EVBox BusinessLine series User manual

Installation Manual
EV-Box Charging Station
BusinessLine Model
Ver. 4 rev. 3
25-05-2016

2
Table of contents
1. Safety regulations...............................................................................................................3
Transport and storage ............................................................................................................................3
2. Product description............................................................................................................4
General ......................................................................................................................................................4
Online – Model with modem .................................................................................................................4
Safety .........................................................................................................................................................4
Mode 3 Controller ...................................................................................................................................4
Operation..................................................................................................................................................4
Warranty....................................................................................................................................................4
3. Control..................................................................................................................................5
Charging stations with RFID reader......................................................................................................5
Start charging .........................................................................................................................................5
Stop charging:.........................................................................................................................................5
Charging Stations without RFID charging card / modem .................................................................5
LED ring indicator ....................................................................................................................................6
Note for installers....................................................................................................................................6
4. Installation ...........................................................................................................................7
Safety requirements................................................................................................................................7
Location.....................................................................................................................................................7
Power supply cable..................................................................................................................................8
Wall mounting ..........................................................................................................................................8
Pole mounting..........................................................................................................................................8
Wall Mounting Bracket ...........................................................................................................................9
Power Supply cable .................................................................................................................................9
Connecting charging station..................................................................................................................9
Finishing installation............................................................................................................................. 10
Maintenance .......................................................................................................................................... 11
Product and environmental characteristics ..................................................................................... 11
5. Installing the modem externally ................................................................................... 12
6. Adding extra connectors (Satellites)............................................................................ 13
7. Technical Specifications.................................................................................................. 14
8. Troubleshooting .............................................................................................................. 15
9. EU Declaration of Conformity ....................................................................................... 17

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1.
Safety regulations
WARNING: RISK OF ELECTRIC SHOCK.
• Please read the documentation provided with the charging station to acquaint yourself
with the safety instructions and directions before installing or using the charging station.
• The charging station is designed and tested in accordance with international standards.
• Use this charging station for charging all mode 3 compatible electric vehicles only. Refer to
your vehicle owner’s manual to determine if your vehicle is suitable.
• This charging station must be used exclusively for the purpose intended.
• Do not operate the charging station if it or the charging cable is physically cracked, frayed,
other otherwise visibly damaged. Please consult the stations owner and/or an electrician right
away.
• This charging station contains no user serviceable parts. Please consult EV-Box or a certified
electrician for more information. Do not attempt to service the charging station yourself.
• These directions for use are valid for different models of the charging station. It is possible
that a number of features are described that are not applicable to your charging station.
• This charging station may only be installed, maintained and repaired by qualified personnel.
Incompetent installation or repairs may result in danger to the user.
• Do not install a faulty charging station.
• For instructions on installation, see Chapter 4.
• The charging station is used in combination with a power source. Always switch off the
power supply before carrying out maintenance. The charging station contains no internal
components that can be maintained by the user. The “0n”/ ”Off” and “green” position of the
charging station's main switch does not guarantee that the system is disconnected from the
power source and does not safeguard against the voltage applied.
• Do not switch on the charging station if the covers are not in place.
• Ensure that the equipment is used under the correct operating conditions.
• Do not use explosive or readily flammable substances in the vicinity of the charging station.
• Persons unable to assess the dangers should not use the charging station.
• Do not direct powerful jets of water onto the charging station, and never operate with wet
hands.
• Ensure that the charging cable is
not kinked or jammed
!
• Make sure the charge cable is positioned so it will not be stepped on, driven over, tripped
over, or otherwise subjected to damage or stress.
• Ensure that the charging cable cannot come into contact with heat sources.
• Always pull on the plug's hand grip, and never on the cable.
•
While charging the charging cable must be completely unwound and connected to the
vehicle without overlapping loops!
This is to avoid the risk of the charging cable overheating.
• In the event of danger and/or accidents, have the charging station disconnected
immediately by a competent person (electrician).
• Please carefully read our instructions and the vehicle instructions in your owner’s
handbook before charging your electric vehicle.
Transport and storage
Ensure that the main power source has been disconnected when storing or transporting the
charging station.
No liability can be accepted for damage during transport if the charging station is
transported in anything other than the original packaging.
Store the charging station in a dry environment. The storage temperature must be between
–25°C and +60°C.

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2.
Product description
General
The EV-Box charging station (Figure 1) is compatible with all mode
3 electric vehicles. The charging station is meant for both indoor
and outdoor use. Usage of the charging station is allowed in an
ambient temperature between -25°C and +60°C. The charging
station is connected to a central system for registration of the
kWh charged.
Online – Model with modem
The smart charging station is designed with a RFID card reader, a Kilowatt hour meter and a
GSM/GPS/GPRS modem. These components together provide for the authorization and
communication of the charging session procedure with the central system (BackOffice) for
processing and settlement of the transactions as required.
A GSM link with the charging
station is essential for the charging station to work properly.
However, a good link cannot
always be obtained in enclosed spaces, for instance a closed or underground car park. In
cases like this, the modem should be positioned outside the charging station along with the
GSM/GPS antenna and connected to the charging station. See Chapter 5.
Safety
There’s no power on the socket of the charging station as long as no plug is inserted and it has
not been started up by the RFID card. In the models with BXXXX-X
1
00 there is a circuit breaker
and a residual current device (type A - 40A-30mA) for each socket. A type B residual current
device is available as an option (Table 7, Technical specifications). Models with BXXXX-X
0
01
do not have residual current devices or circuit breakers. All models feature a circuit breaker
(C6A) for the control circuit.
Mode 3 Controller
The Type 2 socket is connected to the Mode 3 Controller and locking module in accordance
with IEC-61851. This means that the charging station is constantly checking for the presence
of a ground connection. In addition, the current is only switched on once a supported
charging cable has been correctly connected to both the charging station and the vehicle
and the presented RFID card is authorized.
Operation
A charging session may be started by holding an authorized RFID card (Mifare Classic,
13.56Mhz) against the front of the charging station at the round surface showing a hand
with a RFID card (Figure 1). If the charging station is not connected to a vehicle and/or is not
activated by the RFID card, there is no voltage on the socket.
Warranty
EV-Box warranties its equipment and software against errors and defects in materials and
workmanship for twenty-four (24) months from the date of delivery, during which time it will
use its best efforts to repair the errors, if any. However, any such problems encountered out
of any causes that are not attributable to EV-Box, shall be for customer’s risk and account.
Figure 1: BusinessLine

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3.
Control
Charging stations with RFID reader
Start charging
1. Use your charging cable to connect the EV-Box station to your vehicle.
2. Present your charging card (RFID Card) to the card reader.
The charging station will react with a tone. This indicates your card is being validated. It’s
possible that the LED ring will flash yellow for a couple of seconds.
3. The transaction will start automatically (LED ring is Blue).
Stop charging:
1. Present your charging card (RFID Card) to the card reader.
2. The charging session stops (LED ring will be GREEN or Off)
3. Unplug the charge cable from the EV-Box and your vehicle.
Charging Stations without RFID charging card / modem
For charging stations that don’t operate with a RFID card, there will be either a key switch (or
pushbutton) or with an AUTO-START. With the key switch you turn the key or push the start
button to start or stop the transaction. For AUTO-START just plug the charging cable into the
vehicle and the charging station to start the transaction. Unplug the charging cable from the
vehicle to stop the transaction.

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LED ring indicator
The socket is surrounded by an LED ring. It shows the status of the charging station, so that
you can see which mode the charging station is in (see Chapter 8). A blinking yellow LED-ring
(once every second) indicates a paused charging session. This is only possible in a Hub-Satellite
configuration (see chapter 6). Charging automatically resumes when power becomes
available. For charging stations that don’t operate with a RFID card the Led ring is off in stand-
by mode. For RFID card operated charging stations the LED ring is green in stand-by mode.
Note for installers
Once the installation has been done, the LED ring indications can be tested with an
appropriate test equipment or with a service card. These are available as an option.
Flashing RED
RED
Green or OFF
Flashing GREEN
YELLOW
BLUE
Stand-by or
ready for use
Your charging card
is being verified
Faulted, please
contact the
service desk
Awaiting
communication from
your vehicle or vehicle is
fully charged
Charging
Your charging card is
not authorized to start
a session

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4.
Installation
Safety requirements
Connecting and installing the charging station must be done by a qualified technician.
The owner or user is responsible for the installation, operation and maintenance of
the charging station, whereby both the law regarding the safety of persons, animals and
property must be observed, as well as the installation instructions in force in the country of
use.
Read the installation instructions before you start work on the installation.
The charging station complies with Safety Class I (the charging station is supplied with
a ground terminal for safety) and voltage Category III.
The incoming and/or outgoing terminals for the alternating current are fitted with an
uninterruptible grounding for safety. If it is plausible that the ground safety has been
damaged, the charging station must be taken out of operation and secured against being
activated accidentally.
Ensure the correct supply voltage/power and ensure that the meter cabinet is made
properly safe.
Each charging station should be protected by a residual current device Type A
(>30mA/AC). The residual current device must switch off all the phases connected and
the “N”. A residual current device Type B with direct current fault detection >6mA/DC is
necessary for certain electric vehicles. See the vehicle’s owner’s manual. The applied RCB must
comply with local law and regulations.
Never replace a safety component by one of another type.
• All components were correctly connected and operationally tested before dispatch of
the charging station.
• Before switching on the charging station check that the power source available
corresponds to the configuration settings of the charging station as described in the
manual and that all the cables in the charging station have been properly connected.
• Ensure that the equipment is used under the correct operating conditions.
• Never operate the charging station in wet or very dusty surroundings.
• Ensure that there is always adequate free space (at least 20cm) around the charging
station for ventilation purposes.
Location
Position the charging station, where possible, in surroundings not subject to extreme sunlight
and where damage from outside cannot occur. The charging station can be installed on a
stainless steel pole, which can be ordered with the charging station, whereby the supply cable

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enters through the bottom of the pole. The other option is to mount it onto a sturdy wall
between 90cm and 120cm from ground level. The supply line is fed through a cable gland at
the lower side of the aluminium base plate or the hole on the back side of the base plate. The
wall must be able to bear a load of 40kg.
Power supply cable
The charging station is furnished with one or two 16A or 32A sockets, depending on the type.
Some charging stations with two sockets are equipped with an internal safety. These charging
stations must be connected with ONE power supply cable fitted with a properly dimensioned
circuit breaker (type c) in the meter cabinet
For charging stations without internal security each socket must be fitted with its own power
supply cable, each fitted a properly dimensioned RCB taking in account de-rating according to
IEC61439-2. The appropriate wire gauge of the supply cable depends on the power rating and
the distance between meter cabinet and charging station. The voltage drop must not exceed
5%, it is advisable to take into account a maximum allowable voltage drop of 3%. The
maximum wire gauge that can be fitted is 10mm2.
Wall mounting
Mount the charging station on a flat surface with the bottom of the charging station between
70cm and 110cm above ground level. At least 20cm of free space around the station must be
available for ventilation purposes. The wall must be able to bear a load of 40kg. The power
supply cable can be inserted either through the bottom gland of the charging station or
through the hole on the back side of the base plate . For charging stations equipped with an
attached charging cable the power supply cable must be inserted via the hole on the back
side of the base plate.
Pole mounting
Our charging stations can be mounted on a pole in the
ground.
To this end EV-Box offers its’ CombiPole (art. no. 290150 –
Figure 2). Our double BusinessLine stations can be mounted
directly on the CombiPole without additional provisions.
Our single BusinessLine stations are to be attached to our
CombiPole by using the provided BusinessLine Adapter Kit
(art. no. 290165 – Figure 3). The BusinessLine Adapter Kit is
provided with a separate installation manual.
Important NOTE:
Only single BusinessLine charging
stations with a permanently attached charging cable can be
mounted on the CombiPole. This is done by using the
BusinessLine AdapterKit. A pole mounted version of the
double BusinessLine station with permanently attached
charging cables is not available yet at the time of writing.
Figure 2 / 3 / 4
2
3
4

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In the ground:
To install the pole itself dig in the pole to 60cm below
ground level and align vertically (Figure 5). Ensure that the holes for
securing the charging station are in the correct position with respect to
the relevant parking place(s). The pole is provided with anchor blades
of 300 mm x 300 mm. Place the BusinessLine base unit on the Adapter
Kit’s (Figure 4) and tighten the nuts evenly with a hex key so that the
base part is not deformed. The charging stations’ front cover needs to
lock in tightly on the base unit to ensure IP54 level protection.
On foundations
: A pole is available as an option with four bolts for
securing to foundations or on a concrete floor. The base plate measures 195mm x 195mm
with four holes for attachment. The foundation must be able to bear a load of 40kg.
Wall Mounting Bracket
The charging station can also be installed on a wall bracket. The bracket is attached to a plate
measuring 195mm x 195mm with four holes for attachment. Install the bracket at a height of
90 – 120 cm. The wall/foundation must be able to bear a load of 40kg.
Power Supply cable
Lead the supply cable through the slot in the bottom of the pole/bracket
and ensure that it protrudes at least 50 cm above. Ensure that the power
supply cable has sufficient room so that small movements of the
pole/bracket do not lead to a break in the supply cable.
Connecting charging station
• During installation disconnect the power supply both in the
distribution box and by means of the operating switch in the
charging station.
• Accidental switching on of the current during installation must be
prevented. The installation technician must take adequate measures
to ensure this.
• Protect the working environment against unauthorized persons and
inform the surrounding area about the work, for example set up
caution tape or warning notices.
• Use the correct tools and provide resources and protection measures.
Disassemble the cover(s). These are attached to the underside of the
charging station with two hex socket bolts (Figure 3). For this you will need
the Hex key (5mm) provided. Slide the charging station over the pole
(Figure 4).
1. Be sure not to trap any lose wires during the process.
2. Check whether the pole/bracket goes far enough (40 cm) into the
charger and rests on the upper support.
3. Ensure that the power supply cable is passed through and insert it into
one of the holes on the pole, so that it can be easily connected.
4. Connect the power supply cable(s) to the main switch(es) or installation
block.
5. Hold the power supply cable in place with a zip-tie (for strain relief).
Figure 5: Installing a pole
Figure 6: Positioning the
hex socket bolts
Figure 7: Installing
charging station
Figure 8: Securing the
ground

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6. Holes have been pre-drilled in the pole to attach the charging
station by means of the M6 bolt supplied.
7. Connect the pole to the ground with the ground cable and the M6
bolt + washer supplied to the lowermost tube terminal. (Figure 5).
8. Now tighten the tube clamps that have been pre-mounted. For this
use the two M10 socket spanners (Figure 6).
9. Check all plug connections (on the sealed printed circuit with RFID
reader) by firmly pressing the connectors.
Finishing installation
1. Ensure that the circuit breaker / residual current device in the meter
cabinet is in the “On” position and that the main switch in the charging
station is off.
2. Check the resistance value of the ground. This depends on the user settings. Certain EVs
may need a special grounding resistance. Refer to your EV owner’s manual. If grounding is not
sufficient a grounding rod must be implemented closest to the charging station.
3. Hang the covers onto the frame by inserting the top into the edge
at the top of the frame and hinging them downwards (Figure 7).
Please note! Make sure that each cover locks into the frame
properly and that the rubber pads are in place in order to
guarantee IP54 protection.
4. Check also that the cover locks securely into the open notch at the
bottom of the frame.
5. Switch on the supply current at the main distributor / meter cabinet.
The charging station will now carry out an automatic test. The LED ring
around the socket shows the following color indications during the test
(max. 60 seconds)
a)
RED flashing
: Booting, running test protocol and looking for
connection to the network.
b)
GREEN or OFF:
Stand-by, ready for use. (LED ring is off for
charging stations with pushbutton or autostart, for RFID
operated charging stations Led ring is green in stand-by
mode).
6. Carry out a functional test on both connectors in accordance with
the specifications of the charging station. For this use a test box for
charging stations supplied as an option.
7. You can now tighten the cover bolts at the bottom using the Hex
key. (
TIP
: When the charging station is mounted on a wall the space for tightening these cover
screws is very limited. use a small ratchet with a Hex key bit – 5mm)
Figure 9: Tube terminals
Figure 10: Installing covers