Installation Guide

Installation Instructions Homecharge

Chargemaster PLC Mulberry House 750 Capability Green Luton LU1 3LU. 01582 400 331; sales@chargemasterplc.com

Installation Instructions - Homecharge Chargemaster Homecharge Products The Chargemaster Homecharge product must be installed by a fully qualified electrician to current regulations.

Parts supplied with all Homecharge Units 1 x Wallmount Charging Unit 1 x Wallmount Charging Unit Bracket 2 keys User guide Install guide Requirements governing the installation Installation and wire gauge to meet all requirements of BS7671, 17th edition requirements for electrical installations IET Code of Practice for electric vehicle charging equipment installation, 2nd edition For a TT installation, the Ra earth rod impedance shall be less than 100 ohms Parts required for the installation to be supplied by the installer Adaptable box, rated to IP65 with 60A terminal block and ferrules, as shown in the adaptable box install guide Conduit and cable as required For 16A installations: o Supply to be via a 20A, curve D MCB o Supply to be protected by a 30mA RCD o At least 4mm2 cable suitable for domestic installation, subject to cable gauge calculations being undertaken in accordance with the 17th edition wiring regulations and <4.5% voltage drop For 30A installations: o Supply to be via a 40A, curve D MCB o Supply to be protected via a 30mA RCD. o Cable gauge to be calculated in accordance with the 17th edition wiring regulations and <4.5% voltage drop and must be rated at >40A Instructions Supporting Images are provided overleaf.

Note: Please be careful not to scratch the polished surface of the product at any time on unpacking or installation.

Installation of Homecharge Unit From the consumer unit that will be used to supply the Homecharge unit, measure the conduit and cable lengths required to connect to the Homecharge unit at its required location.

Do not install the Homecharge unit near potential sources of water, flammable, explosive or combustible materials.

The recommended mounting height for the unit is 1.2 metres from the floor to the centre point of the unit.

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Ensure the unit is within 0.5 to 3m of the Electric Vehicle (EV) inlet and positioned such that for tethered cable versions, the connector is not strained, cannot be damaged or stepped on.

For Type 2 socket versions of the Homecharge, ensure the lead being used can connect between the desired Homecharge location and where the EV will be parked.

The incoming mains conduit is mounted on the bottom of the unit (see pictures 1 and 2).

Offer the rear bracket of the unit up to the wall at the recommended height ensuring it is level.

Mark the wall through the 3 mounting points in the bracket (see picture 6).

Drill the correct size hole and depth at the marked locations for the fixings to be used.

Fix the bracket to the wall, using the most appropriate fixings for the wall material, ensuring the surface of the stainless steel bracket is not damaged.

Offer the Homecharge unit up to the bracket, locating the lugs on the bracket into the Homecharge rear moulding and secure with the security screw provided at the bottom of the Homecharge unit (see picture 5).

For a 16A Homecharge version, a 20A MCB and 30mA RCD. For a 30A, 7kW version, the supply is to be via a 40A MCB and 30mA RCD (see specification).

It is recommended that at least 4.0mm2 or 6.0mm2 cable is used depending on the installation, cable run and wattage of the unit being installed. Live, neutral and earth connections are required.

Fit sufficient length of cable and conduit from the supply RCD to the Homecharge unit.

The straight fitting M20 threaded end and locknut on the free end of the flexible conduit from the Homecharge unit can be mounted into a conduit adaptable connector box.

Feed the supply cable wires protruding from the Homecharge unit into the conduit terminal box and terminate in a ccordance with the adaptable box installation guide.

Terminate the green/yellow earth wire, brown live and blue neutral wires to the equivalent incoming supply wires.

Test the electrical installation, cabling and circuit protection and earth resistance and ensure the installation is safe.

For tethered Homecharge units, remove the protection wrapping from the EV connector at the end of the tethered cable and dock with the integral docking receptacle in the front of the Homecharge unit.

Operate the MCB. Homecharge Units Power-up sequence: o Check that the unit powers up and that the Red, Green and Amber LEDs switch on and off to confirm a system reset event. o The Amber and Green LEDs then flash alternately for approximately 1 minute while the board initialises. o The Amber LED will then remain illuminated and the green LED will be extinguished.

The unit can now be used to charge an Electric Vehicle.

Homecharge-i Units Power-up sequence: o The Green and Amber LEDs will flash alternately to indicate that the Homecharge-i is trying to find the GSM network. This can take up to one and a half minutes. The Amber LED will then flash 5 times. o The Green LED will then flash 10 times and be extinguished. o The Amber LED will then be illuminated and remain lit as long as the unit is connected to the mains supply.

The unit is now ready to charge the Electric Vehicle.

If a connection cannot be established to the server, the Red LED will flash 10 times.

If there is no GSM signal, the red LED will be illuminated.

Charging an Electric Vehicle For tethered Homecharge products, un-wrap the lead fully from around the Homecharge unit and then plug the J1772 connector or the Type 2 connector into the Electric Vehicle.

Rotate the key 90 degrees to the right to the â&#x20AC;&#x2DC;Onâ&#x20AC;&#x2122; position.

On the Homecharge unit, the Green LED will illuminate to indicate that the unit is charging the Electric Vehicle and the contactors can be heard to engage.

Verify that the car charges. A visual indication is usually given by the car, which is vehicle dependent.

For a Type 2 socket Homecharge, connect the lead provided with the Electric Vehicle between the car and the Type 2 socket on the front of the Homecharge.

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Stop the charge by returning the key to the vertical ‘Off’ position and check that the Green LED extinguishes. The contactors can also be heard to disengage.

Remove the connector from the car.

For a tethered Homecharge, stow the cable by wrapping it around the Homecharge unit and then plugging the connector into the docking station on the front of the Homecharge unit.

On completion of the installation Supply the keys to the customer and explain the installation.

Picture 1 – Homecharge tethered J1772

Picture 2 – Homecharge mains conduit

Picture 3 – Homecharge tethered Type2

Picture 4 – Homecharge Type2 socket

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Picture 5 â&#x20AC;&#x201C;Rear of Homecharge showing mounting method for wall bracket

70mm

100mm Picture 6 â&#x20AC;&#x201C; Wall bracket fixing positions

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Materials: 1x Adaptable IP 65 100mm x 100mm x 50mm.

3x 60amp PVC connector terminal strips.

4x 8x1 screws and red plugs.

Waterproof sealant.

2x 20mm Neoprene washers.

3x 18mm x10 non insulated bootlace ferrule crimps.

Process Prepare the box for installation: Drill the four fixing holes at a diameter less than the thread of the fixing screw.

Mark and drill 20mm hole for adapter and cable entry of the charge unit.

Mark and drill 20mm hole for supply cable entry.

Drill two small drainage holes at the bottom rear corners of the adaptable box no larger than 4mm in diameter.

Remove any burrs caused by drilling.

Positioning: Make sure the box is level.

If sited directly below the charger, centre the box to the unit.

Ensure when positioning the adaptable box the flexible conduit from the unit is not stretched.

Mark the fixing holes.

Installation: Drill and plug holes (using sealant if required).

Apply sealant around any cable entry and fixing points through the back of the box.

Position box and screw to surface.

If necessary cap screws with sealant and wipe.

Adaptor and glands to be tightened.

Cable and terminations: Dress the cables & cut to suitable length for termination (leaving ample length on supply cable for unit exchanges in the future).

The three terminal blocks are to be separated from each other and spaced apart within the adaptable box.

Strip back insulation to match length of the ferrules (18mm).

Insert conductors into the same end of the ferrule.

Crimp with provided bootlace crimping tool.

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Ferrule to be inserted into individual 60amp connector block positioned to the end of the terminal notpast the insulation.

Tighten the furthest screw from entry first and check to make sure ferrule is secure.

Tighten the nearest screw and gently pull on the cables to confirm secure connection.

Do not over tighten the screws.

Dress the cables into the box, see picture below.

Finishing: Locate screws and secure lid of box (Do not over tighten screws use a hand screwdriver).

Wipe over and clean the box.

Affix â&#x20AC;&#x153;DANGER 230Vâ&#x20AC;? label to the lid. See picture below.

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Chargemaster PLC Mulberry House 750 Capability Green Luton LU1 3LU. 01582 400 331; sales@chargemasterplc.com