VORSPRUNG 20163 Electric Vehicle AC Charging Unit User Manual
- June 1, 2024
- vorsprung
Table of Contents
Electric Vehicle AC Charging Unit
User Manual
Model: 20163
20163 Electric Vehicle AC Charging Unit
Thank you for choosing one of our Vorsprung AC charging units. To help you
correctly use, operate, maintain, check and troubleshoot this AC charging
unit, please carefully read this User Manual before use, operate according to
this User Manual only, and keep safe for future use.
This Unit must only be installed & fitted by a Certified Engineer
Installation must only be performed by a Certified Engineer competent in
accordance with the current legislation in force in the geographical location
of the installation.
- Advice provided in this manual does not override any legislation.
- If the advice in this manual is not understood, contact the distributor for further advice and/or training before attempting installation/operation of the equipment.
The manufacturer/distributor cannot accept any responsibility for improper
installation or any problems arising from improper installation.
NOTE: Damage to the equipment, connected systems or to property caused by
improper installation are the responsibility of the engineer.
NOTE: All electrical work must be performed in accordance with the
current Electrical Wiring Regulations in your geographic area.
WARNING
The input and output voltage of this equipment is risk high voltage; this will
endanger people’s life. Please strictly follow all warnings and operating
instructions on the machine and in this manual. Never disassemble the outer
cover of this machine.
Safety Precautions
Installation of this Unit must be Performed by a Certified Engineer
1.1. Turn off the power supply prior to and during the installation, to
prevent electric shock.
1.2. The charging unit’s power cable must be firmly connected and well
insulated. Loose connection and damages will cause circuit failure, which may
cause a fire or casualties in severe cases.
1.3.The installation of the charging unit and connection to the power grid
must be conducted by a trained, certified professional.
1.4.If the unit is dropped at any point prior to installation, it should not
be installed until the engineer has inspected the unit to determine whether or
not it can safely be installed.
1.5. Do not wash or cover the charging unit with any liquid. To clean the
charging body, wipe gently with a lightly damp cloth, avoiding the connector
area.
1.6. Any faults which arise that may impact the safety of the unit should be
addressed by a certified engineer. Please do not attempt any repairs yourself.
1.7.The charging unit should only be installed by a certified engineer. The
seller will not bear any responsibility for any loss caused by uncertified
engineers and personnel for any modifications.
Introduction
This product is a single-phase AC charging unit, mainly used for AC fast
charging of electric vehicles. The design of the product is simple. It
provides card swiping, plug & play charging modes and online charge control.
The principle of industrial design is adopted for the equipment, with the
original function of toppling protection to ensure safe operation of the
equipment. The protection level of the whole equipment reaches IP55, and it
has good dustproofing and waterproofing functions and can be safely operated
and maintained outdoors.
The charging unit is intelligent, with timing, billing (optional), electricity
metering, and human-computer interaction interface.
This product is a single gun 7.4kW AC charging unit, with OCPP for commercial
operation , advance WIFI/App/Bluetooth/RFID control features and Tamper proof
sensor.
It provides AC charge to EVs, and features an intuitive, interactive touch
screen, card reader, electric power metering module and network communication
module.
The customer is the one who purchases the charger and is responsible for its
operation and maintenance. On the other hand, the user is the individual who
uses the charger to charge their electric vehicle.
This EV charger has OCPP, which allows the customer to integrate the charger
with various billing systems or apps for easier payment and management.
However, even if the customer does not set up OCPP, they can still manually
input prices and charge their users based on those prices. In such cases, an
external payment meter would be required for billing purposes.
It’sworth noting that setting up OCPP is highly recommended, as it provides a
streamlined and automated billing system, making it much easier for the
customer to manage the chargerandits users.
This unit comes with a built in electricity meter, providing detailed insight
into electricity usage and expenditure. Perfect for keeping track of how much
electricity your charger has consumed.
This unit comes with a built-in Tamper-proof sensor, The device records any
attempts to remove the front cover and notifies the charge point’s owner.
2.1.Composition
The charging unit is mainly composed of shell, back cover, main control board,
human-computer interface, display module, card swiping module, communication
module, fuse, emergency stop switch, charging interface, charging gun line,
gun line hanging plate, etc.
2.2. Main Features
2.2.1.Modular design, stable and reliable: Modular design principle is adopted
for the equipment, with flexible configuration and convenient maintenance.
2.2.2. All-round protection and safe operation: It has over-voltage
protection, under-voltage protection, overload protection, earth leakage
protection, grounding protection, over-temperature protection, low-temperature
protection, lightning protection and toppling protection, ensuring safe and
reliable operation of the equipment and effectively preventing accidents.
2.2.3. Easy to use: Easy toinstall and use.
2.2.4.High protection level: IP55, supporting outdoor harsh environment, not
needing to set up additional canopy, etc.
2.2.5. Low power consumption: The standby power consumption of the equipment
is as low as 3W, energy saving and low consumption.
2.2.6. Compatibility: The equipment is a simple home version and is configured
in swipe, online control mode or plug & play operating modes.
2.2.7. Structure: Occupying a small space, is lightweight, the equipment is to
be installed to a solid wall or to a compatible floor mount.
Design Specification
Technical Specification
Table-1 Technical Specification of AC charging unit
| Name | Single-phase |
|---|---|
| Maximum output power | 7.4KW |
| Input voltage | AC 220V |
| Input voltage frequency | 50Hz/60Hz |
| Output voltage | AC 230V |
| Output current | 32A |
| Efficiency | ?98% |
| Insulation resistance | 10M0 |
| Power consumption of control module | s7W |
| AC & DC Fault Protection | AC: Type A 30mA RCD + DC:6mA |
| Earthing Protection | PEN Protection Built In – No Earth Rod Needed |
| Operating ambient temperature | -3CPC^–1-50°C |
| Storage ambient temperature | -40°C– + Et0°C |
| Ambient humidity | 5%^95% No frost, no condensation |
| Altitude | Not more than 2000 meters |
| Status indication | LED indicator |
| Screen | 4.3-inch LCD color screen |
| Charging interface | IEC 62196 Type 2 |
| Degree of protection | 9355, IK10 |
| Safety protections | Overvoltage protection, undervoltage protection, grounding |
protection, lightning protection, leakage protection flame retardant
protection, vercurrent protection
Cable Length| 5 meters
Weight| 4.5KG
4.1. PCB Information
-
Power supply
-
Load balancing transformer
-
Voltage transformer: PT
-
Current transformer: CT
-
Leakage protection: AC 30ma
Type A protection& 6MA DC protection -
Input
-
Output
-
Relay
-
PEN protection transformer: Collecting voltage data
-
Charger communication device
-
CP
-
CPU
-
WIFI, Bluetooth, Tamper proof sensor
-
Separate 4G modules can be inserted in this area
-
Connecting network: Ethernet
-
RFID connection port
-
USB interface: Can update the recognition system and import data
-
Indicator connection port
-
Display screen connection port
-
External electricity meter connection port
-
Double gun electromagnetic lock
-
PEN protection: Controlled tripping
Installation
5.1.Site Requirements
5.2.1. The charging unit meets the IP55 protection level and can be installed
both indoors & outdoors.
5.2.2. Please ensure that the ambient temperature is within the range of –
30°C~+50°C.
5.2.3. The altitude of the installation site shall not be higher than 2000
meters.
5.2.4. There should be no vibration, flammables, and explosives near the
installation site.
5.2.5. The installation site should not be located in low-lying areas or areas
prone to water accumulation or flooding.
5.2.6. The unit must be installed onto a wall. If there is no wall support, it
is recommended to use a special EV floor post for installation and fitting.
5.2.7. The unit must be installed vertical, the centre point of the gun base
to the horizontal ground should be between 1200~1300mm.
5.2. Preparation for Installation
Forthe sake of safety, only a Certified Engineer can install and fit the
charging unit. Please do not attempt to install it yourself.
Tool Name| Picture|
---|---|---
Insulation torque spanner| | Fastening the bolts
Combination spanner| | Fastening the bolts
Hydraulic tongs| | Fastening the bolts
Diagonal pliers| | Cutting off the cables
Multi-meter| | Checking electrical
connection and
electrical parameters
Cross screwdriver
(PH2x150mm,PH3x250mm)| | Fastening the screws
Insulation adjustable spanner| | Fastening the bolts
Preparation of Cables
The following cable specifications for charging unit power supply is
recommended:
Cable Name| | Cable Specification|
---|---|---|---
Power line| Minimum Requirement: single- phase 3-core 6mm2 power cable|
Subject to the specific construction length
Circuit breaker| One-phase 40A circuit breaker|
5.3. Installation Process
5.4. Installation Options
Please check you have all parts before installation
5.4.1. Installation Option -1: Wall Mounted Bracket
Accessories:
Mounting Plate: 1 piece
Screws M510mm: 2pcs
Expansion screws M880mm: 4pcs
Screws M4*8mm: 2pcs
Installation method:
- Drill 4 holes (red) to fix the wall mounted bracket on the wall; Use the M8*80MM expansion screws.
- Secure the 2x M5 screws to the two ‘yellow’ holes of the charger, and then hang the charger on the‘yellow’ hole of the wall mounted bracket and pull the charger down to ensure that the screws have latched onto the bracket safely.
- Remove the shell of the charger and secure the 2x M4 screws in the ‘green’ hole to secure the charger against the wall mounted bracket.
- Secure the shell of the charger and check to make sure the installation is secure.
5.4.2. Installation Option -2: Direct to Wall
Accessories:
Expansion screw M6 40mm: 1 piece
Expansion Screws M48mm: 2pcs
Installation method:
- Install one expansion screw M6 * 40MM, ensuring it is extending out of the wall by 3mm
- Secure the charger to this protruding expansion screw by lining it up with the ‘blue’ hanging section and pull it down to ensure that the screw is securely in the ‘blue’hole
- Remove the shell of the charger, install M4 screws in the ‘green’ holes inside the charger to fix it firmly against the wall.
- Secure the shell of the charger and check to make sure the installation is secure.
5.5. Wiring mode
5.5.1. The charging unit comes with an independent power circuit which cannot
be shared with any other electrical devices.
5.5.2. When installing; use a Phillips screwdriver to open the rear wiring
cover on the charging unit, conn ect the three cables (live wire L, neutral
wire N and ground wire PE) to the terminal according to the wiring markings.
5.5.3.To prevent the risk of electric shock, the equipment should ensure that
the input ground wire is firmly grounded.
1- Regular Connection 2- Connection by Load Limiting
2.1- Connection by CT 2.2- Connection by Electric Meter (Optional)
2.3-
Connection by Wireless CT 5.6. Before Initial Use
1) Pre-operating inspection
5.5.1. Before starting the AC unit, make sure of the following things:
5.5.2.The AC unitis installed in a convenient location for maintenance and operation.
5.5.3.The AC unit and accessories are properly connected and firmly installed.
5.5.4.The earth leakage circuit breaker at the AC incoming terminal is suitable for the application.
5.5.5. There are no external objects or parts left on top of the AC unit.
5.5.6. Confirm that all the above items meet the requirements before operation.
5.5.7.Close the earth leakage circuit breaker of incoming power line.
5.7. Initial Screen Set Up
When the device is powered up, the display will prompt the user to insert the
charging gun. There is no need to insert the charger just yet, until the
initial set up is complete. 
5.7.1.Three Charging Configurations
1- Basic Paramater Configuration
In the “Basic Parameter” section, users can input information such as the
charger number, local time, rated current and load balancing
current.
2- Communication Data Configuration
In the “Basic Parameter” section, users can input information such as the
charger number, local time, rated current and load balancing current.
3- Basic Function Configuration
There are 4 charging modes, which will be explained in greater detail below.
-Metering mode: internal meter/external meter
-Ground detection and PEN protection: use/prohibition
5.8. Operating Modes
Online Mode: This mode enables users to schedule and monitor charging
sessions through the “Smart Life” App. With this mode, users can set up
charging schedules for their electric vehicle, track the progress of their
charging session, and receive notifications about their session’s status.
RFID Mode: In this mode, users can swipe their personal RFID (Radio
Frequency Identification) cards to access the charger. This mode allows the
customer to track usage by individual users and charge them for the amount of
energy they use.
Reserved Mode: This mode provides users with more control over their
charging experience. Users can choose to reserve a fixed amount of power to be
charged, a fixed amount of money to be spent, a fixed period of time (e.g, 2
hours), or a specific time frame (e.g., from 12 am to 6 am). This mode helps
users manage their charging sessions more efficiently and can also help reduce
waiting times for charging stations.
Plug and Charge Mode: This mode is the most straightforward mode,
allowing users to simply plug in their electric vehicle and start charging
without any additional setup or requirements.
Select the preferred charging mode, then connect the charging gun. 
5.8.1.0nline Option
From Google play or Apple Store, > ) download either of the following Apps:
Smart Life, Tuya or Vorsprung app for I0S only.
- Download the App and create an account.
- Select the plus sign in the top right corner to automatically discover the device.
- Go to profile settings , enter activation password: 888888
- Enable Wi-Fi and Bluetooth permissions.
- Enter your Wi-Fi information to connect wall socket to the Internet.
- Wait for the connection to load completely before you start any applications.
5.8.2. Single Mode Option –
Charge by RFID Card
5.8.3. Reservation Charging
Option Using RFID Cards
Select a preferred amount
of power and have the charger supply that exact amount of power to your
battery.
Select a preferred amount of money to spend on charging and have the charger
supply that exact cost of charging to your battery GPB.
Select a preferred amount of time to charge your vehicle for.
Reserve a charging slot by scheduling
charge for a certain time of day or night.
5.8.4.Plug & Charge Option
With the plug and charge mode, simply insert the charging gun to your vehicles
socket and charging will begin.
5.8.5. Failure page
- If the equipment fails, the failure page will display and inform the user of the reason behind the fault.
- The unit will not charge until the reason for the failure has been resolved.
Troubleshooting
| Fault phenomenon | Possible causes | Solution |
|---|---|---|
| AC over-voltage | AC input voltage is too high | 1- Ask an electrician to test |
the input voltage of air switch.
2-If the actual voltage is greater than 264Vac for a short time shah for the
peer-to-peer netwock to recover to the normal voltage range.
3-If the actual voltage is greater than 264Vac for a long time, please contact
the power supply department
4-If the actual voltage is less than 264Vac, please contact Seller,
info@vorsprungofficial.com
AC under-voltage| ,
AC input voltage is too low| 1-Ask an electricianto test the input vokage of
air switch.
2-If thevoltage is lower than 85Vac for a short time, wait for the peer-to-
peer network to recover to the normal voltage range.
3-If the actual voltage is less than 85Vac for a long time, please contact the
power supply department.
4-If the actual voltage is greater than 8SVac, please contact Seller; k
info@vorsprungofficial.com
AC over-voltage| AC input current Is too high| I- Immediately turn off the
leakage/over- anent protection switch of the distribution box.
2-Check whether there is a low-impedance connection between two output lines
of AC unit.
3-After the above problems are eliminated, power on again. If the fault still
exists, please contact Seller.
Over-temperature| The rterior temperature is greater than 85•C| 1-Check the
installation environment of AC unit to see whether there Is heating equipment
or devices nearby, and ensure the ambient temperature is below60°C.
2-If thefault can’t be eliminated, please contact Seller;
info@vorsprungofficial.com
Leakage current exceeds the limit| The leakage current is greater
than 30mA| 1- Immed latety disconnect the leakage/ over-current protection
switch of the distribution box.
2-Check whether the output line of AC unit is damaged or has low-impedance
connection to the ground.
3-After the above problems are eliminated, reset the reset switch of leakage
current protector, and power on again. If the fault still exists, please
contact Seller;
info@vorsprungofficial.com
Leakage current sensor is abnormal| The sensor for detecting the leakage
current is abnormal| 1- Immediately disconnect the leakage/ over-current
protection switch of the distribution box.
2-Check whether the output line of AC unit is damaged or has low-impedance
connection to the ground.
3-After the above problems are eliminated, power on again. If the fault still
exists, Please contact Seven
info@vorsprungofficial.com
Ground fault| Theinput/output grounding is poor
or the input I/N connection is reverse| 1-Immediately disconnect the leakage/
over-current protection swich of the distribution box.
2-Check whether the grounding of AC unit input/output line is normal and
whether the input UN is connected according to normal sequence.
3-After the above problems are eliminated, power on again. If the fault still
exists, please contact Seller,
info@vorsprungofficial.com
6.1. Troubleshooting of General Faults
In case of any abnormality during use, If you still cannot troubleshoot a
certain fault, please cut off the power supply of the charging unit and
contact our customer service center.
Guarantee
Subject to the provisions described below, this product is protected for 12
months from the date of purchase against defectsin parts. Any labour cost to
the consumeris not and with not be covered.
Prior to returning any defective products to Vorsprung, the end user must
report the faulty product to Vorsprung. This can be done via e-mail:
info@vorsprungofficial. com. If Vorsprung agrees that the product should be
returned, it will Issue a Returns Authorisation Number. This number must be
clearly marked on the packaging of the product to be returned. The customer
will return the product at their own cost.
Should the product fail to perform as described within the relevant guaranteed
period as set out above, it will be repaired or replaced with the same or
functionally equivalent product by Vorsprung at its discretion, free of
charge, provided the customer:
- Provides Vorsprung with proof of purchase.
- Returns the failed product to Vorsprung with shipping charge prepaid.
Replacement products may be refurbished or contain refurbished materials. If
Vorsprung, by its sole determination, is unable to repair or replace the
defective product, 0it will replace or refund the purchase price of the
product at their discretion.
The guarantee does not apply and will be nulland void if, in judgement to
Vorsprung, the product fails due to damage from storage, incorrect
Installation, accident, inappropriate use or cleaning of the product,
relocation of the product after its first Installation, abuse, misuse, or if
It has been used or maintained in a manner not conforming to product manual
instructions. Damage or failure caused by foreign matters entering the unit.0
Damage caused by dismantling the unit by a non-certified EV Engineer. Damage
caused by force majeure (such as lightning, high voltage, earthquake, fire,
flood, and other natural disasters). Damage caused by water entering the
equipment or other solutions due to improper installation & use. Damage caused
by using power supply and voltage other than those specified. Has been
modified in any way, or has had any serial number or other Identification
markings removed or defaced.
Repair by anyone other than a certified engineer will void this guarantee.
Proof of installation may be requested.
All defective products should be returned to Vorsprung with shipping charges
prepaid.
Should an issue be found with your unit. Vorsprung will return your
repaired/replaced unit free-of-charge to any UK address. Should the return
address be outside of the UK; return postage will be at Vorsprung’s
discretion. If the unit is found not to be defective
return postage will need to be paid by the customer/sender.
Nothing in this agreement will affect the end consumer’s statutory rights.
Vorsprung only supply products for domestic, light commercial and private use.
Vorsprung accept no liability to the end consumer for any loss of profit, loss
of business, business interruption, loss of business opportunity or time
travel incurred.
Electric Vehicle AC Charging Unit
User Manual
Model: 20163
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