Webasto AGBLLT2X 22 kW Type 2 Cable 4.5m Instructions

**Webasto AGBLLT2X 22 kW Type 2 Cable 4.5m Instructions

**

General information

1. Purpose of the document
   This Quick Start Guide forms part of the product and contains introductory information as well as information related to safety and the installation of the Webasto Next product. The comprehensive Installation Manual available under the QR code supplied is required for safe operation of your Webasto Next and for safe installation by an electrician.

2. Using this document

   • Carefully read this Quick Start Guide prior to installing
     and starting up the Webasto Next.

   • Keep these instructions ready to hand.

   • Hand this document on to the following owner or user of the charging station.
     NOTE
     We would draw your attention to the fact that, as part of a professional installation, an installation log should be drawn up by the installer. We also request that you fill in our Check list for the installation of the Webasto charging station.
     NOTE
     Individuals with deficiency in their colour vision require support in the allocation of all fault indicators.

3. Intended use
   The Webasto Next charging station is designed for charging electric vehicles in accordance with IEC 61851-1,
   charge mode 3.

4. Use of symbols and highlighting
   DANGER
   This signal word denotes a hazard with a high degree of risk which, if not avoided, may lead to death or serious injury.
   WARNING
   This signal word denotes a hazard with a moderate degree of risk which, if not avoided, may lead to minor or moderate injury.
   CAUTION
   This signal word denotes a hazard with a low degree
   of risk which, if not avoided, will lead to minor or
   moderate injury.
   NOTE
   This signal word denotes a Special Technical Feature
   or (if not observed) potential damage to the product.
   

5. Warranty and liability
   Webasto shall not accept liability for defects or damage due to the failure to comply with the installation instructions.

Safety

1. General information
   The device must only be used in a technically faultless condition.
   Any malfunctions that adversely affect the safety of persons or of the device must be immediately rectified by a qualified electrician in accordance with nationally applicable regulations.
   NOTE
   It is possible that the signalling in the vehicle differs from that described here. Always read the operating instructions of the respective vehicle manufacturer and always observe these.

2. General safety information
   

   • Hazardous voltages are present within the casing.

   • The charging station does not have its own main
     ON/OFF switch. The protective devices installed in the power supply system are therefore also used to disconnect the power supply.

   • Check charging station for visual damage before use. Do not use the charging station if damaged.

   • Installation, electrical connection and initial operation of the charging station must only be carried out by an electrician.

   • Do not remove the cover of the installation area whilst in operation.
     

   • Do not remove markings, warning symbols and the type label from the charging station.

   • The charging cable must only be replaced by an electrician in accordance with the installation instructions.

   • It is strictly prohibited to connect other equipment/devices to the charging station.

   • Make sure that the charging cable and coupling cannot be driven over, trapped and are protected from any other hazards.

   • Immediately notify Webasto Customer Service if the charging station, charging cable or the charging coupling are damaged. Do not continue using the charging station.

   • Prevent the charging cable and coupling from coming in contact with external heat sources, water, dirt and chemicals.

   • The Webasto Next charging station also meters the plug-in cycles of the charge coupling for service purposes and after 10,000 plug-in cycles, displays a note on the web interface that an electrician needs to inspect the plug contacts on the charge coupling for any signs of wear. If any signs of wear are discovered, the electrician must replace the affected charging cables with genuine Webasto spare parts.

   • Do not attach extension cables or adapters to the charging cable.

   • Remove the charging cable by pulling on the charging coupling only.

   • Never clean the charging station with a high-pressure cleaner or similar device.

   • Switch off the power supply before cleaning the charging sockets.

   • The charging cable must not be subjected to any strain during use.

   • Ensure only persons who have read these operating instructions have access to the charging station.

WARNING

• When not in use, store the charging cable in the designated holder and lock the charging coupling in the remote dock. Loosely wind the charging cable around the remote dock making sure the cable does not touch the floor.
• You must make sure that the charging cable and coupling cannot be driven over, trapped and are protected from all other hazards.

Safety information for installation

• The instructions in this Quick Start Guide must be followed for safe installation.

• You must comply with the locally applicable requirements regarding electrical installations, fire protection, safety regulations, and escape routes at the intended installation location.

• Only use the supplied installation material.

• When open, ESD (electrostatic discharge) precautions must be taken properly to avoid electrostatic discharge.

• When handling electrostatically sensitive boards, wear grounded antistatic wrist straps and properly observe ESD safety precautions. Wrist straps must only be used when mounting and connecting the loading unit. Wrist straps must never be worn on a live Webasto Next.

• Electricians must be properly grounded during installation of the Webasto Next.

• Do not install the Webasto Next in an explosion sensitive area (Ex Zone).

• Install the Webasto Next in such a way that the charging cable does not block any passageways.

• Do not install the Webasto Next in areas subject to ammonia or air containing ammonia.

• Do not install the Webasto Next in a location where falling objects may damage it.

• The Webasto Next is suitable for use indoors as well as outdoors.

• Do not install the Webasto Next in the vicinity of water jets, such as car-wash installations, highpressure cleaners or garden hoses.

• Protect the Webasto Next against damage caused by sub-zero temperatures, hail or similar. We would like to refer you to our IP protection class at this juncture (IP54).

• The Webasto Next is suitable for use in areas without access restrictions.

• Protect the Webasto Next from direct sunlight.
  The charging current may be reduced at high temperatures, or charging may be disabled completely.
  The operating temperature of the 11 kW version is -30°C to +55°C.
  The operating temperature of the 22 kW version is -30°C to +45°C.

• The installation location of the Webasto Next should ensure that vehicles cannot inadvertently collide with it. Protective measures must be implemented if the possibility of damage cannot be ruled out.

• Do not put the Webasto Next into operation if it has been damaged during installation; a replacement will be required.

Safety information for electrical connection

WARNING

• Comply with the nationally applicable requirements pertaining to electrical installations, fire protection, safety regulations and escape routes at the intended installation location. Observe the applicable national installation regulations.
• Each charging station must be protected with its own line circuit breaker and residual current circuit breaker. See Requirements at the installation location.
• Make sure that the electrical connections are deenergised before connecting the charging station to the power supply.
• Do not connect a vehicle during initial start-up of the charging station.
• Make sure that the correct supply cable is used for the power connection.
• Do not leave the charging station unattended with the cover open.
• Change DIP-switch settings only with the power off.
• Register with the power supply company as required.

Safety information for initial start-up

WARNING

• Initial start-up of the charging station must be carried out only by an electrician.
• Prior to initial start-up, the electrician must check that the charging station has been connected correctly.
• Before starting-up the charging station, check the charging cable, charging coupling and the charging station for visible damage. The charging station must not be started up if it is damaged or if the charging cable/charging coupling is damaged.

Safety-relevant LED fault list

1 s, the acoustic signal sounds for 5 s: There is a problem in the voltage or system monitoring.

Danger of fatal electric shock. See Fig. 6. Switch off and secure the power supply to the charging station. Only then unplug the cable from the vehicle. Contact the Webasto Charging Hotline. You can find this on our website at www.webastocharging.com

You can find descriptions of other LEDs (F1-F5) in the comprehensive Online Manual

Cleaning: Safety information

DANGER
High voltages.
Danger of fatal electric shock. Do not clean the charging station with a high- pressure cleaner or similar device
Details on maintenance, cleaning and repair can be found in the manual.

Replacing the charging cable: Safety information

DANGER
Danger of fatal electric shock.

• Switch off and secure the power supply to the charging station.

NOTE
Only use genuine Webasto parts.

Quick Start

1. The Webasto Next must be installed by a qualified electrician.
   Two QR codes are provided for the scan and charge functions; these are located under the protective film applied to protect the wall box.
   The QR codes should be removed and kept.

2. Download the required Apps:

3. Webasto Charger Setup

4. Webasto ChargeConnect
   

5. Open the Webasto Charger Setup app and configure your charging station.
   

6. Scan the QR code on the label in the Quick Start
   Guide or type in the Wi-Fi password manually
   

7. Open the ChargeConnect app and follow the steps to connect the charging station to the
   ChargeConnect Cloud.
   

8. Plug in and enjoy exploring your station’s capabilities.
   You can find a detailed description of your Webasto Next in the comprehensive Online Manual.
   

Installation and electrical connection

DANGER
Observe the safety information provided here Safety

To access further documents use one of the following options:

• The Webasto Service App
  Go to https://apps.apple.com/ or scan the following QR Code to download the app from the Apple App Store.
  To download from the Google Play Store go to
  https://play.google.com/ or scan the following QR Code.
  

• To use the Webasto Service App and access online
  Webasto technical documentation, please scan the QR code or the barcode on your Webasto product box.
  Our operating instructions are also available on our website at http://www .webasto-charging.com/
  documentation. All languages can be found in the download portal on our website

NOTE
The Webasto Next safety concept is based on a power supply system that is earthed at all times, which must always be ensured by an electrician during installation.

Requirements installation space

The following points must be taken into account when
selecting the installation location for the Webasto Next:

• The lower edge of the enclosed mounting template must be at a minimum distance of 90 cm above the ground during installation. See Fig: Live Wall mounting.
• If several charging stations are installed next to each other, a spacing of at least 200 mm must be maintained between each station.
• The mounting surface must be solid and strong.
• The mounting surface must be completely flat (max. 1 mm difference between the individual mounting points).
• The mounting surface must not contain any flammable substances.
• A cable run from the charging station to the vehicle as short as possible.
• No risk of driving over the charging cable.
• Possible electrical connections from infrastructure.
• Pavements and escape routes must not be obstructed.
• We recommend an installation location that is protected against direct sunlight for optimum and fault-free operation.
• The usual parked position of the vehicle, taking account of the position of the charging plug on the vehicle.
• Consideration of local building and fire protection regulations.

NOTE
The mounting distance between the bottom edge of the charging station and the floor must be at least 0.9 m.

Criteria for the electrical connection
The maximum charging current is factory set and is indicated on the type label of the charging station. The maximum charging current can be reduced to the value of the installed circuit breaker using DIP switches.

NOTE
The current value of the selected protective device must not fall below the current value specified on the type label for the charging station or the value set using the DIP switch.
See chapter 3.7, “DIP switch settings” on page 16.

The installation requirements for the charging station should be checked by a qualified electrician before starting connection works.
Comply with the nationally applicable regulations of the authorities and power supply companies, e.g. registration of installation of a charging station.

NOTE
In some countries, single-phase charging is limited to a defined current. Please observe the local connection requirements.
All protective devices specified below must be designed such that every power supply pole of the charging station is disconnected in the case of a fault. You must meet national installation regulations and standards when selecting the protective device.

1. Dimensioning of the Residual Current Circuit Breaker (RCCB)
   The national installation regulations generally apply. Unless otherwise specified therein, each charging station must be protected by an appropriate residual current device (RCD type A) with a trip current of ≤ 30 mA.

2. Dimensioning of the circuit breaker
   The circuit breaker must conform to IEC 60898. The letthrough energy (I²t) must not exceed a maximum 80,000 A²s.
   Alternatively, a residual current circuit breaker combination (RCBO) according to EN 61009-1 can be used. The aforementioned parameters apply for this circuit breaker combination.

3. Mains isolation device
   The charging station does not have its own main ON/OFF switch. The protective devices installed in the power supply system are therefore also used to disconnect the power supply

4. Installation
   See also chapter 4, “Installation” on page 17.
   The supplied installation material is intended for mounting the charging station on a masonry or concrete wall.
   For installation on a stand, the mounting material is included in the scope of delivery of the stand.

   • Take into account the mounting position at the installation location. See Fig: Live Wall mounting.

   • Remove the drill template at the perforation from the
     packaging.

   • Mark the four positions of the drill holes at the installation location using the drill template. See Fig: Live
     Wallmounting.

   • Drill 4 holes of Ø 8 mm in the marked positions.
     NOTE
     The central hole should be used for the building wiring system. The hole shown on the left must be used if the LAN cable is used.

   • Position the bracket over the upper holes and mount using 2 wall plugs and 2 screws, 6 x 70 mm, T25.

   • Remove the lower cover from the connection area of the charging station.
     Fig. 1
     

   • Remove the spiral antikink protection from the connection area of the charging station and place it with the other supplied material.

   • For surface mounting, make a recess for routing the lead on the back of the charging station using the designated lateral predetermined breaking points (if necessary deburr the edge of the break using a round file).

   • Insert the lead through the designated lead-through and fit the charging station on the previously mounted bracket.

   • Mount the charging station using 2 screws, 6 x 90 mm, T25 using the mounting holes in the lower connection area. Do not exceed the max. torque of 6 Nm.

   1. Connecting the charging cable
      NOTE
      Ensure correct fit of the previously pre-assembled rubber seals in the sealing clip.

   • Push the charging cable at least 10 mm beyond the upper edge of the clamping area of the strain relief clamp.

   • Turn the antikink protection spiral several turns onto the sealing clip.
     NOTE
     Do not tighten yet.
     Fig. 2
     

   • Screw in the supplied strain relief clamp in the correct position on the charging cable.
     NOTE
     The strain relief clamp has two position options for charging cable versions 11 kW and 22 kW.
     Ensure that the “11 kW installed” label for an 11 kW charging cable is visible.

   • Fit the strain relief clamp in the correct mounting position using the supplied self-tapping Torx screws (6.5 x 25 mm) and tighten to 5.5 Nm. (Attention: Do not overtighten screws).

   • The strain relief clamp must be flush when securely screwed in.

   • NOTE
     Perform a tension test on the charging cable to make sure that the cable cannot move.

   • Screw the antikink protection spiral onto the sealing clip with a torque of 4 Nm.

   • Using the slot-head screwdriver (3.5 mm), connect the individual cable ends according to the specification in the illustration on the right terminal block with the “out” label.

   • To do this, insert the screwdriver in the designated upper opening of the spring relief for the terminal block and open the clamping spring.

   • Now insert the individual wire into the designated connection opening of the terminal block (lower opening).
     Charging cable| Description
     ---|---
     Blue| N
     Brown| L1
     Black| L2
     Grey| L3
     Yellow-green| PE
     Black-white| Control cable (CP)

   • Then pull the screwdriver out again and perform a tension test to make sure that the individual wires are clamped properly and fully.

   • Connect the black/white control cable (CP) to the terminal (contact 1).
     Fig. 3

NOTE
Push the white spring contact of the connection on the right down while inserting the control cable fully.

    * Perform a tension test to make sure that the cable is clamped properly and fully.

5. The electrical connection
   

   • Check and make sure that the lead is tension-free and
     measures have been taken to secure against being switched on.

   • Check and comply with all the requirements necessary for the connection and mentioned previously in these instructions.

   • Take the cable gland grommets from the supplied material.

   • Slide the cable bushing over the lead.
     NOTE
     Ensure that the insertion aid for the grommet is on the back of the charging station when in the final installed state, however, do not position it in the housing lead through yet.

   • If a data line is also to be connected, use the second supplied cable gland grommet and repeat the abovementioned step.

   • Remove the sheathing of the lead.

   • If a rigid lead is used, bend the individual wires paying attention to the minimum bend radii so that it is possible to connect them to the terminals without significant mechanical stress.

   • Remove the insulation from the individual wires as shown in the illustration. (Note: Avoid damage to the copper braid).
     Fig. 4
     
     

   • Using the slot-head screwdriver (3.5 mm), connect the individual cable ends according to the specification in the illustration on the left terminal block with the “Power In” label.

   • NOTE
     Make sure to connect them using the correct connection sequence for a right rotating field.

   • To do this, insert the screwdriver in the designated upper opening of the spring relief for the terminal block and open the clamping spring.

   • Now insert the individual wire into the designated connection opening of the terminal block (lower opening).

   • Then remove the screwdriver again and perform a tension test to ensure that the individual wires are clamped properly and fully and no exposed copper areas are visible.

   • NOTE
     If multiple charging stations are connected to a common main power supply point, there is a risk of overload.
     A phase rotation must be provided and adapted to the connection configuration of the charging station.
     See online configuration manual: https://webastocharging.com/documentation.

   • Insert the data line into the designated connection in
     the connection area. See Control cable (Control Pilot)
     and Fig. 3.

   • Remove any soiling such as insulation trimmings out of the connection area.

   • Check again for firm attachment of all wires in the corresponding terminal.

   • Next position the cable bushing in the housing leadthrough.

   • NOTE
     Make sure there are no air gaps between the housing and the cable bushing.

The electrical connection in split-phase systems
Terminal configuration

DIP switch configuration: D6 = 0

NOTE
This terminal configuration does not define the unbalance load limit.

LAN cable

For connecting the charging station to the network infrastructure at the installation location. The charging station can be configured and controlled using this connection (prerequisite: connection to the back end or to the local power management system). A CAT 7 network cable or higher is recommended. The LAN cable must be passed through the left-hand opening in the wall box in order to connect it to the LAN socket.

Active power increase
See Fig. 3
The active power increase as per the rules of VDE AR-4100 should be connected as follows.
The two cables from the radio control receiver should be inserted into this connector (position 3 and 4) – the allocation is irrelevant (max. cable cross- section 1.5 mm²).

DIP switch settings

DANGER
High voltages.

• Danger of fatal electric shock.
• Ensure safe isolation from the power supply.
  DIP-switches configure the current setting of the charging station.
  Fig. 5
  
  DIP switch left/ON = 1
  DIP switch right/OFF = 0
  DIP-switch factory setting:

NOTE
Changes to the DIP switch settings become active after restarting the charging station.

The DIP switches should be programmed in such a way
that the output power illustrated below for the singleand three-phase charging operation can be set to the desired current (D1-D6).

Initial start-up

1. Safety check
   Document the results of the checks and measurements carried out during initial start-up corresponding to the applicable installation requirements and standards.
   The local regulations relating to operation, installation and environmental protection also apply.

2. Start-up procedure
   Remove material residues from the connection area.

3. Check that every screw is correctly tightened and every clamp is correctly engaged.

   • Fit the lower cover. u Secure the bottom cover with the mounting screws; carefully tighten the mounting screws to the stop. See Fig. 1.

   • Switch on power supply. – Start sequence is activated (duration up to 60 seconds).

   • White chase light running up and down. See operating status N2.
     Fig. 6
     

   • Perform initial operation check and record measured values in test log. An EV simulator is used for the measurement at the charging coupling.

   • Simulate and test the individual operating and protection functions with the EV simulator. u Connect the charging cable to the vehicle. – The LED changes from green to pulsing blue.

Assembly

Fig. 7

Declaration of Conformity

The Webasto Next was developed, manufactured, tested and supplied in accordance with the relevant directives, regulations and standards for safety, EMC and environmental compatibility.
Webasto Roof & Components SE hereby declares that the radio equipment type “Charging Station Webasto Next ” conforms to Directive 2014/53/EU.
The full text of the EU declaration of conformity can be found at the following web address:
https://webasto-charging.com/documentation

Check list for the installation of the Webasto charging station

Charging station: Webasto Next
Charging power: 11 kW :22 kW
Serial number:_____
Material number____

General : Applicable/

Installation, electrical connection and initial operation of the charging station must be carried out by an electrician.____
Local conditions:
The charging station has not been installed in an explosion sensitive area (EXzone).__
The charging station has been installed in a location where falling objects cannot damage the charging station.____
The charging station is installed in an area protected from direct sunlight, as recommended.__
Please underline the weather conditions on the installation date: sun, rain, overcast, snow or other____
The location of the charging station should be selected such that vehicles cannot inadvertently collide with it.__
The legal requirements for electrical installations, fire protection, safety regulations and escape routes have been met.
The charging cable and coupling has been protected against coming into contact with external heat sources, water, dirt and chemicals._
The charging cable and coupling has been protected against being driven over, trapped, or any other mechanical hazards.___
The customer/user was informed how the Webasto Next voltage is switched off with the installation-side protective devices.__

Charging station requirements:
The cable bushing for the mains lead and signal cable has been installed during installation.___
The kink protection for the charging cable has been screwed onto the charging station and the rubber seal has been fitted correctly into the kink protection._
The appropriate charging cable (11 kW or 22 kW) has been connected to the charging station (as per type label) during installation.____
The strain relief clamp that ensures the charging cable has strain relief has been fitted.____
The specified torques have been observed. The charging cable has been connected as per the instructions.__
Tools and installation remnants have been removed from the charging station before closing the cover.
The locally applicable test logs should be drawn up during commissioning and a copy should be given to the customer.
Customer/client:
Place: Signature:____
Date:_____
Electrician/contractor:
Place: Signature:_____
Date:__

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