Guidelines for Electricians Installing a Charging Station for Electric Cars

8. October 2015 Matthias Suttner Everything About Charging Your Electric Car Tags: , , , 0 Comments

When installing a charging station for electric cars (known as EVSE – Electric Vehicle Supply Equipment in the trade jargon), you have to follow special instructions which go beyond the well-known VDE standards (“Installing high-voltage systems”). The requirements are described in detail in DIN VDE 0100-722 (Requirements for special installations or locations – Supply of electric vehicle; German implementation HD 60364-7-722:201) and apply to every connection point. A connection point can be both a charging station and a standard domestic socket which is used to charge an electric car. We have summarised the most important points which you must follow when installing a charging option for an electric car for you in a set of guidelines for electricians to download – from the basic requirements for installing a charging station for an electric car through to selection of the appropriate site for it.

The Right Charging Station for Your Customer

As an electrician, you know that the domestic socket is not the best choice for charging an electric car over the long term: advantages of a charging station include the shorter charging time and greater ease, along with significantly higher performance – future-proofing goes hand in hand with this, as electric car batteries are getting bigger and bigger. The charging cable which is supplied as standard for the socket (mode 2 charging cable) stays in the electric car when it is on the road. For everyday use, it only takes a single step to charge the electric car at the charging station without getting your hands dirty. You will find what you need to take into account when selecting the right charging station in the blog post “6 things which I have to take into account when buying a charging station for my electric car”.

Checklist: 5 Points Which Have to Be Complied With when Installing a Charging Station

The following graphic shows a schematic view of installation from connection to the grid through to the charging station: Installation of the connection to the puplic electricity through to charging station

A    Grid B    Fuse box C    Lightning protection (optional) D    Main/back-up fuse E    Meter F    Residual current device: type A RCD, type B RCD or alternatively type A RCD with EV direct current detection G   Circuit breaker: tripping characteristics C H    Own electric circuit I     Charging unit (according to VDE 722)

Are the Charging Atation and Length of the Charging Cable from the Charging Station to the Electric Car selected in accordance with the Installation Site (inside or outside)?

  • The installation site must be in accordance with the charging station's protection class (e.g. IP 54, see installation manual)
  • Most charging stations are suitable for both indoor and outdoor use
  • We recommend weather protection to maintain the appearance of the charging station
  • Take into account the customer's preferred parking direction and the position of the socket connection on the electric car when it comes to the length of the charging cable
  • The charging cable should not present any tripping hazards when it is plugged in

Is one Circuit Breaker present for each Individual Electric Circuit?

  • Every charging point must be connected via a separately fused cable
  • The circuit breaker (fuse) should be chosen according to the cable's load capacity and the charging station's charging power
  • The manufacturers of our charging stations recommend tripping characteristics C

Is one RCD present or integrated per Charging Station?

  • Each charging station must be fused using an independent RCD
  • Please note that some charging stations already have an integrated RCD
  • An appropriate RCD should be used depending on the charging power and on which electric cars are to be charged at the charging station
  • A type A RCD is sufficient if the following three requirements are met:
    • Single-phase connection
    • The electric car being charged is guaranteed not to cause smooth DC residual currents (see manufacturer's instructions or simply ask The Mobility House's experts)
    • The owner of the charging station ensures that no electric car on which smooth DC residual currents can arise when charging uses the charging station
  • A type B RCD or type A EV with DC residual current detection is required if the following points are true:
    • Three-phase connection
    • Smooth DC residual currents may arise on the electric car being charged during charging or it is not possible to rule out use of the charging station by an electric car on which smooth DC residual currents can arise during charging
    • The Mobility House recommends charging stations with an integrated residual current device or one of our safety packages (charging station and RCD in the package), in order to provide a cost-effective and uncomplicated solution to the above problems

Are Lengths, Cross Sections and Laying Systems for Cables designed for 22 kW (32 A)?

  • We recommend that the cable is already designed for the future for 22 kW charging power (5-core cable) irrespective of the charging station or the electric car
  • Advantage: little effort is needed to increase the charging power at a later stage (electric cars will have higher charging power and battery capacities in future)
  • The cables are to be sized according to the following 4 criteria: laying system, voltage drop, cable length, required power or strength of current
  • We recommend using a cable with a cross section of 2.5 mm² or larger for a charging current of 16 A
  • Practical tip: we recommend flexible cables for connecting the charging station to enable easier handling, particularly where there are large cable cross sections

Is Future-Proofing for intelligent Charging Stations taken into Account?

  • We recommend a data connection at the charging station's installation site
  • If no mobile data connection is possible, an LAN cable should be installed
  • Advantage: charging station can be linked to billing systems and home management systems (e.g. for photovoltaic (PV) controlled charging)
DOWNLOAD – Guidelines for Electricians as a Checklist

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Our experienced service team will be delighted to answer all your questions about charging your electric car.

Phone: +49 89 4161 430 70 (Germany)
Phone: +43 720 116 500 (Austria)
Phone: +41 43 508 2731 (Switzerland)
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