Installation and User Guide
EV Charger | 202205.NH www.syncev.co.uk
SAFETY INFORMATION
Warning: The supplied SyncEV BG charger is manufactured to be safe
without risk provide they are installed correctly, used, and maintained
in accordance with the manufacturers recommendations and installed
by a competent electrical installer in accordance with national and local
regulations and legislation applicable at the time of installation, eg:
BS7671:2018 amendment 2.
The single phase EV charger should be connected to a 230V/240V
nominal AC supply. The supply should run from a dedicated 40A circuit
breaker. We recommend the use of a Type B curve circuit breakers. The
EV charger features an integral 30mA type-A RCD with 6mA DC leakage
detection and therefore an external RCD is not usually required:
1. For cables without earthed metallic covering installed in walls or
partitions at a depth of less than 50mm and also within walls and
partitions with metal parts, and not protected by steel conduit or similar
then RCD protection is required. This can be achieved by using the
BG IP65 EV protection enclosure (CFEV1A) when mounted next to the
existing consumer unit as it includes a double pole 40A 30mA Type A
RCD device to protect the circuit. This can be used if the cable has no
mechanical protection where it passes through walls and partitions and
if the cable is buried within the ground before reaching the EV charger.
This will be in compliance with the current BS7671 Amendment 2
Wiring Regulations.
2. If the cable is clipped directly to the surface of a wall and does not
pass through a wall or partition to the EV charger then a standard B
type 40A MCB may be installed into the Consumer unit, however RCD
protection may be required for other reasons such as if it forms part of
a TT system and the earth fault loop impedance values cannot be met.
This will be in compliance with the current BS7671 Amendment 2 Wiring
Regulations.
To conform with BS 7671, on occasions a double pole MCB/RCD
or other means of isolation may be required.
Important note: A DC Leakage fault in the vehicle may “blind”
a type “AC” RCD and render it ineective, never feed any EVSE
from an upstream Type “AC” RCD.
EARTHING REQUIREMENTS
The supplied EV charger features an on-board safety monitoring system
to detect low or high voltage supplies and potential earth-neutral
faults, this in accordance with regulation 722.411.4.1 (iv) of BS7671
2018 (Compliant on single phase supplies only). If such a condition is
encountered the charge cycle is ended or prevented and the EV charger
indicator goes red and eectively becomes a double insulated (class II)
device. The vehicle becomes isolated from incoming supply and poses
no risk to touch. This feature removes the requirement for an earth
electrode where it may be ineective or introduce further risk.
The EV charger may be connected directly to a TN-C-S (PME) earthing
system without any special arrangements. It remains the responsibility
of the installer to conduct a risk assessment of the immediate area to a
range of 10 meters (equipotential zone) to ensure no other conductive
metal xings pose risks (mixture of TT/TN-S and TN-C-S), this is
important where cable length may enable charging inside or outside
of a building/ garage where the vehicle is within touch distance.
Where certain conditions dictate an earth electrode must be used it
shall be independent from the distributors earth system with no direct
interconnection (the incoming supply SWA protective earth should be
isolated from the housing and/ or earth electrode). The electrical installer
shall install a suitable electrode complete with termination housing and
covers where appropriate, warning labels should be visible and close
to the unconnected SWA protective earth eg inside the charger.
The earth connection shall be made from the electrode to the charger
via copper conductor earth wire of an appropriate CSA for the
installation. The earth wire shall be installed in conduit where there
is a risk of mechanical damage or UV exposure. Additional note:
SyncEV BG recommend Earth electrode impedance to be <100 ohms.
SURGE PROTECTION
Guidance on requirements for surge protection devices given In
BS7671: section 443.
The EV charger is protected against transient over voltages (+/-2kV
Line-Earth and +/-1kV Line-Line as a requirement of EN 61000-6-1),
a direct lightning strike carries a current of 30~ 200kA the EV charger’s
internal protection would provide little or no protection in such an
event, likewise nor would an SPD rated less than 30kA. If life support
equipment or business operations could be aected by a lightning strike
central SPD protection is advised if it does not already exist.
The guidance on risk calculation in section 443.5 of BS7671 in most
cases is not possible due to unknown location of any SPD already
tted, length of cables to calculate LP etc, it is therefore recommended
a common sense approach is used on choice of SPD (or if required).
ISOLATION AND SWITCHING FOR SAFETY
AND MAINTENANCE
To ensure that the EV charger can be “turned o” to enhance security
and enable maintenance activities, a double pole isolator (or DP RCD or
RCBO) suitably rated must be installed within the customer’s property.
An isolator switch is a mandatory requirement for “new builds”, but
optional for existing dwellings (at customer’s request), the switch should
be mounted at a height of between 500mm and 1500mm above nished
oor level to comply with regulations. The switch should be rated at
45 Amps. All installations must comply to BS7671: 2018 regulations
INSTALLATION
The EV charger is suitable for installation inside and outside on a solid
wall or structure. The installer should consult with the building owner
to establish their preferred installation location. This should take
into consideration the length of charging cable and risk of vehicle
impact etc.
It is recommended the charger is installed at a height of
500mm-1500mm as per building regulations BS8300:2018.
Ensure suitable xings are used depending on the mounting surface.
To avoid unnecessary dust inside the enclosure, it is recommended
to use the included xing hole template drill the surface, before tting
the enclosure.
Ensure installation wall has been checked for electric cabling or
pipework with a suitable detector.
NOTE: if any groundworks are required e.g cable trenching or earth
electrode tment, it is advisable to check if underground services
could be present before commencement. Plans may be available at:
www.linesearchbeforeudig.co.uk (free to domestic users)
The EVcharger is suitable for bottom or rear cable entry, if using rear
cable entry ensure the blanking plug supplied is tted to the open
bottom cable entry hole. If using SWA cable the included 25mm
compression gland is NOT suitable, and an alternative gland will be
required. Do not drill alternative cable entries into the charger housing.
SyncEV BG recommends using EV-Ultra™ – Power & Data Combined
cable on installs that require a CT clamp to use the chargers dynamic
load management capabilities. Please see:
www.doncastercables.com/uploads/EV-Ultra_Datasheet.pdf
If Load Balancing is required, we suggest of the SyncEV BG CT clamp,
EVA120CT1. This should be tted around the incoming power to the
main fuse and the correct max load (A) to be entered during set up and
installation steps.
All of the cables that are to be connected into the supply connector
should have their insulation stripped back 18-20mm. Connectors
supplied are suitable for cables of 4-6mm2and suitable for solid
and stranded cores.
