Ratio Electric SOLAR BOX User manual

Ratio Electric
Solar Box
MANUAL

Manufacturer
Ratio Electric B.V.
Ambachtsstraat 12
NL – 3861 RH Nijkerk
The Netherlands
Tel. [phone]
[email protected]
www.ratio-electric.com
Thank you for choosing
Ratio Electric Solar Box
UK English - Original
EV081 - V00-08 - 01/2022

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Preface
About this document
This manual contains technical descriptions and instructions for the following product:
Category of product Charger for Electric Vehicles
Product name EV Solar Box 32A
Art. No. 378xx
Hardware version* Charger4-kWh-HB-1.2
Serial number
* This is marked on the PCB of the charger.
Write down the serial number of your product in the table above for future reference.
This manual contains all instructions and safety information for installation, commissioning,
use and maintenance of the product.
This manual is intended for:
•the qualified technician who installs the product;
•the end-user who uses the charger;
•the product owner who maintains the product.
Original instructions
This manual has been translated into multiple languages. The original manual is written in UK
English. All other language versions are translations of the original manual.
Copyright
The content of this manual is protected by copyright and other intellectual property laws.
The content of this manual may only be copied, modified, reproduced, translated with
express written permission from the manufacturer. This manual may only be published,
transmitted, displayed or made available to a third party with express written permission from
the manufacturer.
Disclaimer of liability
Ratio Electric B.V. cannot be held responsible for personal injury, damage to the product
or property damage caused by incorrect use, foreseeable misuse or failure to follow the
instructions in this manual. This also applies to unauthorized modifications of the product and
the use of non-approved spare parts, tools or accessories.
Ratio Electric B.V. reserves the right to modify this manual without notification beforehand.

4Ratio Electric Solar Box Manual
Table of contents
1. Safety 5
1.1. Symbols and labels 5
1.2. Intended use 6
1.3. Reasonably foreseeable misuse 6
1.4. Qualification of personnel 6
1.5. Personal protective equipment (PPE)7
1.6. Safety precautions 7
2. Description of the product 8
2.1. Charger components 10
2.2. Sensorbox components 10
3. Technical data 11
3.1. Nameplate/Marking 12
4. Transport and storage 12
4.1. Transport 12
4.2. Storage 12
5. Installation 13
5.1. Preparation 13
5.2. Install the power cable in the
consumer unit 14
5.3. Install the sensorbox in the
consumer unit 15
5.4. Mount the charger to a wall 18
5.5. Connect the power cable to
the charger 20
5.6. Install the data cable in the charger 24
5.7. Install a data cable between
two chargers for power sharing 27
5.8. Checks before finishing the
installation 31
5.9. Finish the installation 32
6. Commissioning 34
6.1. Initial configuration of the charger 34
6.2. Testing 36
7. Use 37
7.1. Display overview 37
7.2. Start charging 38
7.3. During charging 40
7.4. Stop charging 40
8. Settings 41
9. Troubleshooting 42
10. Maintenance 43
11. Service 44
12. Warranty 44
13. Disposal 45
Appendix 1. FCC compliance 46
Appendix 2. EC Declaration of
conformity 47

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1. Safety
Please make sure you have fully read and understood the instructions in this manual before
you start installing or using the product. If you fail to follow the instructions from this manual
you can put persons, surroundings, the environment and the product at risk. Store this manual
in an accessible place near the product for future reference.
Always comply with the information, such as labels and the nameplate, attached directly to
the product and keep the information in a legible condition.
Always comply with any applicable laws and regulations that have not been accounted for in
this manual.
1.1. Symbols and labels
1.1.1. Safety warnings
This manual contains safety warnings that may result in injury when ignored. Each safety
warning is indicated with a signal word. The signal word corresponds with the level of risk of
the described hazardous situation, see the table below.
Signal word Risk of injury Result when instruction is ignored or not followed
correctly
6WARNING Medium Could result in death or serious injury
6CAUTION Low Could result in minor or moderate injury
Safety warnings at the start of a section, apply to the entire section.
Safety warnings that refer to a particular sentence or procedure step are embedded in the
running text.
1.1.2. Notices
Messages that are not hazard-related are indicated with the signal word NOTICE. These
messages do not have a safety alert symbol.
Signal word Meaning
NOTICE Could result in damage to the product when instruction is ignored
or not followed correctly
Note Additional information or emphasis on an instruction

6Ratio Electric Solar Box Manual
1.2. Intended use
The Ratio Electric Solar Box is a private charger intended to charge electrical vehicles using
power from solar panels and household power grid. The product can be operated indoors and
outdoors.
The product must only be operated within its performance limits and under the permitted
ambient conditions, as stated in the technical specifications in chapter 3.
The product can be mounted flush to a wall, or to a separately available pole for pavement
or soil.
Safe use of the product is only guaranteed if it is used as intended.
1.3. Reasonably foreseeable misuse
The following is considered foreseeable misuse:
•Use in an environment that varies from or exceeds the given environmental conditions.
•Use that varies from or exceeds the given operating conditions.
•Failure to comply with the instructions in this manual.
•Failure to eliminate faults, malfunctions or defects of the product that impose safety risks.
•Failure to carry out the inspections and maintenance operations as described in this
manual.
•Unauthorized removal or modification of parts or safety devices of the product.
•Use of spare parts or accessories that have not been approved by the manufacturer.
•Operation in a flammable and/or explosive environment.
•Operation in closed-off or poorly ventilated rooms.
1.4. Qualification of personnel
Only authorized technicians are allowed to perform installation and maintenance of the
product. They must possess the following qualifications:
•are legal of age;
•are familiar and abide by the safety instructions and sections of this manual related to
installation and maintenance of the product;
•are familiar with and abide by the applicable local, national and international laws and
regulations;
•are able to recognize the possible dangers of the product and take the necessary
measures to protect persons and property;
•have received adequate training in the safe installation and maintenance of this product;
•have obtained authorization to access the product.

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1.5. Personal protective equipment
Wear the appropriate personal protective equipment (PPE) according to the manual of any
tools you use during installation of the charger.
Wear insulating gloves when installing wires and touching electrical components to avoid
damaging the product by static discharge.
1.6. Safety precautions
Despite the safe design and construction of the product and the prescribed protective
measures, the product possesses residual risks. This manual provides safety messages to
indicate these risks. The formatting and appearance of safety messages that are dedicated to
a particular section or sentence is explained in chapter 1.1.
Read all the safety warnings and instructions before using the product. Failure to follow the
warnings and the instructions may result in electric shock, fire and/or serious injury.
6WARNING
•This device should be supervised when used around children.
•Do not put fingers into the electric vehicle connector.
•Do not use this product if the flexible power cord or EV cable are frayed, have broken
insulation, or any other signs of damage.
•Do not use this product if the enclosure or EV connector are broken, cracked, open, or
show any other indication of damage.
•Switch off the MCB in your electrical cabinet and immediately contact Customer Support
for service if at any time you think the equipment is unsafe,. Do not use your Solar Box
until the problem is identified and corrected.
•Improper connection of equipment-grounding conductor can result in a risk of electric
shock. Check with a qualified electrician or serviceman if you doubt whether the product
is properly grounded.
•Do not use this product if it does not function according to the instructions in this manual.
Seek advice from Ratio Electric, your vendor, or a qualified electrician or serviceman.
•Do not remove the charging plug while a charging session is active.
•Children should not be allowed to use this product. Do not allow children to play in or
around the product.

8Ratio Electric Solar Box Manual
6CAUTION
•Make certain the supply cable of the product is positioned so it will not be stepped on,
tipped over, or otherwise subjected to damage or stress.
•There are no user serviceable parts inside. Refer to the Customer Support section in this
manual for service information. Do not attempt to repair or service the product yourself.
•Do not operate this product if it or the supply cable or housing is visibly damaged. Switch
off the MCB in the electrical cabinet and contact your Service Representative for service
immediately. Refer to the Customer Support section in the manual for information on the
Service Representative in your area.
•Only use this product to charge electric vehicles equipped with a conductive charge
port. See the vehicle’s owner’s handbook to determinate if the vehicle is equipped with a
conductive charge port.
•Use of any adaptors is not allowed with this product.
•Only use certified type 1 or type 2 charging cables with this product.
NOTICE
•Do not drop the product and avoid bumping.
•Do not store the product in an environment that exceeds the ambient conditions as stated
in this manual.
•Do not expose the internal components product to moisture.
•Do not immerse the product in water or any other liquid.
2. Description of the product
The EV Solar Box is a Mode 3 charger for charging electrical vehicles (EV) that complies with
the IEC61851standard. The Solar Box is equipped with several features to optimise power
consumption and charging performance.
Dynamic Load balancing
The product uses a sensorbox with current transformer(s) to measure the live power
consumption of the power grid per phase and uses that information to manage the power
output to your EV. When more electrical appliances are used, the power output to the EV is
reduced to avoid overloading the power grid.

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Power sharing
If you have purchased more than one charger, you can interconnect the chargers with a data
cable and use the integrated power sharing feature to equally distribute the available power
across the chargers points using the data from the sensorbox.
The sensorbox uses up to three CT clamps, one for each phase of the main grid, to measure
the current flow of the main grid. The sensorbox is also compatible with solar panel
installations and can measure the direction of the current.
One charger is connected to the sensorbox with a data cable. This charger acts as the Main
Controller (MAIN), and manages the power for up to three Sub Chargers (SUB1, SUB2 and
SUB3).
Note: Pure Solar mode is not compatible with power sharing.
User display
The charger is equipped with a user display for easy access of charging data and for adjusting
several settings.
Charge modes
The charger has four available charge modes:
Basic The charger charges the EV using a set maximum power in Amps
(I-Max).
Note: This mode does not have a load balancing feature to prevent the grid connection
from being overloaded.
Smart The charger only charges the EV when the available power is above
the minimum set power in Amps (I-Min) and below the maximum
power that is still available on the main grid.
Note: This load-balancing feature prevents that the grid connection is being overloaded
when multiple electrical users are used at the same time in the house
Smart
(Smart Solar)
The charger only charges the EV when the available power is above the
minimum set power in Amps (I-Min smSolar) and below the maximum
power that is still available on the main grid.
If the charger is charging the EV and there is still net power
generation, the charger uses this surplus of energy to charge the car in
addition to the minimum set power.
Pure
(Pure Solar)
The charger only charges the EV when there is a net power generation
(e.g. from solar panels), that is above the minimum set power in Amps
(I-Min puSolar).
Note: Pure Solar mode is not compatible with power sharing. If you set the charge mode to
Pure Solar, power sharing will be disabled.

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2.1. Charger components
1
25 6 4
3
1User display
2Front cover ring
3Charge socket
4Left arrow button
5Enter button
6Right arrow button
2.2. Sensorbox components
1 2 3 4 75 6
1Phase 1 (L1) CT clamp input
2Phase 2 (L2) CT clamp input
3Phase 3 (L3) CT clamp input
4Mains input*
5Data cable terminal block connector
6Status LED
7CT clamp (3× for 3-phase installation)
*The mains input does not supply power to the sensorbox. It is used to determine the
direction of the measured current. The provided mains input cable must be installed on phase
1 (L1) of the main power grid and is orientation sensitive.

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3. Technical data
Product name EV Solar Box 32A
Art. no. 378xx
Charging System IEC61851, Mode 3
Cable version car connector IEC 62196, type 1 or type 2
Outlet version IEC 62196, type 2 Outlet
Power input single-phase or 3 phase, 230V-400V AC, 16A-32A
Max Power output 3,7 kW, 7,4 kW, 11 kW, 22 kW, 230V-400V AC
Frequency 50 Hz ±5%
Protection against electric shock Class I
Residual current detection DC 6mA
Dimensions 400 mm × 250 mm × 105 mm
Housing PC/ABS-VO
Weight 4 kg (incl. cable)
IP Protection rating IP54, rain-tight
Altitude Up to 2000 m.
Ambient temperature -25 °C to +40 °C
External magnetic field Not exceeding five times the earth’s magnetic field
in any direction.
Sinusoidal wave distortion Not exceeding 5%
Relative humidity (maximum value
at 40 °C)
75%
Markings CE
Ventilation Not supported
Required protection device type Type A
Required protection device rating 30 mA

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3.1. Nameplate/Marking
The product is marked in accordance with the applicable legislation requirements. The
nameplate/marking is located on the bottom of the housing, above the cable inlets.
EV SMART BOX
p/n 378xx Outlet
32 A - 400 VAC V2.15
Serial No.: 123456
1
2
3
4
5
6
7
1Manufacturer
2Product name
3Product number
4Rated input power
5Product serial number
6CE marking
7Firmware/hardware version
4. Transport and storage
4.1. Transport
Transport the product in the original packaging, or suitable replacement packaging that
provides adequate protection from vibrations, bumps, moisture, dust, and debris.
Be careful not to drop the product and prevent it from moving or bumping into objects while
transporting.
Excessive vibrations could loosen wire connections and cause the product to malfunction.
4.2. Storage
Always disconnect the product from the power supply when storing the product.
Store the product in environmental conditions within the limits stated in chapter of 3 this
manual.
Store the product in the original packaging or a suitable replacement packaging to protect
the product from moisture, dust, and debris.
Do not store anything on top of the product.

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5. Installation
5.1. Preparation
6WARNING
•The installation must be done by a qualified and licensed electrician according the local
legislation.
•The electrical installation must be free of power during the entire installation period.
•Since this charger uses circuits that reference to ground, no megging must be done after
connecting to power.
5.1.1. Check the contents
1. Open the box and remove the contents.
2. Place all parts on an empty surface to avoid losing any parts.
3. Check if all parts are present and undamaged using the overview below. In case of any
parts missing or damaged, please contact your local dealer or Ratio Electric B.V.
Ø25 mm
Level
321 4 5
q97 8
6
1Charger
2Front cover ring
3Sensorbox with connector
4Locknut for cable gland
5M25 cable gland
6Drilling template
7Current transformers (3× for 3-phase
installation)
8Mains input cable for sensorbox
9Rubber grommet for data cable
qScrew caps (4×)

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5.1.2. Required tools
•Wood screws 5×35 mm (4×)
•Appropriate wall plugs (4×) (if
applicable)
•Spirit level
•Hammer
•Screwdrivers:
- Size 3 flathead
- TX10 Torx
- Voltage tester
5.1.3. Required wiring and electrical protection
16 A 32 A
Wiring cross section 1-phase* 3 × 6,00 mm2, solid wire*
Wiring cross section 3-phase* 5 × 6,00 mm2, solid wire*
Mains Circuit Breaker (MCB) 20 A, B/C-characteristic 40 A, B/C-characteristic
Residual Current Device (RCD) 30 mA, Type A
Data cable Shielded UTP cable or 4×0,25 mm2 cable*
* max 25 m cable length
5.2. Install the power cable in the consumer unit
1. Switch off the Main Circuit Breaker (MCB) in the consumer unit to cut power to the main
grid.
2. Lay down a power cable and data cable between the consumer unit and the installation
location of the charger.
3. Install a dedicated 30 mA, Type A Residual Current Device (RCD), or use an available 30
mA, Type RCD.
4. Strip the wires of the power cable.
5. Connect the power cable wires to the dedicated RCD in the consumer unit.

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5.3. Install the sensorbox in the consumer unit
1. Mount the Sensorbox to a free location in the consumer unit.
1
(L)
(N)
MAINS
2
3
2. Plug the mains input cable into the sensorbox.
3. Plug the other end of the mains input cable into a power outlet.
Note: The mains input is orientation sensitive. If the mains plug is inserted upside down, the
measurements of the sensorbox will be inaccurate. Check the markings on the sensorbox
for the correct orientation.
1
(L)
(N)
MAINS
2
3
1
(L)
(N)
MAINS
2
3
(N)
1
(L)
(N)
MAINS
2
3
(N)
4. Check on which phase of the main power grid the power outlet is connected.
5. Place a current transformer around the same phase wire of the main power grid, between
the main fuse and the solar panel connections.
6. Insert the 3,5 mm jack of the current transformer to the L1 input on the Sensorbox.

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Note: For correct functioning of the sensorbox, you must install this current transformer
around the same phase as the power supply (L).
Note: Make sure the arrow on the current transformer points towards the entry point of
the main power grid. See the image below for more information on the correct mounting
location of the CT clamps.
CT
Clamp
Sensor
Box
Solar
Panels
1
2
3
Data to
Charging Station
Distribution
box
Main
Fuse
Net L1
L2
L3
N
L1 L2 L3
TVS
KK
L
L
N
User
User
User
User

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1
(L)
(N)
MAINS
2
3
7. Place the remaining current transformers around the other phase wires of the main power
grid, also between the main fuse and the solar panel connections.
Note: Make sure the arrows on the current transformers point towards the entry point of the
main power grid.
Note: It is crucial for the functioning of the charger that you insert the current transformers
into the correct input.
8. Insert the 3,5 mm jacks of the current transformers to the L2 and L3 input on the
Sensorbox.
1
(L)
(N)
MAINS
2
3
40 mm
9. Strip the wires of the data cable (not included).
10. Insert four wires of the data cable into the green terminal block connector.
11. Secure the wires to the terminals. Use a screwdriver.
12. Write down the colours and order of the inserted wires of the data cable.

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1
(L)
(N)
MAINS
2
3
13. Insert the terminal block connector into the sensorbox.
5.4. Mount the charger to a wall
Note: In case you have purchased the optional pole for the charger, check the installation
manual provided with the pole for mounting instructions.
150 mm
225 mm
80-100 cm
1. Tape the provided drilling template to the wall at the installation location, with the
bottom of the template about 80-100 cm above the ground.
2. Ensure the template is level. Use a spirit level.

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Alternatively
1. Hold the charger against the wall at the installation location, with the bottom of the
charger about 80-100 cm above the ground.
2. Ensure the charger is level. Use a spirit level.
3. Mark the locations of the holes in the charger housing on the wall.
4. Carefully remove the charger and lay it on a flat, stable and dry surface.
5. Drill the holes in the wall. Use an appropriate drill and drill bit.
6. Insert wall plugs, if applicable.
7. Align the charger with the holes in the wall and secure it with four 5×35 mm wood screws
(not included).

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5.5. Connect the power cable to the charger
TX10
1. Remove the five Torx screws from the housing lid. Use a size TX10 screwdriver.
2. Move the housing lid to the side to access the inner circuitry of the product.
3. Carefully remove the left cable inlet cover. Use a flathead screwdriver and hammer.