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Etrel INCH Installation & Specification

Electric vehicle charging station
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ELECTRIC VEHICLE CHARGING
STATION
ETREL INCH
ELECTRICAL INSTALLATION
SPECIFICS
Document version: 2.01
Document date: 18. 03. 2025

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  • Page 1 ELECTRIC VEHICLE CHARGING STATION ETREL INCH ELECTRICAL INSTALLATION SPECIFICS Document version: 2.01 Document date: 18. 03. 2025...

  • Page 2: Table Of Contents

    Etrel INCH | Electrical Installation Specifics TABLE OF CONTENTS BASIC DESCRIPTION..............1 About this Document ..............1 Site Preparation ................1 Permits ..................2 Location ..................2 Content, Optional and Extra Equipment ........4 Tools ................... 5 PRODUCT DESCRIPTION............... 6 Components Overview ..............

  • Page 3: Basic Description

    • 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”:...

  • Page 4: Permits

    Etrel INCH | Electrical Installation Specifics I N STRU CTI ON S V AL I DI TY 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...

  • Page 5: Charging Station

    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.

  • Page 6: Chargi N G Stati On Di Men Si On S

    Etrel INCH | Electrical Installation Specifics CHARGI N G STATI ON DI MEN SI ON S 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 •...

  • Page 7: Tools

    Etrel INCH | Electrical Installation Specifics *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, •...

  • Page 8: Product Description

    Etrel INCH | Electrical Installation Specifics 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).

  • Page 9: Components Overview

    Etrel INCH | Electrical Installation Specifics 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, •...

  • Page 10: Grid Connection

    Etrel INCH | Electrical Installation Specifics 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).
  • Page 11 Etrel INCH | Electrical Installation Specifics 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.

  • Page 12: Circuit Diagram

    Etrel INCH | Electrical Installation Specifics CIRCUIT DIAGRAM...

  • Page 13: External Signal

    Etrel INCH | Electrical Installation Specifics 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.

  • Page 14: Cable Cross-Section Selection

    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 mm , dependant 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.
  • Page 15 Etrel INCH | Electrical Installation Specifics Table 1: Minimum cable cross-section for continuous operating current of 32 A. A1 - Insulated single core conductors in conduit in a A1, A2: thermally insulated wall 10 mm A2 - Multicore cable in conduit in a thermally insulated wall...
  • Page 16 SHORT CI RCU I T WI THSTAN D 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 characteristics.

  • Page 17: Other Consumption Or Production Of Electricity At The Location

    (other loads + charging) overcomes the limitation of the grid connection point, the charging should be controlled. Because the charging station needs information of other loads (or production) to be able to react appropriately, Etrel Load Guard device can be used. LOAD GUARD...
  • Page 18 Etrel INCH | Electrical Installation Specifics Figure 6: Use of additional consumption data to prevent overload When there is local production of energy present at the location (e.g., photovoltaics), the available charging current can be higher, and the use of Load Guard make possible to always charge with maximum available current.

  • Page 19: Dimensioning Of A Cluster

    INCH Pro charging station. When selecting the cluster configuration and cluster master it is important to know that INCH Pro can handle power management of up to 36 electric vehicles. This is valid for the most unfavourable scenario with...

  • Page 20: Cabling Route For The Connection Of Multiple Charging Stations

    Etrel INCH | Electrical Installation Specifics Normally the cluster is dimensioned for available power and power management limits the total current of the cluster to allowable levels. Also, possible future upgrades should be considered and could lead to decision to install cables with larger cross-sections.
  • Page 21 Etrel INCH | Electrical Installation Specifics POWER CABL ES POI N T TO POI N T N ETWORK TOPOL OGY Power cables are routed to the first station, which is then connected to the next station with a separate power cable and a separate communication cable.

  • Page 22: Cluster Cables Cross-Section

    CLUSTER CABLES CROSS-SECTION When INCH Pro is designated as cluster master, it is possible to connect 36 INCH Pro charging stations to this cluster, meaning that charging is supported to 36 electric vehicles simultaneously. If industrial computer is...
  • Page 23 When considering charging with full power the available capacity can quickly run out even with small numbers of simultaneously charged vehicles. INCH Pro has implemented power management functionalities with option of software limitation of maximal current of charging for individual charging station or for complete cluster.
  • Page 24 Etrel INCH | Electrical Installation Specifics In the previous table the numbers represent the case when the wiring is still three-phase. Such system allows charging of individual electric vehicles with maximal power of 22,08 kW. Power management can be used to set limitation of the maximal current of the complete cluster (determined by the location, e.g., main fuses).
  • Page 25 Voltage drop in the power cable is proportional to the current of the load. When installing two INCH Pro charging stations, also voltage drops are twice as high as in case of one INCH Pro without considering any additional elements.
  • Page 26 70 mm (Method G) or 150 mm (Method C) cables could be used when connecting 10 INCH Pro charging stations with maximum charging current available. Reviewing the selection of the cable with consideration of voltage drop, shows that allowable distance of conductors is a lot lower than if selecting...
  • Page 27 Etrel INCH | Electrical Installation Specifics Table 12: Voltage drop in conductors with 70 mm cable cross-section and charging current of 320 A. Charging current Conductor Conductor 320 A (Ten INCH Pro 70 mm 70 mm with max. current) Single phase...
  • Page 28 Etrel INCH | Electrical Installation Specifics Table 16: Voltage drop in conductors with 240 mm cable cross-section and charging current of 320 A. Charging current Conductor Conductor 320 A (Ten INCH Pro 240 mm 150 mm with max. current) Single phase...

  • Page 29: Examples Of Connection

    Figure 11: Example of INCH Pro connection Maximal continuous current of the cluster Maximal operating current of the presented case is 960 A. Cables supporting this current would need to be installed in E, F or G method of installation or a bus-bar system could be used.
  • Page 30 Etrel INCH | Electrical Installation Specifics Method of installation E: 400 mm • • Method of installation F: 500 mm • Method of installation G: 400 mm Such a high requirement indicates the possibility of using three main power lines to separate groups of the cluster, each designed for 320 A.
  • Page 31 The cable cross-sections must be determined in accordance with all three criteria. Figure 12: Example of INCH Pro connection – use of double terminal clamps Maximal continuous current of the cluster Maximal operating current of the presented case is 960 A. Cables supporting this current would need to be installed in E, F or G method of installation or a busbar trunking system could be used.
  • Page 32 At L1 the cable cross-section is extremely large indicating the • possible need to use e.g., three main power lines, each connecting 10 x INCH Pro as shown on the following figure. • At L2, L3 and L4 the cables are relatively large, and the junction boxes will need to have double terminal clamps installed for connection of cables.
  • Page 33 CASE 3 : POWER CABL ES FOR CL U STER OF 3 0 I N CH I N EXPAN DED POI N T TO POI N T N ETWORK Figure 13: Example of INCH Pro connection – use of double terminal clamps The figure presented above is showing possible selected configuration, after reviewing Case 1 and 2.
  • Page 34 CASE 4 : POWER CABL ES FOR CL U STER OF 3 0 I N CH CON N ECTED I N SI N GL E-PHAS E When INCH charging stations are connected in single-phase connection, the connected electric vehicles can charge only over one phase, meaning the highest charging power that is available is 7,36 kW.

  • Page 35: Connecting Charging Station

    Etrel INCH | Electrical Installation Specifics CONNECTING CHARGING STATION Before attaching the installation panel to a wall or a pole, it is essential to consider from which direction the cables will be routed to the charging station, as there is a possibility for each installation method according to the specific installation.

  • Page 36: Preparation Of Cables

    Etrel INCH | Electrical Installation Specifics and their diameter (which is determined in the Electrical installation documentation). When dealing with cables with larger diameters, their bending radius must be considered. Appropriate length of cables must reach through the upper opening for later connection of the charging station.
  • Page 37 Etrel INCH | Electrical Installation Specifics Figure 16: Screws located on the green back maintenance door Remove the maintenance doors on the side either using hex key or Important: Key to unlock the key-lock comes with the charging station. regular key if the enclosure came with the keyhole.
  • Page 38 Etrel INCH | Electrical Installation Specifics Figure 20: Cable gland plate Important: Diameter of gland rubbers Bigger cable gland is meant for power supply cables and smaller for are 1.5 cm for the tighter of the rubbers the ethernet cable. As is seen from the picture above smaller gland and 2.1 cm for the looser one.
  • Page 39 Etrel INCH | Electrical Installation Specifics 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.
  • Page 40 Etrel INCH | Electrical Installation Specifics Figure 24: Removing the wire insulation 11. Once all the wires are stripped of wire insulation attach on the end of the wires cable ferrules so that wires can connect to RCD or overcurrent protection and squeeze them with the pliers.
  • Page 41 Etrel INCH | Electrical Installation Specifics Figure 28: UTP gland rubber with filler Figure 29: Removed filler from the gland rubber 13. Insert the UTP cable through the gland and remove the cable jacket Important: UTP cabel from the cable. About 20 cm of UTP cable should be put out of the...

  • Page 42: Mounting Of The Charging Station And Installation Of Cables

    Etrel INCH | Electrical Installation Specifics MOUNTING OF THE CHARGING STATION AND INSTALLATION OF CABLES Once the cables had been prepared, the installation of cables into the charging station can start. Mount the station on the holder that is already attached to the already installed bracket on the wall.
  • Page 43 Etrel INCH | Electrical Installation Specifics Figure 35: Cable gland plate positioned in the appropriate spot Insert the screws in the cable gland plate holes and tighten them so that the cable gland plate is secured in its location. Use the regular cross screwdriver.
  • Page 44 Etrel INCH | Electrical Installation Specifics Figure 38: Ground wire secured to the enclosure using the screw Next step is to connect cables to protection element or MID meter. Connection of all the elements is practically the same. The procedure described below is for connection of RCD, however the procedure can be followed for other connection elements as well.
  • Page 45 Etrel INCH | Electrical Installation Specifics Figure 40: Protection to enable RCD trip inserted into the slot of neutral Now insert all the wires into the RCD/overcurrent/MID unit. Order of the wires and how they are connected is important. In the top connector, which is phase one (L1) of the charging station, wire that will be used to charge one phase EVs should be connected.
  • Page 46 In some countries the colour of the conductors can be different. Special single phase configuration case, MID meter with RCD In case of a single-phase configuration of INCH, with single-phase MID meter and with single-phase RCD element, the power connection is made using the MID meter as indicated on the labels.
  • Page 47 Etrel INCH | Electrical Installation Specifics 11. Attach the back-maintenance doors back onto the enclosure and use the screw to secure it to the location. Figure 43: Side view of the reattached back maintenance door Figure 44: Secure the back-maintenance doors with screws 12.
  • Page 48 Etrel INCH | Electrical Installation Specifics Figure 46: Holder is removed 13. 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.
  • Page 49 Etrel INCH | Electrical Installation Specifics Figure 49: Installed metallic cable holder Figure 50: Charging station with the installed small metal circle where magnetic cable hand can be attached to Figure 51: Charging station with installed big metal circle where magnetic cable hand can be attached to 14.
  • Page 50 Etrel INCH | Electrical Installation Specifics Figure 52: Attach the charging station to the top hooks and push it to the wall 15. Tighten the screw until it is completely fastened and charging station will be completely secured to the wall.
  • Page 51 Etrel INCH | Electrical Installation Specifics Figure 54: Attach the side doors to the Figure 55: Secure maintenance doors enclosure enclosure using hex key Figure 56: Charging station with short cable Figure 57: Charging station with long cable...

  • Page 52: Electrical Measurements

    Etrel INCH | Electrical Installation Specifics ELECTRICAL MEASUREMENTS Electrical measurements must be performed by licensed electrician and must be in accordance with requirements set in national legislation. In this chapter only information on specifics of some of the electrical measurements is given.

  • Page 53: Insulation Resistance Measurement

    Etrel INCH | Electrical Installation Specifics INSULATION RESISTANCE MEASUREMENT Measurements of the insulation resistance of electric cables are performed between active conductors and between active conductors and the protective conductor connected to the earthing system. Normally, the insulation resistance measurement is performed on the electrical installation separately from measurements of the charging station.

  • Page 54: Possible Procedure Of Measurement Of Insulation Resistance

    Etrel INCH | Electrical Installation Specifics Insulation resistance, measured at a test voltage of 250 V d. c. and with disconnected power supply is satisfactory if its value is not less than 1 MΩ. POSSIBLE PROCEDURE OF MEASUREMENT OF INSULATION RESISTANCE...
  • Page 55 Etrel INCH | Electrical Installation Specifics d) Remove 6 screws on back cover. Screws: • Self-tapping 4,2x13 (positions marked in yellow) and 4,2x9,5 (positions marked in blue). Metric M4x10 (positions marked in yellow and blue). • DISCONECTING THE POWER SUPPLY a) Locate the connector circled with red in the picture below.

  • Page 56: Rcd Test

    Etrel INCH | Electrical Installation Specifics e) Close the service plate cover and screw all the screws. f) Remove the holder and set the charging station back in normal position. g) Screw the internal screw, that is holding the charging station in place and close the door of the service compartment.

  • Page 57: Measurements Of The Effectiveness Of Protection Against Electric Shock

    Etrel INCH | Electrical Installation Specifics MEASUREMENTS OF THE EFFECTIVENESS OF PROTECTION AGAINST ELECTRIC SHOCK In the case of TN systems, the effectiveness of protective measures in the event of damage by tripping the power supply is checked by: a) measurement of fault loop impedance, b) verification of the characteristics and/or effectiveness of the associated protection.

  • Page 58: Earth Electrode Resistance Measurement

    Etrel INCH | Electrical Installation Specifics EARTH ELECTRODE RESISTANCE MEASUREMENT Measuring of the resistance of an earth electrode shall be made by an appropriate method. Various methods exist and none of them is ideal, as they all have advantages and disadvantages. The methods, described below, are proposed in standard IEC 60364-6.
  • Page 59 Etrel INCH | Electrical Installation Specifics Electrodes arranged in linear formation Electrodes arranged in triangular formation Earth electrode test instrument according to IEC 61557-5 Earth electrode resistance Temporary probe electrode resistance (voltage) Temporary auxiliary probe earth electrode resistance (current) Figure 59. Measurements of the earth electrode resistance...
  • Page 60 Etrel INCH | Electrical Installation Specifics The test should be performed on the live side of the main switch with the supply to the installation switched OFF and with the earthing conductor temporarily disconnected from the main earthing terminal (MET).
  • Page 61 Etrel INCH | Electrical Installation Specifics The voltage and current coils may be in individual clamps separately connected to an instrument or in a single combined clamp. This method is directly applicable to TN systems and within meshed earthing of TT systems.

  • Page 62: Operation And Charging Procedure

    Etrel INCH | Electrical Installation Specifics OPERATION AND CHARGING PROCEDURE INCH charging station can be controlled locally or remotely, through web interface, or through charging station management system. FIRST POWER UP Before starting the station, it is absolutely necessary to read this manual and the technical specification of the device.

  • Page 63: Setting Of Maximal Charging Current

    Etrel INCH | Electrical Installation Specifics SETTING OF MAXIMAL CHARGING CURRENT Max power is set by the installer based on the grid capabilities where charging station is installed. If there is need to change it, please set the current limitation in the charging station’s web interface before starting the first charging session.
  • Page 64 Etrel INCH | Electrical Installation Specifics Figure 62: Screen saver STEP 2 : AU THORI SATI ON Depending on the charging station authentication mode chosen different screens will be shown that will need different actions from user to continue with the charging session.
  • Page 65 Etrel INCH | Electrical Installation Specifics Insert PIN code Figure 64: Insert PIN code Use mobile app to authenticate Either type the code of the station to the mobile app or scan QR code with mobile. Figure 65: Insert charging station's EVSE code...
  • Page 66 Etrel INCH | Electrical Installation Specifics STEP 3 : CON N ECTI N G THE CABL E After the successful authorization, the screen with the description to connect the cable is shown. Figure 67: Connect the cable to charging station and EV If the cable is connected before the authorization this screen will be left out and after the authorization next screen “Waiting for vehicle to...

  • Page 67: Check Status Of The Charging Station

    Etrel INCH | Electrical Installation Specifics When the departure time is set, or default setting is let through charging data will be shown. What charging information is presented depends on the settings of web interface. Figure 70: Example of shown energy on the LCD screen...
  • Page 68 Etrel INCH | Electrical Installation Specifics Figure 72: Display charging data in web interface L OCAL L Y The charging session can be ended by using the same authorization method as for starting the session (using an RFID card, mobile application,...

  • Page 69: Contact Information

    Etrel INCH | Electrical Installation Specifics CONTACT INFORMATION TECHNICAL SUPPORT DEPARTMENT e-mail: support@etrel.com phone: +386 1 601 0075 CUSTOMER SUPPORT DEPARTMENT e-mail: sales@etrel.com phone: +386 1 601 0075 AUTHORISED SERVICE CENTRES e-mail: support@etrel.com phone: +386 1 601 0075 Etrel d.o.o.