ALFEN Twin 4XL NL Charging Station for Electric Vehicles User Manual

: June 6, 2024
: ALFEN

Table of Contents

Twin 4XL NL Charging Station for Electric Vehicles
References
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Twin 4XL NL Charging Station for Electric Vehicles

Twin 4XL NL
Installation and user manual

EXTERIOR
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2 3 4 5
5 6 7 8

INTERIOR

1385 mm

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335 mm

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Step-by-step installation and
commissioning Twin 4XL NL
Congratulations on your purchase of this Alfen charging station for electric vehicles!
To ensure a safe installation process and to fully utilise all advanced features of your new system, we advise you to read this manual carefully. Please keep this manual for future reference.
Though these operating instructions have been compiled with the greatest possible care, they are subject to change and improvement. For the most recent version, please refer to https://alfen.com/ nl/downloads
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TABLE OF CONTENTS

1. Safety and usage instructions

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1.1 Purpose and intended audience 7

1.2 General safety

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2. Product

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2.1 The charging station

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2.2 Status indications on the interface

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2.3 Operation

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2.4 Technical specifications Twin 4XL NL

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2.4.1 Twin 4XL NL model overview

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2.4.2 Input/ power supply

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2.4.3 Output/ vehicle supply

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2.4.4 Protection/integrated components

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2.4.5 Loading and access

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2.4.6 Operating conditions

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2.4.7 Casing

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2.5 Optional factory settings

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2.6 Accessories

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3. Assembly and connecting

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3.1 Installation preparation and warnings

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3.2 Assembly and installation requirements

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3.3 Mechanical installation

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3.4 Electrical installation

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4. Commissioning the charging station 19

4.1 Safety instructions prior to usage 19

4.2 Commissioning

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5. Connectivity

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5.1 Backofgce management systems 20

5.2 Establishing a connection

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5.2.1 Wireless connection

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5.3 Registering your charging station within

your own backofgce management system

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DECLARATION OF CONFORMITY
Manufacturer: Alfen ICU B.V. Hefbrugweg 28 1332 AP Almere The Netherlands
Declares that the charging stations of the type Alfen Twin 4XL, to which this declaration refers, comply with the provisions of the following European directives: 1) Machinery directive 2006/42/EC 2) Low voltage directive 2014/35/EU 3) EMC directive 2014/30/EU 4) And the following harmonised standards: IEC 61851-1 ed. 3 (2017) – Charging via a conductive connection of electric vehicles General requirements, implemented at national level under: · NL: NEN-EN-IEC 61851-1 · BE: NBN EN 61851-1 · UK: BS-EN 61851-1
Almere, 18 May 2021.
Mr. M. Roeleveld Managing director

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1. SAFETY AND USAGE INSTRUCTIONS

1.1 Purpose and intended audience The Alfen Twin 4XL charging station is intended exclusively for charging electric vehicles, both in situations where there is a separate grid connection (e.g. a domestic meter cupboard) and in public situations. Follow these instructions to ensure that you use the charging station properly.
The installation, commissioning and maintenance may only be performed by a qualified technician (Alfen certified partner).
This qualified technician must meet the following requirements: · Expertise on all relevant general and specific rules
regarding safety and incident prevention; · Knowledge of the relevant electricity regulations; · The ability to identify risks and avoid potential danger; · Awareness of these installation and operation
instructions.

In the following cases, Alfen ICU B.V. shall not be liable in any way for any kind of damage and all warranties on the charging station and accessories will become void: · Non-compliance with these installation and operation
instructions; · Usage in ambient temperatures below -25 °C or above
40 °C; · Improper use ; · Improper handling ; · Installation and/or usage by unqualified staff;
· Self-installed additions or changes to the charging station;
· Usage of replacement parts not manufactured or approved by Alfen.
More extensive safety information is available in the relevant sections of this document.

This manual is valid for the charging station Alfen Twin 4XL, equipped with firmware version 3.2.2.
(or higher)

1.2 General safety

DANGER!
These safety instructions are important to ensuring safe operation. If you do not comply with the safety rules and instructions, there is a risk of electrical shock, fire and/or life
threatening injury.
The use of this charging station is expressly forbidden in the following situations: · In the vicinity of explosive or highly flammable
substances; · If the charging station is located in or close to water; · If the charging station or its individual components are
damaged; · Usage by children or individuals not properly able to
assess the risks associated with using this charging
station.

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2. PRODUCT

2.1 The charging station

On the cover of this manual you will find the corresponding

pictures of the charging station. Here you can find out more

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about the contents of the charging station and how to use

it to charge your vehicle.

The charging station (outside, see page 2) 1 “Charge Point Identifier” 2 LED /RFID-interface 3 RFID reader 4 ‘Quick starter’ instructions 5 Type 2 socket 6 Door handle 7 Cylinder for distribution system operator 8 Cylinder for end customer
The charging station (inside, see page 3) 1 Fuses 2 Type A earth leakage circuit breaker 3 Power meter 4 Identification label 5 Work switch 6 Mains connection box distribution system operator 7 Main protection
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Fig. 2 Location of components
Identification label (13) The identification label (Figure 3) specifies, among other things, the model, production date and serial number. You will find this label on the inside of the charging station door. On the top of the charging station is a smaller sticker with the “Charge Point Identifier” (this is not the serial number) and (if applicable) the helpdesk telephone number. When contacting Alfen, always have your serial number available to facilitate quick support. 1 Type number of the charging station consisting of the
platform name and the last five digits of the article number 2 Serial number, unique number issued by Alfen to the charging station 3 Day of production of the charging station 4 Technical specifications of the charging station, such as the number of phases, maximum charging current and voltage. 5 Article number of the charging station 6 Maximum charging capacity set on the charging station level

Fig. 1 Location of components

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3

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10 UTP (Ethernet) Connection
11 P1 (Smart Meter) Connection 12 SIM card holder (see figure 8 for detailed
location) 13 Identification label with identification number of
the charging station (see description under the heading “Identification label”) 14 On/off switch 4-pole (see Figure 2 for
detailed location)

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Fig. 3: Example of an identification label

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2.2 Status indications on the interface The Alfen Twin 4XL NL uses an interface equipped with LEDs to provide status indications of the charging station,
and inform the user about starting and stopping the
charging process.

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Fig. 4: Display of Twin 4XL NL during charging (charging point left)
Status and information interface; The charging station informs the user of its current status and provides the user with a response to actions performed. The following information is available: 1 Charging side indication 2 Charge card accepted, cable connected 3 Communication with vehicle, or charging completed 4 RFID-reader 5 Active charging transaction 6 Error message 7 User steps when starting the charging process 8 User steps when charging is stopped

Charge card accepted,
cable connected

Communicating with vehicle or
charging complete

Active charging transaction

Error message

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2. PRODUCT
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2. PRODUCT
2.3 Operation Plug & Charge General authorization without charge card

Start 1

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3

Stop 1

2

3

RFID Charging station with user authorization

Start 1

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Stop 1

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2. PRODUCT

2.4 Technical specifications Twin 4XL NL 2.4.1 Twin 4XL NL model overview

Model name
2 x type 2 socket, 3 phase, max. input current 25A per phase, type A RCD, 6mA DC detection
2 x type 2 socket, 3 phase, max. input current 35A per phase, type A RCD, 6mA DC detection
Packing unit

Article no. 934452501
934452504
1 piece

OCPP Charge Point Model NG920-52501
NG920-52504

Charging station package contents

Alfen Twin 4XL NL, installation manual, mounting accessories and RFID charging cards (depending on selected options)

2.4.2 Input/ power supply
NOTICE!
Your installation must comply with the standards and regulations of the location (country) where it is installed. The following tables show our recommendations for charging stations to function properly, given the mentioned preconditions. Printing errors expressly reserved

Input: minimum recommended cable diameters
Nominal voltage Security
Nominal frequency Connection clamps
Earthing Main switch

3 phase 20A charging, distribution system operator connection box 3x25A 934452501: 4 mm2 connection cable 3 phase 20A charging, distribution system operator connection box 3x35A 934452504: 6 mm2 connection cable (assumption max. 50m cable route)
3x230V, 400V potential difference between the phases.
934452501 and 934452504: all pre-protection is already present in the charging station.
50 Hz Strain relief, clamping range for cable diameter 11 mm to 29 mm Cutting modules bottom plate range 13mm – 34mm Range cable clamps: max. 16 mm2 per wire TN system (PE cable) TT system (Earthing facilities are always the responsibility of the owner of the loading object). Four-pole, 80 A, 400 V Connection in the distribution system operator connection box (934452501 and 934452504)

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2. PRODUCT

2.4.3 Output/ vehicle supply

Vehicle connection Output voltage Max. charging current Load balancing

2 x socket type 2, according to IEC62196-2 400 V (934452501, 934452504)
20 A per phase (13.75kW per socket) (934452501, 934452504)
Optional Mandatory for connections with a lower capacity than both outputs combined can supply at the same time

2.4.4 Protection/integrated components

Residual current protection
Energy meter Activation relay Overcurrent protection

Type A 30 mA, per outlet DC current detection 6mA, per outlet
1x power meter per outlet, MID-certified Integrated, simultaneous activation Integrated in firmware, switch-off at: 105% after 1,200 seconds; 112% after 100 seconds; 120% after 5 seconds; 150% after 2 seconds

REMARK
The charge point is equipped with a 6mA detection circuit per output.
The charging current is interrupted on detection of a DC leakage current of 6mA or higher. After 5 minutes, the charging current will be switched on again; if the leakage current of 6mA DC persists, the charging point will interrupt the charging current again. This protocol is repeated up to a maximum of 3 times, the loading transaction remains active, after which the transaction is perma-
nently terminated.

After reinserting the charging cable, the charging station will restart the cycle

2.4.5 Charging and access

Controllers
Communication with vehicle
Status indication Card reader
Internet/network possibilities

Central unit for outputs and communication Mode 3
User interface equipped with LEDs RFID (NFC) ISO/IEC 14443A/B, Mifare 13,56 MHz, DESFire GPRS (2G) LTE Cat M1 (4G) Ethernet/LAN

Supported mobile communication bands Communication protocol
Backend connection

2G: EGPRS quad-band: 850 / 900 / 1800 / 1900 MHz 4G: LTE Cat M1 bands: 3, 8, 20
OCPP 1.5 (JSON) OCPP 1.6 (JSON) 2nd edition, certified OCPP 2.0 (JSON)
ICU Connect (optional) or other management system (upon request)

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2. PRODUCT

2.4.6 User circumstances

Operating temperature
Relative atmospheric humidity

-25°C – 40°C 5 – 95 %

Protection category I
Degree of protection IP54 (casing)

IK protection

IK10

Stand-by consumption Ca. 9-12W

NOTICE!
The mentioned operating temperature assumes the ambient temperature of a product delivered in the standard casing
colour RAL7043. Direct exposure to sunlight may have an adverse effect on the temperature range.

NOTICE!
The temperatures listed in the table refer to the ambient temperature for the charging station, assuming the standard housing colour: RAL7043. Other (darker) colours may have an adverse effect on the operating temperature of the charging station.
If the charging station is exposed to lower or higher temperatures, continuous operation cannot be guaranteed. In case of higher temperatures, the charging station will automatically decrease the charging current to stabilise the internal temperature. This prevents a transaction from being unexpectedly paused.
If the charging station is exposed to direct sunlight, it is possible that the automatic temperature management will be activated below the maximum ambient temperature.

2.4.7 Casing
Type Mounting options Material (casing) Colour (casing) Locking
Dimensions (H x W x D) Casing Packaging
Weight Casing Packaging

Loading pedestal Directly on solid ground or on an optional metal or concrete base Cold-rolled stainless steel 304 RAL 7043 (Trafgc grey) Lockable lever with space for two cylinder locks (not included in delivery) Standard key for door operation included in delivery
1385 x 335 x 220 mm 1400 x 350 x 300 mm
Approx. 40 kg Approx. 2.5 kg

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2. PRODUCT

2.5 Optional factory settings

Factory settings Authorisation
Maximum enabled charging current per output Smart charging options
User availability if temporarily offline
Action if plug is released on vehicle side Choice of management system
Communication through *

Options
Plug & Charge RFID
20A 32A Off Standard load balancing
Accept all RFID passes Only valid passes in database Not available
Stop transactions and release the plug Pause charging until cable plugged back in
Stand alone ICU Connect Various management systems available on request *
Auto detect GPRS UTP/LAN

REMARK
Settings marked with *) may incur additional costs.
The default settings are always displayed first.

2.6 Accessories
Concrete pedestal Dimensions (H x W x D) Weight
Metal base Dimensions (H x W x D) Weight Packaging (H x W x D)
Extra RFID card

Art. 833829300-ICU 570 x 350 x 220 mm 42 kg Art. no. 803828601-ICU 598 x 204 x 300 7.8 kg 50 x 295 x 620 Art. 203120010-ICU

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Package contents The package of the charging station contains: · Alfen Twin 4XL NL, · Installation manual and assembly supplies, · RFID charging cards (depending on selected options) Bottom plate overview
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2 3 4 5 6 7
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Fig. 5: Bottom plate with mounting material Twin 4 XL NL
1 1x Cable clamp k24u 2 1x Wiska stufgng box M12x1.5 3 1x Connection nut 12 M12x1.5 4 1x Cable entry gasket 5 3x Grommet for ethernet cable 6 1x Grommet for ground cable 7 2x Grommet for Smart Charging Network 8 1x Bottom seal
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3. ASSEMBLY AND CONNECTING

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3.1 Installation preparation and warnings
NOTICE!
Read these instructions carefully before installing the charging station. Alfen ICU B.V. is not liable for any consequential damage caused by failure to follow the instructions in this manual.
NOTICE!
The installation must be carried out by a qualified member of staff who has read this manual and acts in accordance with the NEN1010 and IEC 60364 guidelines. Neglecting to comply with these may lead to injury or dangerous situations when working with electricity.
DANGER!
The electric system must be entirely disconnected from every power source prior to performing installation or maintenance work!
DANGER!
The charging station contains electrical components that still contain a charge after being disconnected from the system. Wait at least 10 seconds after disconnecting before beginning to work.

The pre-protection of the Twin 4XL NL with a distribution system operator connection box (934452501, 934452504) is the responsibility of the distribution system operator. · The cable route and charging station are part of a TT/ TN-S system; the unit must be earthed via the main distributor or punched earth pin. · Earthing the charging station is the responsibility of the owner. · It must be determined for each location whether the earthing can be provided by the distribution system operator. · The cable trajectory must be installed in accordance with the usual local professional standards.
REMARK
Site conditions may influence the installation requirements.
REMARK
The installation and cables should be installed to match the maximum charging current to the input of the charging station. This must assume a continuous load (max. simultaneity).
The cable diameters stated in this manual are indicative. The installer is always responsible for choosing the right cable diameter and complying with the relevant standards and legislation.

DANGER!
Installing the station incorrectly may result in fatal injury! When working with electricity, not abiding by installation and environment regulations can lead to hazardous situations.
REMARK
A charging station must always be installed on a power circuit intended for that purpose.
3.2 Assembly and installation requirements Refer to the table in paragraph 2.4.2 for the safety options and required cable thicknesses to create a proper connection.
REMARK
Wear the prescribed personal protective equipment (PPE) when working. Take national and local standards and regulations into account.
Please ensure that the following requirements for the installation of the Alfen Twin 4XL NL are met:

When selecting an installation location, please take the following into account: · Never install in a potentially explosive atmosphere; · Never install in areas prone to flooding without imple-
menting compensatory measures; · Always fully comply with local technical requirements and safety
regulations; · The installation site must have a levelled and solid
foundation; · Maximum atmospheric humidity of 95% ; · Ambient temperature of -25 °C – 40 °C ; · A temperature difference within 24 hours < 35 °C ; · Ensure that the charging station is located in such a way
that users can use their charging cable (approx. 5 meters length) without tension being applied on the cable; · Prevent other drivers from being able to drive over the cable; · Prevent pedestrians from tripping over cables
3.3 Mechanical installation Use the following tools and materials to install the Twin 4XL NL: · Level, Shovel, Stanley knife · Screwdriver for a terminal block
· Wire stripper
· Socket set/spanners

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3. ASSEMBLY AND CONNECTING
4a 4b 3c

Fig. 6: Charging station on base, exploded view and reference to work steps

Preparing the charging station 1. Verify the content of the packaging based on the
required parts a. On the door of the Twin 4XL NL:
The charging point is provided of a lock with a lever suitable for two locks (type euro profile cylinder 17mm).
i. Left lock is from: Owner of charging point ii. Right lock is from: Network company b. Slide the protection away from the lock. c. The charger may contain one, two or no cylinder lock(s). d. Open the lock with the key(s) provided, or the passkey provided, if no cylinders are installed; e. Lever can be pulled out; f. Turn the lever counter-clockwise to open the door .
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Installing the charging station 2. Foundation for ground mounting (with concrete or
metal base): a. Dig a hole 50x50cm – ground level depth: 55cm
and level out horizontally. b. Position the base and level it. c. Place the supplied cable glands and cutting glands
on the sealing plate. Then place it at the bottom of the charging station. d. Provide an earth electrode or earth pin, depending on the regulations in force at the location or instructions.
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3. ASSEMBLY AND CONNECTING

3. Inserting ground cable and earth cable: a. Pass the ground cable through the conduit, concrete base and tule in the sealing plate. See specifications
for suitable cable diameters. b. The overhang from the top of the base
must be at least 25 cm. Due to the mounting
of the strain relief it is recommended to cut the cable only when the charging station is mounted on
the base. c. Pass the earthing cable, coming from the earthing
pin, through the concrete base and swivel in the
sealing plate. See figure 6.

3.4 Electrical installation
WARNING
Read and follow all of the safety instructions in this manual!
DANGER!
The electric system must be entirely disconnected from every power source prior to performing installation or maintenance work! After switching off the power, always wait 10 seconds before continuing the work.

4. Mounting the charging station on the base
a. Insert the four threaded rods supplied M10x80 mm into the sockets on the base. See figure 6.
b. Place the gasket over the threaded ends and
the sealing plate. See figure 6. c. Tilt the Twin 4XL NL, which has been laid out on the back above the base, onto the base over the wire ends and over the power supply cable and ground
cable. d. Cut the cable grommet to size, so that the power
supply cable is firmly clamped in place, and guide the power supply cable through the base plate, which will be mounted in the charging station. Pull the power supply cable to the outside of the charging station to fit the strain relief provided. e. After mounting the strain relief, guide the power
cable back into the charging station/ concrete base, so that the prescribed 25cm
cable length remains in the charging station. f. Fasten the charging station with the included
4 pieces of M10 nuts including lock and V-rings. g. Secure the charging station to the base with 4 x
studs M10x80 mm on the base.

1. Remove the sheath from the power cable with a Stanley knife and remove the sheaths from the loose wires with a wire stripper;
WARNING
Always attach a good earth conductor first
2. The charging point must be properly earthed. First connect the earth pin. A provision has been made in the form of a main grounding rail right at the bottom of the charging station to ground the charging station. (This applies to both a PE cable and a grounding pin)
3. The earthing sleeve/earthing wire of the distribution system operator may only be used as an earthing device with the written consent of the system operator;
4. The earth leakage resistance must be less than the prescribed value: · NEN1010 <167 Ohm · EV-Ready 1.4D <100 ohm
5. Check that the isolating switch is in the off (0) mode. Switch off the main fuse in the installation (for Twin 4XL NL without house connection box) or remove the fuses / switch the circuit breakers to the OFF mode (for Twin 4XL NL with house connection box);
6. Connect the wires of the phases to: i. the dispensers or cartridge holders in the distribution system operator cabinet of the Twin 4XL NL including standard grid connection. PE on separate rail. ii. directly to the isolating switch of the Twin 4XL NL excluding grid connection, PE on separate busbar.

Fig. 7: Example of strain relief
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4. COMMISSIONING THE CHARGING STATION

7. A clamp is required for the strain relief on the cable (see figure 7);
8. Set the isolating switches and earth leakage circuit breaker to the ‘IN- (1) status;
9. For types with a house connection box, place any cartridges supplied in the cartridge holders and close the holders;
10. If a transparent cover is supplied for the internal components, fit it with the plastic bolts supplied;
11. Close the door and check that it is securely closed.
NOTICE!
Ensure that cables do not become trapped when closing the door of the Twin 4XL NL.
NOTICE!
There must be absolutely no gaps between the housing parts. This is at the expense of protection against moisture and dust, which reduces the service life of the charging station.
4.1 Safety instructions before use Please follow the safety instructions below before putting your charging station into operation:
1. Make sure that the charging station is properly connected to the power supply and properly fastened to the foundation as prescribed in this manual;
2. Ensure that the distribution of the electrical supply is separately protected by an appropriate circuit breaker (934452504 / 934452501: fuse links);
3. Make sure that the charging station has been installed in accordance with this manual;
4. Ensure that the casing is always closed during normal use.

4.2 Commissioning
1. Make sure that the earth leakage circuit breakers installed in the charger are switched on and that all fuses are in place;
2. Set the isolating switch to I (ON) mode. If necessary, use a special key to make switching easier;
3. Close the Twin 4XL NL by clicking the door into the lock.
Switch on the power at the power cable if possible. The charging station now performs a self-test. The following steps are followed:
1. The outputs are tested one by one, this is done for each user side in succession: – Lock testing (locking and unlocking) – Internal relays are being tested, you will hear them switching
2. The Interface LED flashes briefly; 3. The red crosses will flash twice; 4. The Alfen Twin 4XL NL is now ready for use.
If the charging station is set up to connect to a management system, this will be done automatically and immediately; 5. If required, the charging station can be further configured. Use the Service Installer software package to access this; 6. Have you had the charging station configured for a Smart Charge functionality? Then, check the settings with the Service Installer application to optimally configure the charging station for the local situation.
REMARK
Would you like to know more about the Service Installer? Then go to our website for the latest version. http://alfen.com/en/downloads.

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5. CONNECTIVITY

5.1 Backoffice management systems You own an intelligent Alfen charging station that can communicate with a management system via an Internet connection. Management systems make it possible, for example, to monitor the energy consumption of individual users, to manage charging remotely or to maintain the
charging station more easily.

If you have purchased additional services from a (backend) partner or from Alfen ICU B.V. (for the ICU EZ services,), then your charging station is configured ex-factory to connect to the selected backofgce management system. The internet connection will be established using a GPRS or a UTP (Ethernet) cable connection. If you opted for a GPRS (SIM card) connection, your charging station is already equipped with its SIM card and will automatically connect once your charging station is commissioned. If the SIM card holder 12 does not contain a SIM card, please contact your backofgce provider or Alfen.
In the next section we will explain how to connect your charging station to the internet via GPRS (SIM card) or a UTP (Ethernet) cable.
5.2 Setting up a connection 5.2.1 Wireless connection To connect wirelessly, the charging station must be equipped with a SIM card suitable for GPRS. Furthermore, correct settings must be configured in order to connect with the preferred backofgce management system. To this end, several options (shortcuts) are available in the Service Installer. With these shortcuts, you can easily select the desired system and the accompanying settings.
REMARK
A connection with a backofgce management system can only be established if you made arrangements with the supplier of this system to start your services. The service of third parties is not included in the service provided by Alfen.

Fig. 8: SIM card holder and UTP port location

5.3 Registering your charging station within your own backoffice management system If you use your own management system or if it is provided by a third party as a service, please make sure to register the right type of charging point.
Each model Twin 4XL NL has its own so-called Charge Point Model that is sent along with the application in accordance with OCPP specifications. This is built up with an indication of the platform, combined with a unique article identification:
· 934452501 · with Alfen NG920 platform: NG920-52501
The table below shows the possibilities. When correctly registered in the management system, the charging station can easily log on.

Article no. 934452501 934452504

OCPP Charge Point Model NG920-52501 NG920-52504

Figure 8 shows the location of the SIM card holder and the UTP port.

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Contact

Alfen ICU B.V. Hefbrugweg 28 1332 AP Almere The Netherlands

P.O. Box 1042 1300 BA Almere The Netherlands

Tel. Sales Support: +31 (0)36 54 93 402

Tel. Service: