INDRA Pioneer Installation Manual
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INDRA Pioneer Installation Manual

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Indra Pioneer
Pioneer Installation Guide
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  • Page 1 Indra Pioneer Pioneer Installation Guide...

  • Page 2: Table Of Contents

    Contents General Description Overview and Intended use environment Protective Earth, Simultaneous Touch (PESTs) Protection General Installation Notes Installation Procedure Commissioning the Charger- Smart Charging Control Load Curtailment and Calibration Technical Specifications and Ratings Certification: Safety Markings and Labels Troubleshooting Servicing and Maintenance Support and Contact Information Models: 190105A101 Type 1 Tethered...

  • Page 3: General Description

    ‘Boost’ functionality overrides any smart grid criteria and provides instantaneous charging capability. Charging using the Pioneer can take place at up to 7kW, but due to modulation capability (measured by the external CT clamp) this power output level can also be reduced.

  • Page 4: Protective Earth, Simultaneous Touch (Pests) Protection

    The Pioneer’s PEST solution can operate under four of the indents of BS 7671:2018+A2:2022 Amendment 1; section 722.411.4.1, for the purposes of design /installation we have two modes of operation which Indra call A & B. Mode A can be configured with or without a reference electrode.
  • Page 5 • Mode B - PME as CPC with trip on L-N voltage measurement. No reference electrode. For installations where an Earth Rod is not possible and/or there are no simultaneous contact or touch voltage risks present. Consideration should \ be given to nuisance trips where the line to neutral voltage may regularly exceed 253v, especially where local renewables are present, Mode A is less sensitive to nuisance tripping.
  • Page 6 Full protection Full protection Full protection DC 6mA Protection Full protection Full protection Full protection Protection for installs Manual management Manual management Manual management with three independent of risk of risk of risk earthing systems (rare) Indra’s unique PEST safety features...
  • Page 8 (protective) earth. In this case, the user touching the EV (and outside tap or lamp post etc) completes the circuit back to source earth. Indra PESTS mode A Indra PESTS mode B...
  • Page 9 Protection against electric shock is provided b a device which The main earthing terminal of the installation electrically disconnects the vehicle from the live conductors is connected to an installation earth electrode by of the supply and from protective earth in accordance with a protective conductor complying with Regulation Regulations 543.3.3.101(ii) within 5 s in the event of the 544.1.1.

  • Page 10: General Installation Notes

    WARNING: FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD PRESENT A HAZARD A) Read these instructions fully before installing or using the Pioneer and keep these instructions for future reference. B) The Pioneer is designed for permanent installation and is suitable for operation on an AC electricity supply having the same voltage and current rating as shown on the product label.

  • Page 11: Installation Procedure

    Installation Procedure Installation Kit and Tools The Pioneer is supplied with the general screws and wall fixings that are required to permanently fix it in position. However, it remains the responsibility of the installer to evaluate the suitability of the installation surface and use the appropriate fixings when appropriate.
  • Page 12 Pioneer. NOTE: ANY DAMAGED OR UNSUITABLE CABLES MUST BE REPLACED Inspect the Pioneer to ensure the charger has not been damaged in transit, not compromised and is safe to connect. Ensure there is an Earth Connection to the Pioneer.
  • Page 13 Keep the remaining screws for later. Hanging the Pioneer Charger Hang the Pioneer onto the bracket (using the top grooves in the back of the charger) and fix to the bracket using the M4 torx bolt, threaded into the bottom of the charger.
  • Page 14 Drilling hole for mains cable gland DRILLING OF TOP LEFT DIMPLE ONLY IS RECOMMENDED After assessing what size of cable is needed to connect to the property’s electrical supply, using an appropriate diameter Armeg Holesaw, drill a hole carefully into the charger using the TOP LEFT dimple as a guide ONLY.
  • Page 15 EXISTING CABLES & PIPES • Attach the lug clamp terminal and run a length of cable (clipping against walls where necessary) back to the Pioneer; terminate with a bootlace ferrule in the second from right push-down terminal. • Suggested cable use either 4mm2 or 6mm2 Solar Cable (EN5061), with double insulation •...
  • Page 16 Example reference electrode including 4-foot rod, mechanical protection and EN5061 cable clipped direct to the wall Connecting the Mains cable • Feed the mains power cable (L, N & CPC) through the left-hand mains power gland. • It is advised to crimp the ends of these three wires using bootlace ferrules and con- nect the Live, Neutral and CPC wires to their respective Push-Down Terminal Block.
  • Page 17 The far-right push-down connector is for CPC Ground The second from right push-down connector is for the TT Reference Electrode The second from left push-down connector is for Neutral The far-left push-down connector is for Live (These are also denoted on the motherboard itself) Type 1 &...
  • Page 18 Images of ‘pig-tailed’ mains cables into the charger.
  • Page 19 BLUE/ BE WE Image showing location and orientation of the two cores of the External CT clamp, as wired into the IDC terminal on the Pioneer To connect the external CT clamp, you must push a length of CAT5e cable through the gland and then separate the cores.
  • Page 20 The External CT clamp location shall be left to the installer’s discretion, depending on installation. However, it must be clipped around the Live main grid supply cable and secured with the red security cable tie.
  • Page 21 • You must fit the red security cable tie around the CT clamp clasp to prevent removal. • If the Pioneer does not see a CT clamp or the signal is poor quality, and you have configured the unit for load curtailment, the unit will revert to 6A max charging to protect the service head fuse.
  • Page 22 CT Clamp Gland Jelly Crimps (CT and data in this example) Picture: Join located within the consumer unit feeding the EVSE 5. Complete the commissioning process in the installer app. 6. Fit the red security cable tie (Note, this will not be supplied until G100.2 comes into force).
  • Page 23 Hardwired Ethernet Link If the customer hasn’t opted for the 4G or Wi-Fi wireless options, the below section relates to hardwiring a CAT5e connection back to the properties’ router. • Push a length of the ethernet (CAT5e) cable through the left-hand gland and then attach an RJ45 connector to its end.
  • Page 24 If it doesn’t pass the test, then re-crimp. If it does pass, plug one end of the cable into the female RJ45 connector on the Beaglebone within the Pioneer and the other end into the house’s router port.
  • Page 25 PRIOR TO UNBOXING THE WIRELESS CELLULAR DONGLE, it is important to NOTE ON YOUR JOB CARD the unique Pioneer device’s serial number, along with the serial number of the dongle. This will allow pairing of, and association between, these two products.
  • Page 26 CRITICAL CARE POINT Avoid knocking any components on the PCB as serious damage may occur Ensure the USB extension cable is neatly and tightly routed down the right-hand side. Incorrect Correct routing of routing the cable of cable Ensure the USB extension cable is neatly and tightly routed down the right-hand side CRITICAL CARE POINT Ensure the USB cable is routed tight to...
  • Page 27 Replace the Front of the Charger Screw in the six M4x10 Torx on the front body, these should be tightened to a torque of 2.0N/m, no tighter.
  • Page 28 MAKE SURE ALL COVERS AND FIXINGS ARE IN PLACE; ALSO ENSURE THAT THE PIONEER IS SECURED PRIOR TO ENERGIZING THE CIRCUIT Turn the power on at the consumer unit /breaker to the Pioneer. Note: If internet connectivity is not able to be established, then after 10 mins the device will go into ‘home alone’...

  • Page 29: Commissioning The Charger- Smart Charging Control

    Commissioning the Charger- Smart Charging Control Accessing Smart Control Installer Portal To enable smart control of the Pioneer EV charging unit, it is necessary to confirm the commissioning of the device using the Installer Portal on the following address: https://app.ev.energy/commissioning/Indra/activate.
  • Page 30 • The next stage is to input the “Property Max Draw” based on the DNO fuse rating at the property. Select either 60, 80 or 100A and click “Next”. If the DNO fuse rating is not clear, select 60A to prevent any inadvertent damage to/ failure of the fuse.

  • Page 31: Load Curtailment And Calibration

    DNO to change the fuse and/ or restrict charging to priority devices. It may also result in penalties from DNOs. If the customer has bought the Pioneer specifically to use the solar charging or data collection features, it is vital that an external CT clamp is installed.
  • Page 32 • If curtailment is not required, click “No”. You should then be taken to the following screen where you will be prompted to enter the customer details. • If curtailment is required, click Next. The following screen will then require you to enter the manual current reading in amps to check if calibration is required.
  • Page 34 1. An EV is present 2. Pioneer is connected to the customer’s (or your own) electric vehicle (for socketed variants the customer’s intermediate charging cable will be required) 3. EV Battery State of Charge is less than 90%...
  • Page 35 Dynamic Calibration can be triggered by clicking “Start”. This Calibration cycle can take up to 5 minutes to complete. Once completed, you will be prompted to enter a new reading from the handheld clamp meter/ multimeter. Note: The in-app telemetry power readings may take up to 30 seconds to refresh, to ensure you are comparing updated readings...
  • Page 36 This action should have reduced the difference between the power readings to be within 5% of the truth. Where successful, the install summary page will reflect an audit of actions related to Dynamic load calibration and relevant telemetry information: Getting a 5% difference in readings is ideal but may not always be possible due to the length of cable run or similar influences.
  • Page 37 3. You have an EV Charging Station Test Adapter with a 3-pin plug output 4. You have a minimum 2kW fixed load such as a Fan Heater or Kettle 5. Pioneer is plugged into the EV Test Adapter (either via the tethered cable or the customer’s own intermediate charging cable) This action should have reduced the difference between the readings to be within 5% of the truth.
  • Page 38 Getting more than 50% difference in readings for fixed load calibration will mean that subsequent re-work of the CAT5E cable terminations, along with ensuring the CT clamp is positioned correctly on the Live incoming feed (as per section “Attaching the External CT Clamp”) In this event, installers are advised of the need for further calibration or rework to reduce difference in readings.
  • Page 39 Enter your Customer’s information • In the Installer Portal, after calibrating the charger, you should be prompted to enter the customer’s email address, installation site postcode and first line of the address. • After completing all fields, click “Next”. Optionally, you can add the last 13 digits on the customer’s MPAN from their electricity bill.
  • Page 40 • Once the calibration process has been worked through and the commissioning successfully completed from the above there will be a success message and the customer will then receive a welcome email directing them to the ev.energy app.
  • Page 41 Charger Security Seal Once the calibration process has been worked through via the app and the commissioning successfully completed, the unit can be sealed with the security tag.   Place the security seal over the screw hole.  Use the QR code to record the security code number in the portal.
  • Page 42 Attach the Fascia • Clip the top two tabs of the fascia into their recess of the grey front body. • Screw in the two M4x8 Security torx in the bottom of the charger. Tightening to a torque of 1.0N/m DO NOT over-tighten as damage to the plastic tabs will occur...
  • Page 43 Pioneer, several times, leaving a very short tail (only applicable for tethered type 1 & type 2 variants, 190105A101 & 190105A102) • Push the male charging connector into the blank holster recess of the Pioneer charger, so that it clips/ latches into position and is held •...

  • Page 45: Technical Specifications And Ratings

    Technical Specifications and Ratings General Specification Model Name Pioneer Mode 3: Type 2 socket, Type 1 Mode or Type 2 tethered cable Overall Dimensions 200mm x 130mm x 420mm Weight 3.5kg (excluding cable) Operating temperature -20°C to 50°C Charging Cable Length Up to 4.5m...

  • Page 46: Certification

    CE Marking OLEV Accreditation under Electric Vehicle Home Scheme Compliance: • Pioneer permits installations to meet BS 7671:2018+A2:2022 Requirements for Electrical Installations • BS EN 61851-1:2019 Electric vehicle charging system – general requirements • BS EN 61851-21:2017 Electric vehicle charging system – electric vehicle off-board charger EMC requirements for connection to an AC/DC supply •...

  • Page 47: Safety Markings And Labels

    The outer enclosure is marked with the model information WEE Symbol- ALL END OF LIFE SMART ENERGY PRODUCTS MUST BE RE- TURNED TO Indra RENEWABLE TECHNOLOGIES LTD FOR APPROPRIATE RECOVERY & RECYCLING. If this cannot be achieved, then the customer must take the end of life prod- uct to a designated collection facility (DCF) as detailed by their local author- ity (LA).

  • Page 48: Troubleshooting

    Troubleshooting LEDs relating to the primary LED light: All LEDs are off • The charger is not receiving power; it may be disconnected from the mains. Primary LED lit, white Solid white LED demonstrates: • The charger is all set up ready to go Flashing white LED demonstrates: •...

  • Page 49: Servicing And Maintenance

    • Fixed load calibration has been triggered by the installer to calibrate the CT clamp. Servicing, Maintenance & Support The Pioneer MUST NOT be repaired by the customer. Repair of the charger is to be carried out ONLY by the manufacturer or their approved installation partners.

  • Page 50: Support And Contact Information

    Support and Contact Information For technical support, product queries and information please contact: Email support@Indra.co.uk Telephone 01684 770631 www.Indra.co.uk...

This manual is also suitable for:

190105a101190105a102190105a103

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