Alfen Twin 4XL NL Installation and User Manual

Introduction

Congratulations on your purchase of this Alfen charging station for electric vehicles!

To ensure a safe installation process and to fully utilise all advanced features of your new system, please read this manual carefully. Keep this manual for future reference.

Though these operating instructions have been compiled with the greatest possible care, they are subject to change and improvement. For the most recent version, please refer to https://alfen.com/nl/downloads.

Declaration of Conformity

Manufacturer: Alfen ICU B.V., Hefbrugweg 28, 1332 AP Almere, The Netherlands

Declares that the charging stations of the type Alfen Twin 4XL comply with the provisions of the following European directives:

• Machinery directive 2006/42/EC
• Low voltage directive 2014/35/EU
• EMC directive 2014/30/EU

And the following harmonised standards:

• IEC 61851-1 ed. 3 (2017) - Charging via a conductive connection of electric vehicles - General requirements, implemented at national level under: NL: NEN-EN-IEC 61851-1, BE: NBN EN 61851-1, UK: BS-EN 61851-1

Almere, 18 May 2021.

Mr. M. Roeleveld, Managing director

1. Safety and Usage Instructions

1.1 Purpose and Intended Audience

The Alfen Twin 4XL charging station is intended exclusively for charging electric vehicles, in situations with a separate grid connection or in public situations. Follow these instructions for proper use.

Installation, commissioning, and maintenance must be performed by a qualified technician (Alfen certified partner) who meets the following requirements:

• Expertise on relevant general and specific safety and incident prevention rules.
• Knowledge of relevant electricity regulations.
• Ability to identify risks and avoid potential danger.
• Awareness of these installation and operation instructions.

This manual is valid for the Alfen Twin 4XL, equipped with firmware version 3.2.2 (or higher).

1.2 General Safety

DANGER!

Failure to comply with safety rules and instructions risks electrical shock, fire, and life-threatening injury.

Use of this charging station is expressly forbidden in the following situations:

• In the vicinity of explosive or highly flammable substances.
• If the charging station is located in or close to water.
• If the charging station or its individual components are damaged.
• Usage by children or individuals not properly able to assess the risks.

NOTICE!

Alfen ICU B.V. is not liable for damages and warranties are void if:

• These installation and operation instructions are not followed.
• Used in ambient temperatures below -25°C or above 40°C.
• Improper use or handling.
• Installation or usage by unqualified staff.
• Self-installed additions or changes.
• Usage of non-Alfen manufactured or approved replacement parts.

More extensive safety information is available in relevant sections.

2. Product

2.1 The Charging Station

The charging station (outside) features:

• 1 "Charge Point Identifier"
• 2 LED/RFID-interface
• 3 RFID reader
• 4 'Quick starter' instructions
• 5 Type 2 socket
• 6 Door handle
• 7 Cylinder for distribution system operator
• 8 Cylinder for end customer

The charging station (inside) contains:

• 1 Fuses
• 2 Type A earth leakage circuit breaker
• 3 Power meter
• 4 Identification label
• 5 Work switch
• 6 Mains connection box (distribution system operator)
• 7 Main protection

Identification Label (13): Located on the inside of the charging station door, it specifies model, production date, and serial number. A smaller sticker on top provides the "Charge Point Identifier". Always have the serial number available when contacting Alfen.

The identification label details include:

• 1 Type number (platform name + last five digits of article number)
• 2 Serial number (unique Alfen number)
• 3 Day of production
• 4 Technical specifications (phases, max. current, voltage)
• 5 Article number
• 6 Maximum charging capacity

Other components (Fig. 1):

• 10 UTP (Ethernet) Connection
• 11 P1 (Smart Meter) Connection
• 12 SIM card holder
• 13 Identification label
• 14 On/off switch (4-pole)

Example Identification Label:

Warning: Before accessing electrical components, disconnect all power supplies.

Made in the Netherlands by Alfen.com. CE IP54.

2.2 Status Indications on the Interface

The Alfen Twin 4XL NL uses LEDs for status indications and user feedback during charging.

Interface Status Meanings:

• 1 Charging side indication
• 2 Charge card accepted, cable connected
• 3 Communication with vehicle, or charging complete
• 4 RFID-reader status
• 5 Active charging transaction
• 6 Error message
• 7 User steps when starting the charging process
• 8 User steps when charging is stopped

Visual indicators:

• ✔️ Charge card accepted, cable connected
• ⏳ Communicating with vehicle or charging complete
• ⚡ Active charging transaction
• ❌ Error message

2.3 Operation

Plug & Charge (General authorization without charge card):

Start: 1. Connect cable. 2. Plug into vehicle. 3. Charging begins. ✔️ ⏳ ⚡

Stop: 1. Disconnect cable. 2. Unplug from vehicle. 3. Charging stops. ⏳ ✔️

RFID (Charging station with user authorization):

Start: 1. Connect cable. 2. Present RFID card. 3. Plug into vehicle. 4. Charging begins. ✔️ ✔️ ⏳ ⚡

Stop: 1. Disconnect cable. 2. Unplug from vehicle. 3. Remove RFID card. 4. Charging stops. ⏳ ✔️ ✔️

2.4 Technical Specifications Twin 4XL NL

2.4.1 Twin 4XL NL Model Overview

Packing unit: 1 piece

Charging station package contents: Alfen Twin 4XL NL, installation manual, mounting accessories, and RFID charging cards (depending on selected options).

2.4.2 Input/ Power Supply

NOTICE!

Your installation must comply with local standards and regulations. The following tables provide recommendations for proper function, subject to preconditions. Printing errors expressly reserved.

2.4.3 Output/ Vehicle Supply

2.4.4 Protection/Integrated Components

REMARK: The charge point has a 6mA DC leakage current detection per output. Charging is interrupted if 6mA DC is detected. It will attempt to restart after 5 minutes, and if the leakage persists, it will interrupt again. This repeats up to 3 times before permanently terminating the transaction. Reinserting the cable restarts the cycle.

2.4.5 Charging and Access

2.4.6 User Circumstances

NOTICE!

The mentioned operating temperature assumes ambient temperature for a product in standard RAL7043 casing. Direct sunlight may adversely affect the temperature range. Darker colours may also affect operating temperature. Continuous operation cannot be guaranteed at extreme temperatures. The station will reduce charging current to stabilize internal temperature. Automatic temperature management may activate below maximum ambient temperature if exposed to direct sunlight.

2.4.7 Casing

2.5 Optional Factory Settings

REMARK: Settings marked with *) may incur additional costs. Default settings are displayed first.

2.6 Accessories

Concrete pedestal

• Art. 833829300-ICU
• Dimensions (H x W x D): 570 x 350 x 220 mm
• Weight: 42 kg

Metal base

• Art. no. 803828601-ICU
• Dimensions (H x W x D): 598 x 204 x 300
• Weight: 7.8 kg

Packaging (H x W x D): 50 x 295 x 620

Extra RFID card: Art. 203120010-ICU

3. Assembly and Connecting

3.1 Installation Preparation and Warnings

NOTICE!

Read these instructions carefully before installing. Alfen ICU B.V. is not liable for consequential damage due to failure to follow instructions.

NOTICE!

Installation must be performed by qualified staff aware of NEN1010 and IEC 60364 guidelines. Non-compliance can lead to injury or dangerous situations.

DANGER!

Disconnect the electric system from all power sources before installation or maintenance. Wait 10 seconds after power off before working.

DANGER!

The charging station contains live electrical components even after disconnection. Wait 10 seconds after disconnecting before beginning work.

DANGER!

Incorrect installation can result in fatal injury. Failure to follow regulations can lead to hazardous situations.

REMARK: A charging station must always be installed on a dedicated power circuit.

3.2 Assembly and Installation Requirements

Refer to paragraph 2.4.2 for safety options and required cable thicknesses.

REMARK: Wear prescribed Personal Protective Equipment (PPE) and comply with national/local standards.

Ensure the following requirements for Alfen Twin 4XL NL installation:

• Pre-protection is the responsibility of the distribution system operator (using connection box 934452501, 934452504).
• The cable route and charging station are part of a TT/TN-S system; the unit must be earthed via the main distributor or earth pin.
• Earthing the charging station is the owner's responsibility.
• Verify if the distribution system operator can provide earthing for the location.
• Install cable trajectory according to local professional standards.

REMARK: Site conditions may influence installation requirements.

REMARK: Install cables to match the maximum charging current to the station's input, assuming continuous load. Cable diameters are indicative; installers are responsible for correct selection and compliance with standards.

When selecting an installation location, consider:

• Never install in a potentially explosive atmosphere.
• Never install in areas prone to flooding without compensatory measures.
• Always comply with local technical requirements and safety regulations.
• The installation site must have a levelled and solid foundation.
• Maximum atmospheric humidity: 95%.
• Ambient temperature: -25°C - 40°C.
• Temperature difference within 24 hours: < 35°C.
• Position station so users can connect their charging cable (approx. 5 meters) without tension.
• Prevent drivers from driving over the cable.
• Prevent pedestrians from tripping over cables.

3.3 Mechanical Installation

Tools and materials for installing the Twin 4XL NL:

• Level, Shovel, Stanley knife
• Screwdriver for terminal block
• Wire stripper
• Socket set/spanners

Preparing the Charging Station:

1. Verify packaging contents against required parts.
2. On the door of the Twin 4XL NL: The charging point has a lever lock suitable for two 17mm euro profile cylinder locks.
   • Left lock: Owner of charging point.
   • Right lock: Network company.
3. Slide protection away from the lock.
4. The charger may have one, two, or no cylinder locks.
5. Open the lock with provided key(s) or passkey if no cylinders are installed.
6. Lever can be pulled out.
7. Turn the lever counter-clockwise to open the door.

Installing the Charging Station:

2. Foundation for ground mounting (with concrete or metal base):
3. Dig a 50x50cm hole, 55cm ground level depth, and level horizontally.
4. Position and level the base.
5. Place supplied cable glands and cutting glands on the sealing plate, then place at the bottom of the charging station.
6. Provide an earth electrode or earth pin, according to local regulations.

Inserting ground cable and earth cable:

3. Pass the ground cable through the conduit, concrete base, and tule in the sealing plate (refer to specifications for cable diameters).
4. The overhang from the top of the base must be at least 25 cm. Cut cable only when the station is mounted on the base due to strain relief mounting.
5. Pass the earthing cable from the earthing pin through the concrete base and swivel into the sealing plate (see figure 6).

Mounting the charging station on the base:

4. Insert the four supplied M10x80 mm threaded rods into the base sockets (see figure 6).
5. Place the gasket over the threaded ends and the sealing plate (see figure 6).
6. Tilt the Twin 4XL NL (laid on its back) onto the base, over the wire ends and power supply/ground cables.
7. Cut the cable grommet to size for a firm clamp of the power supply cable. Guide the cable through the base plate mounted in the station. Pull the power supply cable outside the station to fit the strain relief.
8. After mounting strain relief, guide the power cable back into the station/base, ensuring the prescribed 25cm cable length remains inside.
9. Fasten the charging station with the included 4 x M10 nuts (with lock and V-rings).
10. Secure the station to the base with 4 x M10x80 mm studs on the base.

3.4 Electrical Installation

WARNING

Read and follow all safety instructions in this manual!

DANGER!

The electric system must be entirely disconnected from every power source before installation or maintenance. Wait 10 seconds after switching off power before continuing.

1. Remove sheath from power cable with a Stanley knife and from loose wires with a wire stripper.

WARNING

Always attach a good earth conductor first.

2. The charging point must be properly earthed. Connect the earth pin first. A main grounding rail is provided at the bottom of the station for grounding (applies to PE cable and grounding pin).
3. The earthing sleeve/wire of the distribution system operator may only be used as an earthing device with the system operator's written consent.
4. Earth leakage resistance must be less than the prescribed value:
   • NEN1010 <167 Ohm
   • EV-Ready 1.4D <100 ohm
5. Check that the isolating switch is in the OFF (0) mode. Switch off the main fuse (for types without house connection box) or remove fuses / switch circuit breakers to OFF (for types with house connection box).
6. Connect the phase wires to:
   • i. The dispensers or cartridge holders in the distribution system operator cabinet of the Twin 4XL NL, including standard grid connection. PE on a separate rail.
   • ii. Directly to the isolating switch of the Twin 4XL NL, excluding grid connection, PE on a separate busbar.

4. Commissioning the Charging Station

4.1 Safety Instructions Before Use

Follow these safety instructions before putting your charging station into operation:

• Ensure the charging station is properly connected to the power supply and securely fastened to the foundation as prescribed.
• Ensure the electrical supply distribution is separately protected by an appropriate circuit breaker (934452504 / 934452501: fuse links).
• Ensure the charging station has been installed in accordance with this manual.
• Ensure the casing is always closed during normal use.

4.2 Commissioning

1. Ensure earth leakage circuit breakers are ON and all fuses are in place.
2. Set the isolating switch to ON (I) mode. Use a special key if necessary.
3. Close the Twin 4XL NL by clicking the door into the lock.

Switch on power at the power cable. The charging station performs a self-test:

1. Outputs are tested one by one (user side): Lock testing (locking/unlocking), internal relays tested (audible switching).
2. Interface LED flashes briefly.
3. Red crosses flash twice.

The Alfen Twin 4XL NL is now ready for use.

• If configured for a management system, connection is automatic and immediate.
• If required, further configuration can be done using the Service Installer software package.
• For Smart Charge functionality, check settings with the Service Installer application for optimal local configuration.

REMARK: For information on the Service Installer, visit alfen.com/en/downloads.

5. Connectivity

5.1 Backoffice Management Systems

Your Alfen charging station can communicate with a management system via an Internet connection for monitoring energy consumption, remote charging management, and easier maintenance.

If additional services were purchased, your station is pre-configured to connect to the selected management system. Internet connection is established via GPRS (SIM card) or UTP (Ethernet) cable. If using GPRS, the station is equipped with a SIM card and connects automatically upon commissioning. If the SIM card holder is empty, contact your backoffice provider or Alfen.

Connection to the internet can be via GPRS (SIM card) or UTP (Ethernet) cable.

5.2 Setting Up a Connection

5.2.1 Wireless Connection

For wireless connection, the charging station needs a GPRS-suitable SIM card. Correct settings must be configured in the Service Installer to connect to the preferred backoffice management system. Shortcuts are available in the Service Installer for easy system and settings selection.

REMARK: Connection to a backoffice system requires prior arrangements with the service supplier. Third-party services are not included.

Figure 8 shows the location of the SIM card holder and UTP port.

5.3 Registering Your Charging Station Within Your Own Backoffice Management System

If you use your own management system or a third-party service, ensure you register the correct type of charging point. Each Twin 4XL NL model has a Charge Point Model sent with the application, following OCPP specifications. This includes platform indication and a unique article identification.

• Article no. 934452501: OCPP Charge Point Model NG920-52501
• Article no. 934452504: OCPP Charge Point Model NG920-52504

Correct registration in the management system allows the charging station to log on easily.

Contact

Alfen ICU B.V.
Hefbrugweg 28
1332 AP Almere
The Netherlands

Postal Address:
P.O. Box 1042
1300 BA Almere
The Netherlands

Tel. Sales Support: +31 (0)36 54 93 402

Tel. Service: +31 (0)36 54 93 401

Website:
www.alfen.com/nl/oplaadpunten-ev
www.alfen.com/en/ev-charge-points