Document version: 1.56
Document date: 2722. 87. 2021 2024
Table of Contents
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Charging station is equipped with standard socket (with/without shutters) or with charging cable and standard Type 2 vehicle connector (Type 2 according to EN 61851-1 or EN 62196-2). EV parking place must be placed within the reach of the charging cable.
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Charging station (with Type 2 cable or Type 2 socket (with/without shutters)),
Wall mounting bracket,
9 ×wall plugs for securing the mounting bracket using screws to the wall,
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Charging station INCH can be equipped with cable or with socket (with/without shutters). If it is equipped with a socket (with/without shutters), users need to have their own cable. Standard cable length of 2.5 m should be taken into consideration when determining correct placement of charging station and parking space.
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22 kW (32 A): three-phase charging spots with cable or with socket (with/without shutters). The maximum charging current is 32 A per phase.
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According to the alignment of the power cable, the location of the installation pipe is determined. The pipe is placed into the foundation and used to connect the charging station to the network. It is recommended that the installation pipe ends over the foundation and not beneath the foundation. The bending radius of the power cables must be considered when placing the installation pipe. The dimension of the pipe depends on the number and diameter of power cables which will be inserted. In the case of clustering of charging stations in the same area, it must be considered that two power cables will be inserted into the installation pipe. The size of the opening at the top of foundation enables the installation of two installation pipes that are used when the clustering of charging stations is executed.
Important: Make sure that the anchoring structure is completely inserted, tha is in horizontal position and that the part with holes is oriented towards the sky.
The concrete base is placed into the construction pit to the level that enables the top of the underground anchoring element to reach the desired final height. The final height in this case is the level of surface finish after completed works (for example the top level of paving stones, tiles, or curb). The concrete base is levelled so that the anchoring element can be vertically aligned. It is of utmost importance that the anchoring element is aligned very precisely. Lean concrete mix should be used for the concrete base (with less cement than water).
Important: When inserting the anchoring structure be sure that the orientation is appropriate depending on how you want your charging station turned.
The installation pipe is inserted through the opening of the underground foundation anchor and attached with a wire to prevent it from slipping into the foundation during concrete works. The installation pipe, which has been cut to its final length, must be clogged on both ends with paper or similar material, so that the concrete cannot enter the pipe.
The concrete works can be started at this point. First the area around the installation pipe is concreted, where the pipe must remain accessible after the concrete works are finished.
Once the concrete reaches the level of the frame, the concrete works continue through the upper opening of the underground anchoring element, where the installation pipe is placed. The entire space inside the frame must be filled with concrete. In the case of low temperatures, the concrete must contain anti-icing additives.
The next step is precise levelling of the foundation and the concrete around the frame, where the finishing tiles will be placed. Precise levelling of the underground anchoring element is important for later installation of the charging station. After the construction of the foundation is finished, the charging station can be aligned only with the use of washers, placed on the bolts of the underground anchoring element.
The concrete must be left to dry for at least 48 hours (two days) before the cables are inserted into the foundation and the charging station is installed on the foundation.
Installation of Safety Arches
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The figure above shows the upper plate of the underground anchoring structure, together with its dimensions. The installation pole for INCH charging station(s) is fixed to the bolts on the underground anchoring structure. A ring spanner is used to fix the station to the foundation. The pole has at the strategically located height weakened structure. This allows pole to break at that specific point in case a car hit it. A pole already has drilled holes where mounting bracket can be attached and secured with bolts.
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Figure 10: Dimensions of the wall mounting bracket
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Figure 11: INCH mounting pole
Figure 12: Completely covered hole after the installation on the pole
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When installing the charging station on the wall serviceman must consider measurements of the station that are 45x27x13.5 cm, additionally to that dimensions extra space around the station must be available for installation purposes and later for maintenance.
Figure 23: Positions of drilling holes of the wall mounting bracket
At the top, on the left side and at the bottom of the station at least 10 cm of space needs to be kept free to simplify later maintenance. On the right side where the maintenance door is located at least 40 cm of room needs to be available to allow serviceman to open the door and access the charging station insides to conduct maintenance.
Measure and mark the final mounting height on the selected location of the installation. Height of the wall mounting bracket bottom should be around 100 - 120 cm from the ground.
When considering the height and location of the charging station keep in mind if the cables come from the other side of the wall into the charging station, hole needs to be drilled where cable will be routed into the charging station.
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Figure 24: Location of the hole when the cable comes from the other side of the wall
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Press the mounting bracket against the wall and mark the places where holes need to be drilled to insert the anchors and screws. If cables are routed through the wall, make sure that the electrical box has been installed at the right location before installing the mounting bracket. On the picture below screws location is shown with the red circles.
Important: In some cases for example when the mounting bracket is secured to the soft insulation e.g. Styrofoam special wall plugs are needed.
Figure 25: Location of screws where the holes need to be made in the wall
Drill 9 holes and insert the anchor screws in each hole.
Align the bracket with the drilled holes and insert the screws to attach the mounting bracket to the wall in its final position.
Before you fasten the screws attach the installation holder. It is very hard to attach it later when the bracket is already secured to the wall with screws. Removing it after the installation is easy due to the design of the holder.
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Figure 26: Frontside view of the installation holder
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The exact dimensions are dependent on the installation, e.g., what kind of wall is being used is important in decision if the support is adequate, and on determining the number and the position of holes to be drilled in the mounting surface and what kind of screws should be used.
Figure 28: Possible mounting of adapter plate for installation of mounting bracket
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Remove the maintenance doors on the side either using hex key or regular key if the enclosure came with the keyhole.
Important: Key to unlock the key-lock comes with the charging station.
Figure 34: Doors with keylock Figure 35: Doors with hex screw
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In the bigger gland you should make sure that the rubber inside is of correct size. For cable’s dimensions of up to 5x6 mm2 use the tighter rubber which should be already inside the gland by default. For the cables with the 5x10 mm2 use looser rubber.
Important: Diameter of gland rubbers are 1.5 cm for the tighter of the rubbers and 2.1 cm for the looser one.
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Figure 38: Rubbers in cable gland
The rubber can be changed after the removal of the gland plastic top (it need to be unscrewed) and by simply pushing the rubber out of the gland. After the new rubber is inserted into the gland screw the plastic gland top back on.
Proceed with the preparation of cables. First the cable jacket of power supply cables needs to be removed. Around 15 cm should be removed so that the wires lengths are sufficient to connect them to the elements inside the charging station.
Pull the power supply cable through the gland. About 15 cm of power supply cable should be pulled to the other side of the gland. About 2 cm of cable jackets should be put through the cable gland as well. This will make cable manipulations inside the charging station easier.
Important: Inserting cables through the gland is easier by loosening the gland screw cap by turning it counter- clockwise.
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Figure 43: Cable ferrule for the protective earthing conductor
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Important: Make sure that cables are inserted in correct cable glands.
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Insert the UTP cable through the gland. About 20 cm of UTP cable should be put out of the gland.
Important: UTP cabel used should be UTP Category 6, 4x2 AWG LSOH.
Figure 47: Ethernet cable with the removed cable jacket pulled through the UTP gland
After the cable is through the gland put the UTP plug on the UTP cable without cable jacket.
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Important: Make sure that each wire is in its own slot of the connector.
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Figure 55: Ground wire secured to the enclosure using the screw
Next step is to connect cables to connection element (RCD, MCB or MID meter). Connection of all the elements is practically the same. The only difference is that the RCD element needs additional protection wire. The procedure described below will be for RCD, but you can follow it also for other elements.
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 RCD/MCB/MID in which conductors will be connected are unscrewed.
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Figure 56: Check that the marked screws are unscrewed so that you can insert the conductors
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If using charging station with cable for charging, cable holder must be attached when the charging station is removed from the station holder. There is not enough space available to do it while the charging station sits on top of the holder. To attach enclosure to the plate, align the cable holder holes with holes on the plate.
Figure 64: Cover the holes of the metal hook with the holes on the plate that is located on the enclosure as it is shown on the figure
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