Table of Contents
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1. Basic Description
About this Document
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Charging Station Dimensions
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Figure 1: INCH DUO dimensions
Additional information of charging station dimensions:
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Screwdriver,
Hex screwdriver,
Self-adjusting crimping pliers for cables' end sleeves,
Wire trippers and
Cable rippers.
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Figure 2: Equipment used for the installation of charging station
Possible Charging Station Placements
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The charging station INCH Duo enables two vehicles to charge at the same time, one on each charging spot. Accordingly, an appropriate number of parking places need to be maintained in the direct vicinity of the station.
Figure 3: Possible parking arrangements
1: Although possible, it is not recommended to have only one parking spot reserved for INCH Duo. 2 and 3: Possible arrangement of INCH Duo with two dedicated parking spots. 4. Different arrangements dependent on the location are possible.
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It supports the weight of the charging station.
It prevents tilting of the charging station.
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Figure 4: Assembled underground anchoring element
The dimensions of the underground anchoring element are:
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Screw nuts on each anchor rod. There are six rods in the anchor package. Be careful to observe the nut positions on the rod as pictured below:
Figure 5: Anchor rod with initial screw positions
2. Place the rods into the anchor frame holes. Screw nuts on the other side at the top of the frame, where the rod enters through the frame. Tighten upper and lower nut firmly. Repeat for all 6 rods.
Figure 6: Insertion of anchor rods into the upper frame (bottom view)
Figure 7: Insertion of anchor rods into the upper frame (top view)
3. Place the L profile on the bottom of the anchor. Place all tree rods in one line into the L profile holes and screw nuts also on the bottom of the L profile, where the rod enters through the L profile. Tighten upper and lower nut firmly. Repeat for the second L profile and other three rods.
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Figure 8: Insertion of anchor rods into the bottom L profile
During final mounting, the charging station is attached to the six protruding bolts of the underground anchoring element. The screws on each of the six bolts need to be removed first and are later used to fix the casing of the charging station to the foundation once it has been placed in the correct final position.
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The first step of the construction work is to prepare an excavation with the minimum basic dimensions of 550 mm x 420 cm and at least 600 mm in depth. If the charging station is combined with safety arches, a larger excavation is needed. If necessary, the dimensions of the foundation can be enlarged by adding reinforcing steel to the concrete foundation to enable construction of a larger foundation.
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Figure 9: Basic excavation – longitudinal section
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Figure 10: Basic excavation – transversal section
The two figures above show a longitudinal and transversal section of the basic excavation, together with the dimensions of the underground anchoring element which is concreted into the foundation. The basic excavation is suitable for installation of charging station without safety arches. One of the requirements of basic installation is to carefully observe that the height of the upper edge of foundation is precisely aligned with the height of surface finish in the area around the charging station.
Important: When inserting the anchoring structure be sure that the orientation is appropriate depending on how you want your charging station turned.
Construction of the Foundation
Important: When inserting the anchoring structure be sure that the orientation is appropriate depending on how you want your charging station turned.
Important: Make sure that the anchoring structure is inserted into the whole in horizontal position with the the part with holes oriented towards the sky.
The procedure for the construction of foundation and placement of the underground anchoring element into concrete is as follows:
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The station can be protected by one or two safety arches that can be placed at both sides of the station (2 arches) or only at the front (1 arch).
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Figure 11: Longitudinal section of the excavation with two safety arches
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Figure 12: Longitudinal section of the excavation with one safety arch
The figures above show a longitudinal section of the excavation in all cases where the charging station is combined with safety arches. The arches must be removed at least 15 cm from the sides of the charging station to enable normal opening of station's maintenance doors.
The height of the concrete base must reach such a level that the height of the safety arches will be exactly 70 cm above the surface finish. Safety arches need to be precisely levelled during the concrete works to prevent any later tilting.
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Figure 13: Transversal section of the excavation and safety arches on the curb with two safety arches
The figures show a transversal section of the excavation when the charging station is placed on the pavement and combined with safety arches. The safety arches need to be placed as close to the roadside curb as possible. The underground anchoring element is moved back accordingly, so that the rear side of the charging station (anchoring element) is aligned with the front side of the rear arches of the safety arches.
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Figure 14: Transversal section of the excavation and safety arches on the curb with one safety arch
3. INSTALLATION
Installation on the Foundation
The inserted installation pipe must be secured with wire so that it does not sink into the concrete. In addition, it needs to be temporarily clogged with paper or similar material at both ends so that the concrete cannot enter the pipe.
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Figure 15: Securing the installation pipe
After the foundation with the built-in anchoring structure and installation pipe is constructed, the charging station can be installed on the foundation. The foundation must be left to dry for at least two days before the cable routing and installation works can begin.
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Shorten the earthing strip to the appropriate length and drill a hole in it.
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Figure 16: Earthing strip with a hole
The casing of the station is fixed to the bolts on the underground anchoring structure after the screws on these same bolts have been temporarily removed. After the charging station is placed on the foundation, all the bolts must extend through the bottom plate of the casing. A ring spanner is used to fix the station to the foundation using the previously removed screws.
Some of the bolts may require the use of a ring spanner with an offset handle. Care must be taken not to damage the thread of the bolts on the foundation while fixing the charging station. After the installation of the casing on the bolts, one of the bolts is used to attach the grounding cable shoe.
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Figure 17: Mounting INCH Duo on prepared foundation
4. Cable Management
Insertion of Cables Through the Installation Pipe
After the installation pipe is built into the concrete foundation, it is used for cabling and connection of the charging station. The concrete foundation must be left to dry for at least two days before the cables can be inserted in the installation pipe.
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Figure 18: Placing of installation pipe and insertion of cables
Supply cables are routed through the underground anchoring structure with the use of installation pipe as shown in the figure above. The exact way of cable routing depends on the type of cables used and their diameter (which is determined in the project documentation). When dealing with cables with larger diameters, their bending radius must be considered.
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Remove 20 mm of insulation from all cables and attach and compress the appropriate crimp tubes on all cables. To prevent cables from getting in the way of mounting the charging station, twist them into an installation pipe.
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Figure 19: Preparation of cables
Power Supply Compartment
The power and communication cables are routed through the foundation after the casing of the charging station is installed. Care must be taken not to damage the equipment inside the charging station.
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A three-phase 5-wire power cable is used for the connection, based on the type of connection. Standard terminals enable connection of cables of up to 50 mm2 diameter. Customization with additional clamps is possible up to 95 mm2.
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Figure 20: Overview of the power supply compartment
The configuration of the charging station depends also on the type of grid connection. The charging station is usually connected to an existing installation.
Figure 21: Power supply compartment cover
To enable access to the power supply compartment first unscrew and remove the protective cover.
There is a sticker on main connection element showing the correct designation of phases and neutral conductor. Remove the sticker and make sure that screws inside the main miniature circuit breaker (MCB) in which wires will be connected are unscrewed.
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Figure 22: Connection of charging station to the power grid
To the main circuit breaker of the charging station, three supply phase conductors are connected in right order of phases. Normally, this would mean connecting from left to right, phase 1 (L1, brown), phase 2 (L2, black), phase 3 (L3, grey).
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Figure 23: Example of the power supply compartment additional components
Also, the neutral conductor (N, blue) must be connected to the neutral pole of miniature circuit breaker and PE conductor (PE, yellow/green) to the earthing clamp.
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The software configuration must be properly made in charging station web interface and in the charging management platform (e.g., Etrel Ocean).
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Figure 24: Connecting the cables
Connection of the Protective Earthing (PE)
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Cut off the network cable to the appropriate length to reach the Ethernet connector. Do not make the wire routing too tight or too loose.
Use the network cable pliers to attach the RJ45 connector to the network cable.
Insert the RJ45 connector into the Ethernet connector.
If a network switch is installed in the station, the UTP cable is connected to its Port 4 (for means of clustering or DLMS communication with the meters). When there is no network switch installed, the network cable is connected directly to the Ethernet port of the main controller of the charging station, located on the station's doors. Ethernet port is located on the lower left side.
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Figure 25: Connecting the UTP cables
Finishing Work
Before closing the station, check the condition of the over-current protection elements and the residual current devices. Switches must be set to ON position.
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Check the condition of all four elements. Close the charging station door and lock it. Connect the charging station to the power supply in the electrical cabinet. Turn on the power supply where the station is connected.
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Figure 26: Positions of MCBs and RCDs
The hole in the bottom of the charging station should be filled with polyurethane foam filler (or similar material).
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