Document version: 1.6
Document date: 22. 7. 2024
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Table of Contents
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Basic Description
About this Document
The safety and installation instructions "Quick Start Guide" that come with the charging station includes quick installation procedure should be read first:
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All the documents are available in the installation manuals section, accessible from the INCH product page, at the web page https://etrel.com/charging-solutions/inch/
Site Preparation
Confirmation of Readiness
Before carrying out the installation, the client must confirm his readiness usually with a statement, that all the requirements for the preparation of the location and additional image material are met, which allows remote checking of compliance.
Access to Installation Site
An access to the location should be made possible to service vehicle for installation and servicing of charging stations.
Support During Installation
The responsible staff for both electricity installations and IT communications should be present on the location or available for immediate remote support.
External Factors
Installation cannot be carried out in the event of extremely rainy or snowy weather or other external factors that can prevent safe mounting, installation, and commissioning of charging stations. The charging station installation should be cancelled under such circumstances.
Instructions Validity
The client shall check with manufacturer for the latest valid version of instructions before the preparation of location(s) for installation of charging stations. Please make an inquiry with the point of contact at the retailer or manufacturer’s support of your charging station to request the latest instructions version when necessary.
Permits
Location and Building Permit
The charging station is a simple object and there is usually no need to acquire any building permits for its installation. If the installation site is a part of municipal property, consent of the relevant authorities must be acquired before the charging station can be installed. Installations must be performed in accordance with possible additional requirements of the national regulation.
Connection to the Grid
The charging station must be connected to the low-voltage electricity distribution network. No special permit is required to connect to an existing network behind the metering point. The connection can be done by any authorised electrician. Installations must be performed in accordance with possible additional requirements of the national regulation.
Parking Permits
Parking must be possible in the direct vicinity of the station and permitted by the operator or owner of the parking area. Estimated time for a full charge depends on the current state of the battery and the vehicle's charging power. Charging procedure usually takes between 30 minutes and up to 8 hours. Installations must be performed in accordance with possible additional requirements of the national regulation.
Location
Charging station should be installed in the vicinity of the parking spot that will be used to park and charge electric vehicles. They can have charging socket located in various positions. Consequently, cable length to connect EV and charging station is important.
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Charging station must not be installed in explosion hazardous areas (EX zone)
Required Space
Charging station can be mounted on the wall or installed on the mounting pole. Mounting plate for installation on the wall is supplied with every INCH and mounting pole is additional component that can be ordered.
Basic installation of the charging station’s mounting pole without arches requires an excavation of minimal dimensions of 500 mm x 420 mm (floor plan) and depth of 600 mm. If the charging station is installed together with two safety arches, dimensions of the required dimensions are approximately 750 mm x 500 mm. Please find more information in chapter Construction Works.
Charging Station Dimensions
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Figure 1: Charging station INCH dimensions
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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.
Content, Optional and Extra Equipment
Charging station (with Type 2 cable or Type 2 socket (with/without shutters)),
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*Optional, depending on the purchased model.
Tools
To execute the installation of charging station multiple tools are needed:
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Figure 2: Equipment used for the installation of charging station
Possible Charging Station Placements
The placement of charging station into its environment must allow easy access to all electric vehicles for which the station is intended. The charging station can be installed on the pavement, parking lot, in a parking garage or elsewhere, considering the specific conditions of each of these placements. In all these placement options, the station can also be installed together with the safety arches.
Due to the station's service doors opening outwards, the space in front of the station (approximately 50 cm) needs to be free of any obstacles to enable simple charging. Safety arches (or car park barriers or bollards) can be used to prevent direct contact of vehicles with the charging station.
Street (Pavement) Placing
The charging station must be placed so that it does not interfere with pedestrian mobility while providing EV charging services. When certain interference is unavoidable, the placement of the station should prioritise pedestrian safety and minimise the risks of tripping over charging cables or suffering collisions with the station. The charging station should be placed as close to the roadside curb as possible.
When the charging station is combined with safety arches, these need to be placed as close to the roadside curb as possible, while the station is moved further back from the roadside so that its back edge is aligned with the front side of the rear arches of the safety arches. The safety arches should be mounted at least 15 cm away from both sides of the station.
Parking Lot Placement
Single station
A single charging station is usually placed on one of the sides of the parking lot. The station must be placed in a way to enable simple and practical charging of electric vehicle.
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Back-to-back placing of two charging stations can be used to place together two charging stations, usually in the central position of the parking lot. It is strongly recommended to add safety arches to this placement. In this case, both charging stations can be mounted on the same installation pole within one pair of safety arches.
Parking Garage Placement
In the parking garage placement, the specific installation of supply cables needs to be considered. The cables are routed to the charging station from the bottom or from the top. In case of clustering of larger number of charging stations, considerations about the needed cables cross-section must be made.
Possible Parking Arrangements
It is recommended that each INCH charging station to have dedicated parking spot.
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Both options (for the charging cable to be plugged at either the front or the rear end of the vehicle) should be considered. Each charging station can serve more than one parking spaces, however only one vehicle can charge at the same time.
Recommendations
Use street signs or special marking to designate special EV parking places, which should be easily distinguishable from conventional parking places.
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Electrical installation must be performed in accordance with local laws and safety regulations. The diameter of the electrical conductor depends on its length, method of installation, etc. Up to 5 x 10 mm2 cables can be used directly. This must be determined by the contractor.
Grid Connection
The charging station can be connected directly to the electricity distribution network or to an existing electrical installation nearby.
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Five wires are routed to the station, including three phase wires, grounding wire, and the neutral wire (when connecting to an existing installation). For single phase connection (slow charging option), only one phase wire with sufficient diameter can be routed to the station, together with neutral and earthing conductor. Dimensioning of the wires is determined in the project documentation. Grounding wire must be connected to the main grounding busbar.
Connection to the Station Operator's Communication Network
The charging station uses network connection to communicate with the Control centre in order to cyclically send information about its status, perform identification of users (on the Control centre level), forward events that occur during its operation and execute billing for the services performed.
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Wireless connection. The station connects to an existing 2G/3G/4G mobile network with an GPRS/UMTS router built into the station.
CONSTRUCTION WORKS
Underground Anchor
The underground anchoring structure is built into concrete foundation and is made of stainless steel. The preparation of the foundation depends on the structure of the ground on the designated location. The underground anchoring structure can be combined with reinforcing steel.
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The pipe is later used for the insertion and connection of supply cables. The installation pole designed for two units allow the connection with two separate pipes.
Excavation
The first step of the construction work is to prepare an excavation with the minimum basic dimensions of 500 mm x 420 mm and at least 600 mm in depth. If the charging station is combined with safety arches, a larger excavation is needed.
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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.
Construction of the Foundation
For construction of foundation and placement of anchoring structure into concrete follow these steps:
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
The charging station manufacturer supplies optional safety arches:
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If safety arches are added to the charging station, the foundation needs to be prepared in advance, to add the safety arches to the same foundation as for the underground anchor.
Excavation and Foundation Construction for Safety Arches
When safety arches are installed together with the charging station, the contractor must prepare the foundation accordingly. Safety arches are placed in the same foundation together with the charging station. If safety arches are added to the charging station, the foundation needs to be enlarged accordingly (as presented on the figures below).
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Figure 8: Transversal section of the excavation and safety railings on the curb
INSTALLATION
Installation of the Pole on the Foundation
In the case when charging station will be installed on the pole, there is no need to drill any holes to insert the bracket as it comes already installed on the column. But the underground anchoring structure needs to be prepared.
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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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Figure 20: Charging station on the self-standing pole after the installation
Installation on a Wall
Cables Routed to the Back of the Station Through the Wall
When installing the wall mounting bracket cable location behind the wall needs to be known and hole drilled where cable will be routed into the charging station. Hole should be located on the right bottom side of the mounting bracket. Measurements of the hole should be sufficient to allow manipulation with cables and their installation inside the charging station.
Cables Routed to the Back of the Station from Above
When the cables are connected from the top before the mounting bracket is installed four wall spacers need to be attached to the mountain bracket. Wall spacers will allow the cable to come from the top and behind the mounting bracket from where they will be inserted into the charging station.
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Figure 21: Mounting bracket installed on the wall spacers
Cables Routed to the Back of the Station from the Ground
Cables are routed to the bottom of the station through a cable duct/raceway. The cable raceway must be positioned so that it leads directly to the black round rubber seal at the bottom edge in the middle of the station.
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Figure 22: Wall mounting bracket installed on mounting pole with temporarily attached installation holder
Installation of Wall Mounting Bracket
Users have two possibilities how to mount the charging station. In the first option charging station is mounted to the wall. In the second option, mounting pole is used that comes with already attached bracket. In both options the charging station is mounted to “wall mounting bracket”.
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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
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Figure 27: Bracket fasten on to the wall with the installation holder in its place
Installation of Wall Mounting Bracket on a Narrow Pole
Installation on a surface that is narrower than the wall mounting bracket requires additional consideration and material. The solution is to prepare an adapter plate that will be used to install mounting bracket.
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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Figure 30: Possible locations of holes to screw the adapter plate to the surface
Cable Management
Before the mounting bracket is secured to the wall or the pole it is vital to consider from which direction cables will be routed into the charging station as every option need some sort of a variation with the installation of the mounting bracket.
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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Appropriate length of cables must reach through the upper opening for later connection of the charging station (around 40 cm).
Preparation of Cables
Connection of cables can be done once the mounting bracket is securely fastened either on the wall or on the pole and the charging station installation holder is attached to the 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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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 49: UTP cable with inserted connector
Mounting of the Charging Station and Installation of Cables
Once the cables had been prepared the start of the installation of cables into the charging station can begin.
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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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