innohome Charlie Electric Vehicle Charging Station User Guide

Charlie electric vehicle charging station

Installation and User Guide

Introduction

This manual provides installation, operating, and maintenance instructions for Charlie’s electric vehicle charging station.

This user manual contains all the information necessary for the safe installation and operation of the electric vehicle charging station. Electrical installations and connections must be carried out only by a qualified electrician and in compliance with local regulations. Read the instructions carefully before installation
and use and keep the manual for future reference.

Safety

Safety signs used in the instructions

Danger: Indicates a hazard that will result in death or serious injury if not avoided.

Warning: Indicates a hazard that can result in death or serious injury if not avoided.
Indicates a hazard that can result in damage to property or moderate injury.

Danger: The electric vehicle charging station is not intended for use by children or by persons with reduced sensory, physical or mental capabilities, or whose lack of knowledge and experience does not ensure the safe operation of the device.

Danger: The electric vehicle charging station is meant only for charging electric vehicles.

Danger: The electric vehicle charging station should only be used in a technically faultless condition and in compliance with the instructions in the installation and user guide.

Installation competence requirements

Installation must be performed by a qualified electrician. Appropriate tools and testing equipment are required.

Communication with property owners and other relevant parties

Before the installation, communicate with the property owner or supervisor about the electrical systems of the site.

The following items must be clarified before starting the work:

• Electrical features of the site such as the load capacities of the power supplies
• Location of the electrical distribution board of the site
• Availability of separating circuit breaker arrangements for charging station
• If the site requires an access permit, arrange it with the property owner or manager before installation

Work and electrical related safety
Safe work practices are mandatory. Only proper and described tools are allowed to be used. Personal protective equipment (PPE) is mandatory. At a minimum, appropriately protective shoes, gloves, and eye protection must be worn.

Intended use

Innohome Charlie is a wall-mounted mode-3 electric vehicle charging station designed for charging electrically powered vehicles.

Charging station classifications

Product parts

Charging station product details

Charlie VIN Plate

Charging station main parts

1. Type 2 charging cable socket
2.  LED indicators

Charlie internal structure

1. DIP Switch S1 (see: Installation – Dip switch setting alternatives)
2. DIP Switch S2 (see: Installation – Dip switch setting alternatives)
3. 1-phase contacts (L1, N, PE)
4.  Strain relief for bottom-side cable inlet
5.  3-phase contacts (L2, L3) (Charlie-3)
6. Load Balancing connector (Charlie-2 and Charlie-3)
7. External input connector
8. Strain relief for back-side cable inlet

Delivery contents

Before installation, make sure you have all the needed parts and accessories of the product. If you notice missing items, contact the reseller or product importer immediately. In the case of missing or broken parts, only replacement parts provided by the product reseller, importer or vendor are allowed to be used.

1. Charlie electric vehicle charging station
2. Wall mounting screws (Steel zinc plated full thread pan head TX25 ZP 4.5×30) and wall plugs (6×30 WIP)
3. Strain relief and installation screws (Pan head BN 20138).
4. Screws for closing the charging station cover from the bottom (Hexalobular socket flat BN2041)
5.  Screw for closing the charging station cover from the top (Pan head TX20 MP 4×10)
6. Installation template

Warranty

Charlie electric vehicle charging station is meant to be used as described in this installation and user guide.

The warranty and liability exclude damage resulting from:

• Incorrect or inappropriate installation, setup, or use of the product
• Neglect of instructions concerning transportation, installation, use, or maintenance
• Structural or electronic modifications, or changes made to the charging station that is not in accordance with the guidance provided in this document

Before installation

Installation checks

Before installation, make sure of the following:

• The location for the electric vehicle charging station is already agreed upon with the property owner or supervisor
• The power supply cabling is rated according to plan installation and local regulations
• Needed parts and accessories of the product are available
• Appropriate tools and accessories are needed during installation are available
• The power supply is disconnected
• For current leakage protection, a Type-A, ≤ 30mA RCD (Residual Current Device) is required for vehicle charging supply. If not already available, it must be installed
• For short circuit protection, a separate circuit breaker must be installed. Circuit breaker breaking current should be selected according to local regulations and configured maximum charging current at the charging station (DIP switch configuration)

Needed tools

•  Comprehensive hand toolset including insulated screwdrivers

• Informative warning tags during the separation of the power supply, and preventive lock or another preventive measure for circuit breakers

• Power tools; an electrical power drill with drill bits

• Electrical testing tools:
  ◦ Standard-compliant multimeter (with accessories)
  ◦ Standard-compliant earth resistance meter (with accessories)

• Charging station installation template (included in the product sales package)

Disconnecting power supply

Danger: Make sure the power supply for the charging station is disconnected before starting the installation.

To avoid both personal and equipment hazards, follow these installation steps:

1. Make sure that the power supply is disconnected by opening the circuit breaker (power supply OFF).
   a. Lock the circuit breaker to open position (power supply OFF) by using a dedicated lock accessory or use other preventive means for reconnection prevention.
   b. Place a prohibition sign stating “Do not connect” to the locked switch.

2. Make sure there is no power supply at the power supply cabling. Measure with a multimeter.

Installation

Note: Before the installation, the location for the charging station must have been agreed upon with the property owner or manager.
The appropriate power supply cabling must also be available.

Note: Assure that wall material is capable to handle the weight of the charging station. In special materials please use appropriate fastening measures.

1. Select the correct installation height for the charging station.
   Mark the screw locations on the wall using the installation template included in the package.

2. Make sure the marked spots line up horizontally and drill holes according to the hole markings.

3. Remove the charging station cover.

4. Install the charging station following options A) or option
   B) depending on the cable inlet.

Installing the charging station – Wiring Option A

When the cabling is installed through the bottom-side cable inle

Danger: Make sure the power supply for the charging station is disconnected before installation. Do not turn the power on until electrical wiring is finished.

1. Before installation of the charging station, it is recommended that the power supply cabling is prepared at first.
   Note: Leave PE wire 20 mm longer than the other wires.
   This ensures it will be the last remaining connection if the cable is pulled by excessive force. Recommended stripping length for wiring option A: 1-phase power supply

Recommended stripping length for wiring option A: 1-phase power supply for IT power grid

Recommended stripping length for wiring option A: 3-phase power supply

2. A rubber grommet is used to prevent dust and moisture from entering the charging station. To prepare the grommet, make a small cross-shaped cut where the power cable enters the grommet.

3. Place the charging station against the wall according to the markings. Mount the charging station on the wall before routing the cable.

4. Pull the power supply cable through the cable inlet.
   Make sure the non-stripped part of the cable reaches past the strain relief. There must be enough cable for restraining fixing and the electrical connections.

5. Route the cabling so that you are able to place the cable to the strain relief.

6. Fasten the strain relief.
   Note: The strain relief can be used in two ways depending on the cable diameter.

7. Tighten the strain relief.

8. Separate the power supply wires and mark them if necessary.

9. Make sure the wires cannot come into contact with each other.

Installing the charging station – Wiring Option B

When the cabling is installed through the back-side cable inlet

Danger: Make sure the power supply for the charging station is disconnected before installation. Do not turn the power on until electrical wiring is finished.

1. Before installation of the charging station, it is recommended that the power supply cabling is prepared at first.
   Note: Leave PE wire 20 mm longer than the other wires. This ensures it will be the last remaining connection if the cable is pulled by excessive force. Recommended stripping length for wiring option B: 1-phase power supply

Recommended stripping length for wiring option B: 1-phase power supply for IT power grid

Recommended stripping length for wiring option B: 3-phase power supply

2. A rubber grommet is used to prevent dust and moisture from entering the charging station. To prepare the grommet, make a small cross-shaped cut where the power cable enters the grommet.

3. Pull the power supply cable through the right-hand side power inlet before fixing the charging station to the wall. Make sure the non-stripped part of the cable reaches past the strain relief. There must be enough cable for restraining fixing and the electrical connections. Do not tighten the fixings yet.

4. Make sure the device is in the correct position according to the markings and mount the charging station.

5. Route the cabling so that you are able to connect the cable to the strain relief.

6. Attach the strain relief.
   Note: The strain relief can be used in two ways depending on the cable diameter.

7. Tighten the strain relief.

8. Separate the power supply wires and mark them if necessary.

9. Make sure the wires cannot come into contact with each other.

Wiring

Wiring for 1-phase power supply

1.  Protective earthing wire (PE)
2.  Neutral wire (N)
3.  Phase wire (L)

Wiring for 1-phase power supply for IT power grid :

1. Protective earthing wire (PE)
2. Phase wire (L2)
3. Phase wire (L1)

Wiring for 3-phase power supply:

1.  Protective earthing wire (PE)

2. Neutral wire (N)

3. Phase wire (L1, L2, L3)

4. Make sure that the wires cannot come into contact with each other.

5.  Make sure all the wires are connected firmly to the charging station’s connectors.

DIP switch configuration

Danger: Make sure the power supply for the charging station is disconnected before installation. Do not turn the power on until electrical wiring is finished.

1.  Make sure all the wires are connected firmly to the charging station’s connectors.
2. Set the DIP switches for appropriate power grid network topology and supply rating according to site setup.

Example of DIP switch positions for Charlie-1,
1-phase, 32A charging current

|

DIP switch configuration

Check that host mode is selected| Set current setting according to supply fuse and cabling capacity. Do not exceed power supply connection capability. If current settings are not done, the charging station will not operate.
---|---
Host / Client mode setting (DIP S1)| Current setting in host mode (DIP S2)
|
|
Configure used power grid topology|
TN/TT or IT power grid settings (DIP S1)|

TN or TT
Power Grid|

IT Power Grid|

Load balancing
(Charlie-2 and Charlie-3)

Load balancing set up consists of a host charging station unit (1) and up to three client units (2).

Wiring for load balancing
The client charger units are connected to the host charger using the right- hand side cable inlet. A rubber grommet is used to prevent dust and moisture from entering the charging station. Before inserting the cables, make a small cut in the grommet for each cable entering the cable inlet. Recommended cable type for RS-485: ELAQBY/ELAKY 2X2X0,6 or similar.

Setting up DIP switches for load balancing (Charlie-2 and Charlie-3)

DIP switches for load balancing

Set up the host and client units| Set up a different address for each client unit
---|---
Host / Client mode setting (DIP S1)
| Device address setting in client mode (DIP S2)
|

|
|

RS-485 termination setting DIP S1

External input connection (Charlie-2 and Charlie-3)

Charlie-2 and Charlie-3 products have input connectors for potential free control signals from 3rd party units. When a signal occurs in input Charlie-2 and Charlie-3 will limit the maximum charging current into 8A. When the signal returns to a normal state, the maximum charging current returns into a predefined value.

Connect the potential free output of the control unit to connector pins CC + and CC-

Setup DIP switch position for Normally Closed or Normally Open output of 3rd party control unit.

External charge mode (Host only) (DIP S2)

| External charge control is enabled when the relay is open (NC,
Normally Closed)
| External charge control is enabled when the relay is closed (NO,
Normally Open)

Closing the charging station cover

After the wiring installation is done, close the charging station cover.

1. Push the cover horizontally towards the back part of the charging station. Make sure the clips inside the top part of the cover attach properly to the holes on the back part of the unit.
2. Attach the screws on the bottom of the charging station cover.
3. Attach the screw on the top of the charging station cover

Taking the charging station into use

Test measurements must be performed before taking the charging station into use.

Danger: Test measurements are performed using high voltages.

Connecting the power supply

Before connecting the power supply, make sure that all the needed cable installations are completed and that the earth resistance measurements have been made according to local regulations.

1. Remove the signaling warning tag from the circuit breaker or power supply switch of the charging station.

2. Remove the dedicated lock or other preventive measures from the circuit breaker or power supply switch.

3. Connect the power supply to the charging station by operating the circuit breaker.

4. Test the functionality of Type-A RCD by pressing the RCD test button.

Measurements after power supply connection

Verify the operation of the charging station after the power supply has been connected.

Danger: Test measurements are performed using high voltages.

1. Check the indicators of the charging station. Refer to LED descriptions for more details.
2. It is recommended to use an EV charging station installation tester to ensure functionality.

Testing the charging station in normal use

Before this test, make sure that the charging station has been tested by using testing equipment.

1. Make sure all the wires have been connected correctly and the charging station cover is attached.
2. Connect the vehicle charging cable to the charging station.
3. Connect charging cable to the vehicle
4. Make sure that the LED in the charging station switches to charging mode. See LED indicators for more details.
5. Check that the charging indicator of the vehicle is activated.

User Guide

The Charlie electrical vehicle charging station is easy to use.
It is ready to use straight after installation. Simply connect the charging station and vehicle with the charger cable. LED indicators show the status of the charging station.

LED functions and their explanations

1. LED Green| 2. LED Blue| 3. LED Red| 4. LED Functions
---|---|---|---

OFF

|

OFF

|

OFF

|

Device not operational

BLINKING

|

OFF

|

OFF

| Initialization

ON

|

OFF

|

OFF

| Standby/Ready

ON

|

ON

|

OFF

| EV connected, not charging

ON

|

PULSING

|

OFF

| EV connected, charging
| |

BLINKING

| Error: See Troubleshooting

Charging

Connect the vehicle to the charging station.

Connect the charging cable first on the charging station (1), then to the vehicle (2).

Danger: Do not open the charging station cover!
Danger: Do not use a damaged charging station or charging cable.
Danger: Adaptors or conversion adapters and cord extension sets are not allowed to be used.

Troubleshooting

LIGHTS| POSSIBLE CAUSES|

DETAILS

---|---|---
Green| Blue| Red| |

ON

|

PULSING

| BLINKING

| Charging currently limited, high temperature.|

Charging is active. The vehicle is being charged, but the charging has been lim­ited to 6A due to high internal temperature.

BLINKING

|

BLINKING

|

BLINKING

| Device configuration error|

The charging station is not set up correctly. Please contact a qualified electrician to check the device configuration. Turn the circuit breaker off. Re-configure the DIP switches.

BLINKING

|

OFF

|

BLINKING

| The power relay is faulty|

The charging station is not operational. Turn the circuit breaker off. Wait for 5s and turn it back on. If the same problem persists, please contact a qualified electrician to check the device configu­ration.

Cable lock motor malfunction
RS-485 communication error
Internal HW error
No RS-485 connection to the host device

ON

|

OFF

|

BLINKING

| The current value of the cable is invalid|

The charging process has failed. Please check the cable connector for damag­es. If the cable connector is broken. Please replace the charging cable and try again. If the problem persists, please contact a qualified electrician.

6mA residual current has been detected
Protective ground lost, 6V to 12V change detected
Cable locking mechanism status invalid

EU Declaration of Conformity

As the product’s manufacturer, we declare under our sole responsibility, that this product corresponds to:

• The Low Voltage Directive 2014/35/EU
• The RoHS Directive on the Use of Hazardous Substances 2011/65/EU And the following harmonized standards and technical data are used:
• Electric Vehicle Conductive Charging System – Part 1: General Requirements IEC 61851-1:2017
• Electric Vehicle Conductive Charging System – Part 21-2: Electric Vehicle Requirements For Conductive Connection To An AC/DC Supply – EMC Requirements For Off Board Electric Vehicle Charging Systems IEC 61851-21-2:2018
• Degrees Of Protection Provided By Enclosures (IP Code) IEC 60529:1989 + A1:1999 + A2:2013
• Low-Voltage Switchgear And Controlgear Assemblies – Part 7: Assemblies For Specific Applications Such As Marinas, Camping Sites, Market Squares, Electric Vehicle Charging Stations IEC 61439-7:2018
• Technical documentation for the assessment of electrical and electronic products with respect to the restriction of hazardous substances (RoHS) EN 50581:2012

Tested by an independent, accredited testing laboratory (Dekra Testing and Certification, S.A.U., NB:1909)

Signed for and on behalf of Innohome Oy:

Juha Mört, CEO

Disposal (WEEE)

In compliance with the European directive WEEE (2012/19/EU) on waste and reduction of hazardous substances of electrical and electronic equipment, it must not be disposed of as unsorted municipal waste. Instead, this device must be collected separately in accordance with local recycling regulations.

 Contact

www.innohome.com
Copyright notice
This document and its content are proprietary of Innohome Oy.
Content copying, reproducing, or printing in any form or means
is forbidden without the written consent of the company.
© Innohome Oy 2020 – All rights reserved.

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