Badger Power Electronics Amstel 7.4kW Smart Guide

Amstel 7.4kW
Smart
Socket
User & Installation Manual

1. Safety Information....................................................................1
1.1. Important safety instructions.....................................1
1.2. Notes..............................................................................2
2. Specication...............................................................................3
2.1. Datasheet.....................................................................3
2.2. Features.........................................................................4
2.3. Dynamic Load Balancing.............................................4
3. Preparation for Installation....................................................5
3.1. Installation requirements............................................5
3.2. Electrical Wiring Diagram............................................6
3.2.1. 230V Single Phase.........................................6
3.3. Installation Considerations.........................................6
4. In the Box....................................................................................7
5. Installation Instructions..........................................................8
5.1. Step-by-Step Installation Instructions for:................8
5.1.1.BottomWiringConfiguration.....................8
5.1.2.TopEntryConguration.............................10
5.1.3.RearEntryConguration...........................12
5.2. Set the Operating Current .......................................14
5.3. Emergency Shutdown Button...................................14
5.4. Leakage Test...............................................................15
6. Operating Status......................................................................16
6.1. Power ON Checking...................................................16
6.2. LED Lights Instruction................................................16
6.3. Buzzer Prompt Description.......................................17
7. Maintenance Instructions.....................................................18
7.1. Product Servicing........................................................18
7.2. Warranty Description.................................................18
7.3. Safety Notice...............................................................18
7.4.RiskNotication..........................................................19
User Manual Contents......................................................1

1. Precautions...................................................................................21
2.Description....................................................................................21
2.1. Introduction....................................................................21
2.2. Performance...................................................................21
3. Installation Instructions............................................................22
3.1. Accessories.....................................................................22
3.2. DIN Rail Installation.......................................................22
3.3. Flush Mounted Installation...........................................23
3.4. Connection......................................................................24
4. Safety Instructions & Troubleshooting..................................25
4.1. Instructions.....................................................................25
4.2. Troubleshooting.............................................................25
DLB Box Manual......................................................................20

• Read this entire document before installing or using the EV Charger.
• Keep children away from operating the EV Charger.
• The EV Charger must be grounded through a permanent wiring
system or an equipment grounding conductor.
•Donotinstallthemountingbracketnearammable,explosive,harsh,
orcombustiblematerials,chemicals,orvapours.
•DonotexceedspeciedEVChargeroperatingparameters.
• Never spray water or any other liquid directly at the wall mounted EV
Charger. Never spray any liquid onto the charge handle or submerge
the charge handle in liquid. Store the charger connector above
thegroundtopreventunnecessaryexposuretocontaminationor
moisture.
•DonotuseEVChargerifitisdefective,appearscracked,frayed,
broken,orotherwisedamaged,orfailstooperate.
•Donotattempttodisassemble,repair,tamperwith,ormodifytheEV
Charger yourself. Any maintenance must be performed by authorised
technical personnel or our company’s technical support. Contact us for
anyrepairsormodication.
• Handle with care when transporting the EV Charger. Do not subject
ittostrongforce,impactorpull,twist,tangle,drag,orstepontheEV
Charger to prevent it or any components from damage.
• Do not touch the EV Charger’s end terminals with sharp metallic
objects,suchaswire,tools,orneedles.
• Do not insert foreign objects into any part of the EV Charger.
•UseoftheEVChargermayaectorimpairtheoperationofany
medicalorimplantableelectronicdevices,suchasanimplantable
cardiacpacemakeroranimplantablecardiovasculardebrillator.
Checkwithyourelectronicdevicemanufacturerconcerningtheeects
that charging may have on such electronic devices before using the EV
Charger.
This document contains important instructions and warnings that
must be followed for both installation and maintenance of the EV
Charger.
1.1. Important Safety Instructions
1. Safety Information
WARNING
1

• Do not use private power generators as a power source for
charging.
• Incorrect installation and testing of the EV Charger could
potentially damage either the vehicle’s battery and/or the
EVChargeritself.Anyresultingdamageisexcludedfrom
New Vehicle Limited Warranty and the EV Charger Limited
Warranty.
• Do not operate the EV Charger in temperatures outside its
operating range of -25°C to +55°C.
1.2. Notes
• Ensure that the EV Charger’s charging cable is positioned so it
willnotbesteppedon,drivenover,trippedon,orsubjectedto
damage or stress.
• Do not use cleaning solvents to clean any of the EV Charger’s
components.TheoutsideoftheEVCharger,thecharging cable
andtheconnectorendofthechargingcableshould be
periodically wiped with a clean dry cloth to remove
accumulation of dirt and dust.
• Be careful not to damage the circuit board when removing the
power entry knock-out.
CAUTIONS
2

2.1 Datasheet
2. Specication
3

2.2. Features
•Built-inwithover-voltageprotection,over-currentprotection,
overtemperatureprotection,groundfaultdetection,CP
abnormal signal protection and Type ARCD for Europe
standard.
• Operating temperature range: -25°C to 55°C.
•IP55protectingrate,operatinghumidityrange0-95%forindoor
and outdoor.
•Built-intemperaturesensorforfireprotection.
• Easy cable storage.
• The EV charger can be wall-mounted or pole-mounted. There
arethreewiringconfigurationsfortheEVcharger- bottom,top
and rear wiring.
• RFID card or auto-start charging modes.
• International CP mode or compatible modes.
•Ratedchargingcurrentcanbesetaccordingtodifferenthome
load conditions.
• Lightning protection ensures personal safety.
• Standard: EN IEC 61851-1 IEC 61851-21-2.
•Corrosionresistance:MeetGB/T10125-1997artificial
atmosphere corrosion test and salt spray test.
•Certificate:CE & UKCA.
2.3. Dynamic Load Balancing
Dynamic Load Balancing is integrated within BPE EV Chargers which
regulates its power output to harmonise with other household
loads to avoid current overloads. This is achieved by reducing the
current draw of the EV Charger so the system operates smoothly
below the house limit. This optimises home power usage without
tripping the breaker.
4

Installation of the EV Charger requires that you:
•Calculatetheexistingelectricalloadtodeterminethe
maximumoperatingcurrent.
• Calculate the distance to ensure minimal voltage drop.
• Obtain any necessary permits from the local authority that has
jurisdictionandconrmthatthefollow-upinspectionhasbeen
scheduled by an electrician after the installation is complete.
• Use only copper conductors.
• Use conductors that are sized in accordance with local wiring
regulations. The selected cable must be able to sustain periods
of constant load of up to 40A.
• Use protective devices. The circuit protection device chosen
must incorporate a suitable residual-current device (RCD)
and over-current protection in relation to the electrical load
selected.
Choose the Best Location for the EV Charger:
• Determine the parking location of the vehicle to ensure that
the charge cable reaches the charge port.
• Determine the parking location of the vehicle to ensure
that the current charge cable reaches the charge port in an
enclosedgarage,typicallyonthevehicle’schargeportside.
•Inawell-ventilatedarea.Avoidinstallationinanenclosedbox,
or adjacent to hot appliances.
• 1.2m above the ground.
•190mmfromanyobstacletoallowcablecollected.
Note:
The EV Charger is approved for outdoor use. Protection from rain
is recommended but not required.
3. Preparation for Installation
3.1. Installation Requirements
5

3.2. Electrical Wiring
3.2.1. 230V Single-Phase
TheL, N and PEshouldbewiredaccordingtolocalrequirements.
Thephaseusedmustmeasure230V(±10%).
• WARNING: Each ground must be connected to neutral
atonlyonepoint,ortheEVchargercannotoperate.
• WARNING:BeforeinstallingtheEVcharger,identifythe
type of utility service connection available on site. If you
are unsure about the type of connection available at
theservicepanel,consultanelectricianforassistance.
3.3. Installation Considerations
Three congurations are available to install the EV Charger:
The location of the conduit determines which installation method to
follow.Iftheconduitrunsalongtheoororlowtothewall,usethe
bottomentryconguration.Iftheconduitcomesfrominsidethe
wall,usetherearentryconguration.Iftheavailableconduitcomes
fromtheceiling,usethetopentryinstallation.
Note: Throughoutthemanual,“conduit”isusedasthestandard
term for the protective tubing that houses the service wiring. In
regionswhereconduitisnotused(Europeforexample),acable
comprised of service wiring enclosed in a protective jacket may be
substituted for conduit if allowed by local regulations.
Here are some additional guidelines:
• Conduit openings are sized for 32mm conduit.
• Conduitneedstobemetalandameretardant.
• Use an appropriate circuit breaker.
• Tokeepthehousingwaterproof,usecableglands.
6

4. In The Box
1234
5 6 7 8
9 10
NO. Item Quantity
1 EV Charger 1
2WireBox 1
3WireboxMountingTemplate 1
4RFID Card 1
5 M32*1.5 cable gland 1
6 M6*8 Screws 4
7 8*40 Socket head screw and anchoring 6
8 8*40 Flat head screws and anchoring 2
9Position Template 1
10 DLBbox 1
7

5.1. Step-by-Step Installation Instructions
5.1.1. Bottom Wiring Conguration
Step 1
Position
Position the mounting template
on the wall where the EV
Charger will be located.
The picture shows
the distances we recommend.
At a minimum of 120cm from
floorlevel.
Drilling pilot holes.
Drill the holes according
to the instruction on the
positiontemplatefordierent
installation and wiring
congurations.
Step 2
Install the Mounting
Bracket
Insert the 8*40 Socket head
screwsintotheholes,anduse
the screw driver to make the
6pcs 8*40 Socket head screws
anchor the mounting bracket
on the wall.
Wall
Drill
The 6 points on
the position plate
Side of wall
Floor level
>0.5M
>1.2M
Screwdriver
Mounting Bracket
8*40 Socket
head screws
Note: Hooks and socket are not
included. For reference only.
5. Installation Instructions
8

Step 3
Install the EV Charger to
the Mounting Bracket
Align the side holes of the EV
Charger to the panel’s side
holes.
Installation
Use the 4pcs M6*8 screws
toxtheEVChargertothe
mounting bracket as picture
shows.
Step 4
Wiring
Note: Consult with your local
electrician or refer to your
local code for proper wire
sizing appropriate for the
currents in your EV Charger.
Note: It is the installer’s
responsibility to identify
whether additional
grounding is required to
ensure that local restrictions
are met. Grounding must be
installed at the power source
and not at the cable entry to
the EV Charger.
As the picture on the left
shows,usethescrewdriver
to loosen the screws on
the EV Charger cover. Wire
the cable to the appropriate
terminal.
Left hole
position Right hole
position
M6*8
bolts
Wiring diagram
L N PE
Wiring terminals
9

5.1.2. Top Wiring Conguration
Step 1
Position
Position the template on
the wall where you wish to
install the EV Charger.
The picture shows
the distances we
recommend.
At a minimum of 120cm
fromfloorlevel.
Drilling pilot holes.
Drill two holes according
to the instruction on the
position template.
Step 2
Insert the 8*40 Flat head
screwsintotheholes,and
use the screw driver to
makethe2pcs8*40at
head screws anchor the
wireboxontothewall.
>0.5M
>1.2M
Wall
Drill
Side of wall
Floor level
Two points on the
top and bottom of
position plate
Screwdriver
Wirebox
8*40 Flat head
screws
Note: Hooks and socket are not
included. For reference only.
10

Step 3
Knock out on the back of
the EV Charger
Find the hole for the knock
out located on the back on EV
Charger.
Use the 4pcs M6*8 screws
toxtheEVChargertothe
mounting bracket as the
picture shows.
Step 4
Wiring
Note: Consult with your local
electrician or refer to your
local code for proper wire
sizing appropriate for the
currents in your EV Charger.
Note: It is the installer’s
responsibility to identify
whether additional grounding
is required to ensure that
local restrictions are met.
Grounding must be installed
at the power source and not
at the cable entry to the EV
Charger.
As the picture on the left
shows,usethescrewdriverto
loosen the screws on the EV
Charger cover. Wire the cable
to the appropriate terminal.
Left hole
position Right hole
position
M6*8 bolts
Perforating like
image
Back of EV Charger
Insert power
cord into the top
of connection
box
Wiring position
Connect L+N+PE
through the rear of
the device
11

5.1.3. Rear Wiring Conguration
Wall
Drill
Side of wall
>1.2M
Floor level
>0.5M
The 6 points
on the position
Step 1
Position
Position the mounting
template on the wall where
the EV Charger will be located.
The picture shows the
distances we recommend.
At a minimum of 120cm from
floorlevel.
Drilling pilot holes
Drill the holes according
to the instruction on the
positiontemplatefordifferent
installation and wiring
configurations.
Step 2
Install the Mounting
Bracket
Insert the 8*40 Socket head
screwsintotheholes,anduse
the screw driver to make the
6pcs 8*40 screws anchor the
wireboxmountingbracketon
to the wall.
plate
Hole for the
rear entry (not
limited to the
wall only)
Screwdriver
Wirebox
Mounting
Template
8*40
Expansion
bolts
12

Step 3
Secure the EV Charger to
the Mounting Bracket
Find the hole for the knock
out located on the back on EV
Charger.
Use the 4pcs M6*8 screws
toxtheEVChargertothe
mounting bracket as the
picture shows.
Step 4
Wiring
Note: Consult with your local
electrician or refer to your
local code for proper wire
sizing appropriate for the
currents in your EV Charger.
Note: It is the installer’s
responsibility to identify
whether additional grounding
is required to ensure that
local restrictions are met.
Grounding must be installed
at the power source and not
at the cable entry to the EV
Charger.
As the picture on the left
shows,usethescrewdriverto
loosen the screws on the EV
Charger cover. Wire the cable
to the appropriate terminal.
Left hole
position Right hole
position
M6*8 bolts
Perforating like
image
Back of EV Charger
Wiring terminals
13
hole on the
through the
Cable
wall and
connect to
the black
hole of EV

5.2. Reinstall the sealing cover and Turn Power ON
• Use a screwdriver to tighten the screws on the sealing cover.
Ensure to tighten screws to these specification: 1.5N·M~1.8N·M
torque.
• Recommend to install a circuit breaker: 40A/2P 30mA.
5.3. Emergency Shutdown Button
• Located on the side of the Amstel 7.4kW is a larger red
emergency shutdown button.
•Intheeventofanemergencyoranotherdangerousscenario,
you must press down on the emergency shutdown button.
ThiswillimmediatelyceaseallpowerowingthroughtheEV
Charger.
• Do not use this feature to end a charging session.
•ToresettheEmergencyShutdownButton,youmustrotateit
clockwise until the button springs back up to the ready position.
WARNING:Becarefulofelectricshock!Beforeuse,use
avoltmetertoconrmthatthereisnovoltageonthe
power supply line or terminal to ensure that the power
hasbeencuto.
14

5.4. Leakage Test
• Located just below the Emergency Shutdown Button is a small
red button which is designed to perform a Leakage Test to
ensure that there are no faults within the EV Charger.
•Whenpressingthisbutton,theMCUwillcontrolthecircuitto
send out a small 10mA analog DC leakage to the Type ARCD to
ensure it is functioning properly.
• This action should be carried out each time you are about to
start a charging session.
15

6.1. Power ON Checking
6. Operating Status
NO. Check Content
1Check and ensure the circuit breaker for the EV Charger is correctly
selected.
2ConrmthatthereisnoshortcircuitbetweentheACoutputL/N/PE
of the charging.
3ConrmthattheEVChargerisnotconnectedtothevehicle.
4Ensure the circuit breaker is closed.
5Thechargerispoweredon,andthepower-on-self-checkis
completed in about 10 seconds.
6
Afterthepower-on-self-checkiscompleted,observethestatusofthe
LEDindicator.Normalstandby:GreenashinglightON.Equipment
failure: Yellow light always ON.
6.2. LED Light Instructions
EV Charger LED Light
No Power Lights OFF
Power ON Checking Green,Yellow,RedLightsFlashing
Stayby Green light ON
Plug the connector but do
not activate with RFID card
(the vehicle is not ready for
charging)
Streaming lights from up and down in a circle.
Plug the connector but do not
activate with RFID card (the
vehicle is ready for charging)
Fast streaming lights going up and down.
Plug the connector but do
not activate the RFID card
(the vehicle is not ready for
charging)
Streaming lights from up and down to middle
Charging Streaming lights from the middle to up and
down
Emergency Stop Protection Yellow light ON
CP Signal abnormal YellowandredLEDflickeralternatively(1
second intervals)
16