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INCH Electrical Installation Specifics

INCH Electrical Installation Specifics

Document version: 1.9

Document date: 22. 7. 2024

 

Basic Description

About this Document

The safety and installation instructions "Quick Start Guide" that comes with the charging station includes quick installation procedure should be read first:

  • Etrel_INCH_QuickStartGuide.pdf

  • Etrel_INCH_QuickStartGuide_Figures.pdf

The document in front of you contains information on the physical layout of the INCH charging station. As it is necessary to think in advance about the accompanying electrical works, basic information about them is also included.

More information about electrical works is available in the document “Electrical Installation Specifics”:

  • Etrel_INCH_Electrical_Installation_Specifics.pdf

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.

The sufficient cable length to easily connect the electric vehicle with the charging station, regardless of where the EV’s charging socket is located, should be between 3 and 7 m and depends on the charging station location in comparison to parking spot. Shorter length cables are recommended as they are easier to handle.

Make sure that in a typical connection scenario there are no obstructions in the way of the charging cable. When in use, the charging cable should be laid so that it will not be stepped on, tripped over, or otherwise subjected to damage or stress.

Charging station should be mounted so that the plug of the charging station is located approximately 120 cm above the ground. This height enables averagely high user the easiest operation of charging station and connection of charging cable. It also provides best view and operation of the LCD screen.

Etrel INCH charging station and its components (cable, casing, LCD screen...) are developed to be installed in the outside area meaning that charging station is resilient to the external actors (UV rays, rain, snow, cold etc.). Installing it in the closed-up area, for example in garage, will prolong the lifespan of the charging station and keep it in a pristine condition for longer.

There is no function of ventilation implemented in the charging station.

Location of the charging station must meet the following criteria:

  • The charging station must not be submersed in water or any other fluid and should not be installed in flood risk areas.

  • The operational temperature of the charging station is between - 25°C and + 65°C.

For locations where the charging station will be exposed to direct sunlight and high ambient temperatures during the day, it is recommended to install protection from direct sunlight, otherwise the temperature inside the station may exceed 65°C.

  • 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 document Etrel INCH Physical Installation, in chapter Construction Works.

Charging Station Dimensions

image-20240722-081217.png
Figure 1: INCH dimensions

Additional considerations of dimensions:

  • Basic dimensions of the station: 450 mm x 270 mm x 135 mm

  • Basic dimensions of the mounting pole base: 242 mm x 157 mm

  • Free space needed:

    • 150 mm on the left and right side.

    • 500 mm at the front (space to enable simple operation and maintenance).

Charging station is equipped with standard socket (with/without shutters) or 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)),

  • Wall mounting bracket,

  • 9 × wall plugs for securing the mounting bracket to the wall,

  • 9 × screws to mount the bracket to the wall,

    • Screws dimensions: 4.5 x 40 and 4.5 x 60 [mm],

  • Cable gland rubber seal for smaller cable dimensions

  • *9 × wall spacers

  • *2 × keys to open charging station service doors,

  • *Hex key to open charging station maintenance doors,

    • Hex key dimensions: 2.5

  • *Magnetic cable holder,

  • *Etrel Load Guard device.

*Optional, depending on the purchased model.

Tools

To execute the installation of charging station multiple tools are needed:

  • Screwdriver,

  • Hex screwdriver (if charging station without key lock on maintenance doors),

  • Utility knife,

  • Self-adjusting crimping pliers for cables' end sleeves,

  • Wire trippers and

  • Cable rippers.

image-20240722-081554.png
Figure 2: Equipment used for the installation of charging station

PRODUCT DESCRIPTION

The Etrel’s charging station INCH is highly configurable and can be tailored to the client’s specific needs. It allows charging of electric vehicle with power of up to 22,08 kW and can be equipped with any standard Type 2 socket (with/without shutters) or vehicle connector (EN 61851 or EN 62196-2). 


The actual number of maximal charging power can differentiate the exact value for one charging spot considering voltage of 230 V is 22,08 kW.

Charging is limited to 32 A, however voltage specified as 230 V, can be between 207 V and 253 V (+- 10 %). This means that the actual charging power can be lower or higher of the specified 22,08 kW.

Another factor heavily influencing what is the charging power is the power factor (cos Fi), which is determined by the internal charger in the electric vehicle. This factor is always lower than one, meaning that all power is not active, there is also reactive component. The correct designation of charging power would therefore be 22,08 kVA.

No matter the specifics, the charging power of Mode 3 charging spot is commonly referenced as 22 kW. This simplification is used in this document as well. 


Charging station comes with the LCD screen that guides through the charging process and provides important charging information. Charging station comes with several connectivity options (including Wi-Fi, LTE and Ethernet) and open protocol support and can be seamlessly integrated in the smart home system.

Certified utility-grade MID meters or other options (MCB, RCD) can be installed in the station. The station can be equipped with an RFID identification module, which prevents unauthorized use and is necessary to enable different billing and reservation processes and other advanced functionalities. The station also supports remote identification with SMS or other external identification means.

The casing of the charging station is robust enough to withstand any unfavourable weather conditions and potential damage which may occur in open public areas. The compact dimensions of the charging station allow its installation in a small area, for example close to the edge of the pavement or roadside curb.

The design allows easy replacement of key components that can be damaged due to wear or vandalism (especially charging sockets).

Components Overview

The Etrel INCH charging station contains the following components:

  • Casing of the station,

  • charging spot (Type 2 socket (with/without shutters) or vehicle connector, single- or three-phase),

  • main controller of the station,

  • LCD display that guides user through the charging process,

  • optional user identification module with RFID card reader,

  • ethernet communication connection point,

  • possible built-in smart energy meter,

  • three-phase grid connection point optionally equipped with standard electrical safety protection required by local regulation.

  1. LCD screen

  2. Status light

  3. Settings button

  4. Confirmation button

  5. Socket (with/without shutters)

  6. Maintenance doors

  7. Charging cable

Figure 3: Etrel INCH with socket (with/without shutters)

Figure 4: Etrel INCH with cable

Base Specifications

  • Input: 2x230/400V~; 3W+N+PE; 50/60 Hz; 32 Amax

  • Output: 2x230/400V~; 3W+N+PE; 50/60 Hz; 32 Amax

  • Maximum charging power: 7.4 kW (1-phase), 22 kW (3-phase)

  • Device power consumption: From 5 W, depending on the actual configuration.

Grid Connection

The charging station can be connected directly to the electricity distribution network or to an existing electrical installation nearby. Supply power depends on the charging power of each socket (according to the configuration of the charging station).

The following supply power is required:

  • 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.

Supply power of the charging station must be dimensioned appropriately.

Charging power can be limited in the settings of the charging station on the scale between 6 A and 32 A. The charging station can also be set up to allow local power management for a cluster of charging stations.

In the execution phase of the grid connection project, the following requirements need to be met:

  • Selectivity of the functioning of protection devices needs to be ensured:

    • The main overcurrent protection should be at least one class greater than the one used for the protection of the charging station or have a higher delay.

    • Differential protection (RCD) which is used in the charging station operates at a low current (ΔI 30 mA, without delay). The selectivity of this protection on the level of facility is achieved with a higher delay or a greater current differential.

  • 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 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.

The connection also enables communication from the Control centre towards the charging station, which enables remote access to the station for needs of maintenance or remote control.

The charging station could require a connection to the station operator's WAN network (charging infrastructure control centre). To access the WAN network via an internet connection, some additional security requirements need to be observed.

Network connection can be executed in several different ways:

  • Direct connection to the station operator's WAN network. Connection can be established directly with a UTP cable or a fibre optic converter.

  • Wireless connection. The station connects to an existing 2G/3G/4G mobile network with an GPRS/UMTS router built into the station.

Specification of frequency bands and transmitting power (it is possible that not all modules are part of an actual device).

LTE module

Frequency bands:

LTE-FDD: B1 (2100 MHz), B3 (1800 MHz), B5 (850 MHz), B7 (2600 MHz), B8 (900 MHz), B20 (800 MHz)

LTE-TDD: B38 (2600 MHz), B40 (2300 MHz), B41 (2500 MHz)

WCDMA: B1 (2100 MHz), B5 (850 MHz), B8 (900 MHz)

GSM/EDGE: B3 (1800 MHz), B8 (900 MHz)

Transmitting power:

33dBm±2dB for GSM

24dBm+1/-3dB for WCDMA

23dBm±2dB for LTE-FDD

23dBm±2dB for LTE-TDD

LTE Router

Frequency bands:

4G (LTE-FDD): B1 (2100 MHz), B3 (1800 MHz), B5 (850 MHz), B7 (2600 MHz), B8 (900 MHz), B20 (800 MHz)

4G (LTE-TDD): B38 (2600 MHz), B40 (2300 MHz), B41 (2500 MHz)

3G: B1 (2100 MHz), B5 (850 MHz), B8 (900 MHz)

2G: B3 (1800 MHz), B8 (900 MHz)

Transmitting power:

21.9 dB

Wi-Fi module

Frequency band:

2.4 - 2.4835 GHz

Transmitting power:

up to 15 dBm

RFID module

Frequency band:

13.56 MHz (HF)

Transmitting power:

up to 8 dBm

Circuit Diagram

External Signal

If hardware that is installed in the charging station supports connection of external signals to the charger, the additional connector above Ethernet connector in the service area will be present.

Digital Inputs and Digital Outputs

Charger supports connecting two digital inputs and one digital output. Inputs and outputs are operating on 12 VDC, therefore two of the pins are also 12 VDC and GND. Check pinout on the image below.

The use and logic of these digital input and outputs is settable via web interface of the charging station.

Do not use external 12 VDC for power supply. Digital output allows maximal load of 100 mA! Be careful not to make short circuit, which could be dangerous to persons and could also damage the charging station.

Cable Cross-Section Selection

The required cable cross-section is determined considering the maximum current, the allowable voltage drop and the expected short-circuit current. Cross-section can be determined by calculation or from a table, in the usual way, in accordance with IEC 60364-5-52.

When determining the cross-section of the cables, it is also necessary to include the method of installation, the material of the conductors and the insulation material. The temperature conditions at the location and the length of the cable also have an impact.

In general, the cable cross-section for the INCH connection is between 4 - 10 mm2, dependent on the installation method. Larger distances or clustering of several charging stations could require cables with larger cross-section and to connect INCH additional junction box is needed.

We recommend that at least the specified cable cross-section is selected for all phase conductors, for the neutral conductor and for the protective conductor. When choosing cables with a larger cross-section, the losses will be smaller, which is especially important for longer cable routes.

Minimum Cables Cross-Section

The calculation of necessary cables cross-sections should be part of electrical project and should consider the specifics of the actual location. The plan of installation should be prepared by licensed electrician or electrical planner in accordance with national legislation. Values given in this chapter are only informational.

The cables cross-sections are determined by three criteria:

  • Continuous operating current.

  • Voltage drop.

  • Short circuit withstand.

Continuous Operating current

The cross-section of cables must be large enough that continuous charging with maximal current is safe and does not damage the cables. Different installation options and environmental conditions are possible.

In the following table, the installation method can be checked for the minimum cable cross-section when connecting one INCH charging station. These values ​​apply for copper conductors with XLPE insulation at reference air temperature of 35 ° C. For installation of cables in the ground, temperature of the ground is set as 25 ° C and soil thermal resistivity as 2.5 K*m/W. Charging current of 32 A is being considered.

 

Table 1: Minimum cable cross-section for continuous operating current of 32 A.

 

A1 - Insulated single core conductors in conduit in a thermally insulated wall

A2 - Multicore cable in conduit in a thermally insulated wall

This method also applies to single core or multicore cables installed directly in a thermally insulated wall (use methods A1 and A2 respectively), conductors installed in mouldings, architraves and window frames.

A1, A2:

10 mm2

 

B1 - Insulated single core conductors in conduit on a wall

B2 - Multicore cable in conduit on a wall

This method applies when a conduit is installed inside a wall, against a wall or spaced less than 0.3 x D (overall diameter of the cable) from the wall. Method B also applies for cables installed in trunking / cable duct against a wall or suspended from a wall and cables installed in building cavities. 

B1:

6 mm2

B2:

10 mm2

 

C - Single core or multi-core cable on a wooden wall

This method also applies to cables fixed directly to walls or ceilings, suspended from ceilings, installed on unperforated cable trays (run horizontally or vertically), and installed directly in a masonry wall (with thermal resistivity less than 2 K.m/W).

C:

6 mm2

 

D1 - Multicore or single core cables installed in conduit buried in the ground

D2 - Multicore or single core cables buried directly in the ground

D1, D2:

6 mm2

 

E - Multicore cable in free-air

This method applies to cables installed on cable ladder, perforated cable tray or cleats provided that the cable is spaced more than 0.3 x D (overall diameter of the cable) from the wall. Note that cables installed on unperforated cable trays are classified under Method C. 

E:

4 mm2

 

F - Single core cables touching in free-air

This method applies to cables installed on cable ladder, perforated cable tray or cleats provided that the cable is spaced more than 0.3 x D (overall diameter of the cable) from the wall. Note that cables installed on unperforated cable trays are classified under Method C.

F:

25 mm2

 

G - Single-core cables laid flat and spaced in free-air

This method applies to cables installed on cable ladder, perforated cable tray or cleats provided that the cable is spaced more than 0.3 x D (overall diameter of the cable) from the wall and with at least 1 x D spacings between cables. Note that cables installed on unperforated cable trays are classified under Method C. This method also applies to cables installed in air supported by insulators. 

G:

25 mm2

The installation option F and G are not advised, as additional junction box is needed to enable connecting cables with cross-section larger than 10 mm2.

At sites, where the cross-section of already existent cables is smaller than recommended minimum, the limitation of maximal current can be made in the charging station’s web interface to allow the connection of charging station, without the need to replace all the cables.

Voltage drop

The requirement for the maximum voltage drop of the installation can be different across different countries. Usually, it is required that the voltage drop of the installation is below 4 % (or in some cases below 5 %).

The length of the conductors and charging current are major factors determining the adequacy of cables cross-section, however voltage drop occurs on other components or devices as well. Because of it, some reserve should be considered when selecting cables cross-section.

 

Table 2: Voltage drop in conductors with 6 mm2 cable cross-section and charging current of 32 A.

Charging current
32 A

Conductor

6 mm2

Single phase

Conductor

6 mm2

Three phase

L - length [m]

Voltage drop [%]

Voltage drop [%]

10

0,90

0,78

20

1,80

1,56

30

2,70

2,33

40

3,59

3,11

50

4,49

3,89

 

Table 3: Voltage drop in conductors with 10 mm2 cable cross-section and charging current of 32 A.

Charging current

32 A

Conductor

10 mm2

Single phase

Conductor

10 mm2

Three phase

L - length [m]

Voltage drop [%]

Voltage drop [%]

10

0,54

0,47

20

1,09

0,94

30

1,63

1,41

40

2,18

1,88

50

2,72

2,36

60

3,26

2,83

70

3,81

3,30

80

4,35

3,77

Lower voltage drop also means that the power losses of charging process will be lower. The life cycle assessment and calculation of benefit of using cables with larger cross-section could help mitigate the higher cost of investment.

Short circuit withstand

Charging station INCH can have already installed miniature circuit breaker which protects against overload and short circuit. This protection can also be part of installation with different tripping c