•!

Check the settings of your charging station in your online account ( check by user)

•!

Check whether the modem is in contact with the GSM network.

Updated: September 2015 14

9.! EU Declaration of Conformity

MANUFACTURER'S DECLARATION

(in accordance with Appendix II-B of the Machinery Directive)

EV !Box B.V., Pedro de Medinalaan 31, 1086XP Amsterdam, The Netherlands, declares under sole responsibility that the product:

Article H116X-XXXX: EV-Box Charging station, 1-phase 16A

Article H132X-XXXX: EV-Box Charging station, 1-phase 32A

Article H316X-XXXX: EV-Box Charging station, 3-phase 16A

Article H332X-XXXX: EV-Box Charging station, 3-phase 32A to which this declaration refers is CE certified and complies with the essential requirements of

EMC Directive 2004/108/EC and Low Voltage Directive 2006/95/EC in accordance with standards:

EN 61000-6-3 (2007) & IEC 61851 Part 22CDV (06 15-12-2010) section 11.12 (EMC)

EN 61000-6-2 (2005) & IEC 61851 Part 22CDV (06 15-12-2010) section 11.12 (EMC)

EN 61000-3­ 2 (2006)

EN 61000-3-3 (1995) + A1 (2001) + A2 (2005)

EN 60950-1 (2006) + A11 (2009) + A1 (2010)

IEC 61851-1 (2010)

IEC 61851-22 (2002)

IEC 60364-4-41 (2007)

EN 62196-1 (2003)

EN 60335-1 (2012) + AC (2014) Safety of household and similar appliances

Updated: September 2015 15

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