Malmbergs EVC04-AC22 Series Installation Manual

Electric vehicle charger

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ELECTRIC VEHICLE CHARGER

EVC04 Series

Installation Guideline

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Summary of Contents for Malmbergs EVC04-AC22 Series

Page 1 ELECTRIC VEHICLE CHARGER EVC04 Series Installation Guideline...
Page 2: Table Of Contents
2.6.3 - LOCKED CABLE FUNCTION (Model with Socket)..................28 2.6.4 - POWER OPTIMIZER (REQUIRES OPTIONAL ACCESSORIES)................29 2.7 - LOAD SHEDDING.............................32 2.8 - MONITORING OF WELDED RELAY CONTACTS FAILURE.................33 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 1...
Page 3 4.9 - CHANGE STANDALONE MODE SETTINGS OF THE DEVICE................52 4.10 - CHANGE STANDALONE MODE SETTINGS OF THE DEVICE................53 4.11 - MAKING SYSTEM MAINTANENCE OF THE DEVICE..................55 FIRMWARE UPDATE SCREEN FLOW (With Display Models) .................56 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 2...
Page 4: Safety Information
It should not be located in a recessed area or below floor level. • This device is intended only for charging vehicles not requiring ventilation during charging. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 3...
Page 6: Description
Blank : Case-B Connection with normal socket T2S : Case-B Connection with shuttered socket T2P : Case-C Connection with Type-2 plug T1P : Case-C Connection with Type-1 plug Cabinet EVC04 Table-1 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 5...
Page 7 Model reference table does not include all model variants of EVC04. EVC04-AC7SW EVC04-AC7SWA EVC04-AC7SLA-T2P EVC04-AC7SWDA-T2S EVC04-AC7SLWDA-T1P EVC04-AC11SLD EVC04-AC11SWDA EVC04-AC11SLWDA-T2P EVC04-AC11SLWDA-T2S EVC04-AC22SLDMID EVC04-AC22SWDA EVC04-AC7SWD-T2P (2E) EVC04-AC22SLWDA-T2P EVC04-AC22SLWDA-T2S EVC04-AC22SWDMID(CT)- Table-2 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 6...
Page 8: General Information
Charging station Charging station communication cable gland nut communication cable gland nut Charging station supply inlet Charging station supply inlet gland nut gland nut IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 7...
Page 10: Electric Vehicle Charging Station Exploded Picture
Rear Cover Real Terminal Connection Cable Bush M32x1.5 DC Sensor Cable Bush M20x1.5 Rail Connection Plastic Blind Flange Card Isolation Plate Charging Plug Card Isolation Plate Charging Cable IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 9...
Page 11: Socket Equipped Models
Rear Cover Real Terminal Connection Cable Bush M20x1.5 DC Sensor Plastic Blind Flange Rail Connection Cable Bush M32x1.5 Card Isolation Plate Plastic Blind Flange Card Isolation Plate IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 10...
Page 12: Mid Models
Charging Plug Cosmetic Label Cable Bush M32x1.5 Hinge Plastic Blind Flange Real Terminal Connection Charging Cable DC Sensor Card Isolation Plate Card Isolation Plate MD Component MID Glass IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 11...
Page 13: Socket Equipped Models
Cable Bush M32X1.5 Sealing Ring Rear Cover Front Cover Plastic Blind Flange Real Terminal Connection Hinge DC Sensor Card İsolatıon Plate Card İsolatıon Plate MID Glass MID Component IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 12...
Page 14: Required Equipment, Tools And Accessories
Screwdriver Flathead Screwdriver (Tip Right Angle Screwdriver Adapter / Pointed Spudger width 2.00-2.5 mm) Torx T20 Security Bit Cat5e or cat6 ethernet RJ45 Crimping Tool cable Table-4 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 13...
Page 15: Technical Specifications
2P -40A - 30mA RCCB Type-A which are not equipped with RCCB Type A) Required AC Mains Cable 3x 6 mm² (< 50 m) External Dimensions: Ø 13-18 mm IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 14...
Page 16: Connectivity
-35 °C to 55 °C (without direct sunlight) Humidity (–25°C to +50 °C for RCCB equipped models) 5% - 95% (relative humidity, no deviation) Altitude 0 - 4,000m IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 15...
Page 17: Installing Charge Station
2 User RFID Card Installation and User Guide ELECTRIC VEHICLE CHARGER EVC04 Series ELECTRIC VEHICLE CHARGER Installation Guideline EVC04 Series Riktlinjer för installation Installation Guideline Riktlinjer för installation IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 16...
Page 18: Product Installation Steps
Please power off the charging station mains supply Remove the cover screws with Torx T20 security L-Wrench or Right Angle Screwdriver Adapter using Torx T20 Security Bit. Open the cover. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 17...
Page 19: Wall Mount Installation
Mounting the charging station on wall is now finished. Before next step (7), Please check the instructions for Single Phase or Three Phase cable connections in sections 2.3 or 2.4. Figure-7 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 18...
Page 21 Before closing the cover of the charging station, check instru- ctions in sections 2.6 and 2.7 if any function related to these sections are used. Figure-10 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 20...
Page 22: Single Phase Charging Station Ac Mains Connection
Tighten the screws on the terminal block as shown in the image with the tightening tourqe of 2.5Nm. Electric Terminal AC Cable Color AC L1 (Brown) AC Neutral (Blue) Earth (Green-Yellow) Table-5 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 21...
Page 23: Three Phase Charging Station Ac Mains Connection
Tighten the screws on the terminal block as shown in the image with the tightening tourqe of 2.5Nm. Electric Terminal AC Cable Color AC L3 (Grey) AC L2 (Black) AC L1 (Brown) AC Neutral (Blue) Earth (Green-Yellow) Table-6 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 22...
Page 25: Dip Switch Settings
Brief descriptions of the DIP switch pin settings can be found in below table. Pin Number Description Pin-1 Reserved Pin-2 External Enable Input Functionality Pin-3 Locked Cable Function (only for socket models) Pin-4-5-6 Power Optimizer (Requires Optional Accessories) Table-9 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 24...
Page 26: Data Cable Connection
Insert the cable through the RCCB housing holes. Finally, to connect the wires on mainboard, check the following sections in 2.6 and 2.7 depending on the function(s) to be used. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 25...
Page 27: External Enable Input Functionality
If the external relay (RL) is in non-conducting (open), the charging station will not be not be able to charge the electric vehicle. You can connect potential free input signals as shown in above circuitry (see figure-17). See section 2.6.1-Data Cable Connection. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 26...
Page 29: Locked Cable Function (Model With Socket)
Turn on the power to your charging station. The the charging cable to the socket outlet. cable becomes locked and the charging station starts behaving as a cable model. Table-11 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 28...
Page 30: Power Optimizer (Requires Optional Accessories)
When 4, 5, 6 pins are in OFF position, power optimizer functionality is disabled. DIP Switch Positions Current Limit Value Power Optimizer Disabled Table-12 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 29...
Page 31 10-11: A-B (COM) Modbus connection over RS485 for single phase charging station models. (See section 2.6.2- STP Connection) Related board wiring of Power Optimizer connections can be made as shown below: IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 30...
Page 33: Load Shedding
Load Shedding Input + Load shedding Input – Table-15 Load Shedding Input State Behaviour Opened Contact Charge at max. available current Closed Contact Charge at min. current (8A) Table-16 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 32...
Page 34: Monitoring Of Welded Relay Contacts Failure
The circuitry block diagram that must be used at the fuse box of the charging station is shown below. EVSE 230V L1_W CN33 Figure-24 See section 2.6.1- Data Cable Connection CN33 Figure-25 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 33...
Page 35: Factory Reset
Toggle the first position of dip switch which is on the smart card of the charger shown in figure 28. After that please turn on the charger again. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 34...
Page 36: Setting Ethernet Port Of Charger To Static Ip In Standalone Usage Mode
Charging station sets the Ethernet port to 192.168.0.10 adress statically and subnet mask will be set to 255.255.255.0 Toggle Figure.29 If the charger’s Ethernet port is needed to be set in DHCP mode, this should be done from the webconfig interface. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 35...
Page 37: Webconfig Ui Enable / Disable
Daisy-Chain connection can be done as shown in Figure-32. Here, Ethernet router/switch/hub is used to route the traffic in the medium and any device can communicate with IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 36...
Page 38: Ocpp Connection
Make sure the charging station is powered-off. 3.1 - CONNECT OCPP OVER CELLULAR NETWORK Insert the Micro SIM card in the cellular module SIM card slot as shown in the below figure. Figure-31 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 37...
Page 39: Connect Ocpp Over Ethernet
8 individual wires. placing them in the following order: white/ orange, solid orange, white/green, solid blue, white/blue, solid green, white/brown, solid brown. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 38...
Page 41: Commissioning
You should assign static IP address to your PC in 192.168.0.254 network which means that IP address should be in a range of between 192.168.0.1 and 192.168.0.254. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 40...
Page 42: Open Web Config Ui With Browser
After typing your current password and new password twice, you will be redirected to the login page again to log in with your new password. All spaces you will see are mandatory in this page. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 41...
Page 43: Main Page
Technician can select display language from the general settings page. Available languages for display language are as shown in figure below for now. After selecting the language, user can save selection by “Save Button”. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 42...
Page 44 Similary, “Sunset Time” defines the transition time of high to low backlight level. Sunrise and sunset time based configuration is periodic daily setting. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 43...
Page 45: Display Service Contact Info
Figure.40 4.5.5 - Display Service Contact Info: Technician can enter the requested contact info of the service from this menu to be able to shown in display. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 44...
Page 46: Logo Settings
4.5.6 - Logo Settings: Technician can change the display logo of the station from the logo settings by uploading the required logo. The new logo should be in 80x80 pixels and .png format. Figure.42 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 45...
Page 47: Installation Settings
Note: For example, if the charging station’s current limiter is set to 16A in hardware and it is written and set 32A in web configuration interface, the station takes 16A. Figure.44 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 46...
Page 48: Unbalanced Load Detection
Default value for this option is set as disabled but if the user wants to use external enable input function, the setting should be set as “enabled” IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 47...
Page 49: Lockable Cable
Figure.46 4.6.5 - Lockable Cable: This option is set “disabled” in web configuration user interface by default. Figure.47 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 48...
Page 50: Change Ocpp Settings Of The Device
You can select the OCPP settings type you want from the menu which is at the left side of the page. For example OCPP Connection,OCPP Version,Connection Settings and OCPP Configuration Parameters. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 49...
Page 51: Change Network Interfaces Settings Of The Device
Gateway” and “Primary DNS” spaces are mandatory. If you set Wi-Fi as enabled, “SSID”, “Password” and “Security” are mandatory. You should fill all spaces in suitable formats. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 50...
Page 53: Change Standalone Mode Settings Of The Device
Select “Accept All RFID’s” mode to authenticate all RFID’s. Select “Autostart” mode to allow charging without the need for authorization. It will be enough to plug to start charging. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 52...
Page 54: Change Standalone Mode Settings Of The Device
4.10 - MAKING SYSTEM MAINTANENCE OF THE DEVICE In LOG FILES Page, you can download OCPP or HMI logs by clicking buttons. Download log files will be shown after a few seconds. Figure.57 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 53...
Page 55 After the firmware update is finished, your charger will restart automatically. You can see the latest firmware version of your charger from webconfig UI in main page. Figure.59 IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 54...
Page 56: Firmware Update Screen Flow (With Display Models)
Restore Config File button and upload the backup file. The system only accepts the .bak files. Figure.61 In SYSTEM RESET Page, you can make Soft Reset and Hard Reset by clicking the buttons. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 55...
Page 57 New password must contain at least 1 lowercase letter, 1 uppercase letter, 1 numeric character and minimum 6 characters. All spaces are mandatory. Figure.63 In FACTORY DEFAULT CONFIGURATION Page you can make factory reset to the device. IG v16.3.0 2021 © 2021 Malmbergs - All rights reserved English - 56...
Page 59 Malmbergs Elektriska AB Västra Bangatan 54, PO Box 144, SE-69223 Kumla, Sweden 50627359...

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