pod POINT 1.0-Solo-3 Array Circuit Installation Guide

In the absence of any negligence or other breach of duty by Pod Point, Pod Point is not responsible for any injury, loss or damage caused by any works, services, products or equipment provided or performed by the customer or a third party (and not by Pod Point or a party for which it is responsible) in relation to the installation and/or commissioning of the Array Circuit.
If the installation and/or commissioning of the charger is not performed by Pod Point, it is the customer’s responsibility to ensure that any third party appointed to install and/or commission the Array Circuit is appropriately qualified and does so in compliance with all applicable regulations and with reference to the guidance provided in this document (and associated documents linked within). Pod Point provides this guidance as a reference only and it is not a substitute for the appointment of competent persons to carry out installation and commissioning.

The Array Circuit is not intended to be installed by 3rd parties.
A dedicated supply is required, installation should not be done using a common supply.

Do not open, move, modify, rewire, tamper or interfere with your Array Circuit once it has been installed.
The customer must ensure that an installed Array Circuit is not opened, moved, modified, re-wired, or otherwise tampered or interfered with, without first referring to Pod Point’s latest technical guides and/or notifying Pod Point directly and complying with Pod Point’s recommendations.

Please also see the charger’s applicable warranty terms which may be affected by taking such action. If you have any concerns in relation to a Pod Point that has already been opened, moved, re-wired or otherwise has been tampered or interfered with, please notify Pod Point directly so that appropriate advice can be provided, noting that Pod Point assumes no responsibility for your installation by virtue of providing such advice.
In the absence of any negligence or other breach of duty by Pod Point, Pod Point is not responsible for injury, loss or damage caused by the Array Circuit. being opened, moved, modified, re-wired or otherwise tampered or interfered with by the customer or a third party (and not by Pod Point or a party for which it is responsible).

Safety Instructions

This symbol is used throughout this guide to indicate a warning. Failure to follow these warnings could result in failure of the equipment, personal injury or result in the warranty being void.
This symbol is used throughout this guide to indicate danger. Failure to follow the instructions within this guide could result in personal injury or electric shock.

This product shall only be installed by suitably qualified and competent persons.

This product shall only be maintained by suitably qualified, competent and instructed persons.
Installation and maintenance work should be carried out in accordance with the current version of BS 7671 and any other national or local regulations, legislation or guidance applicable at the time of installation. Please also consider referencing the IET Code of Practice for Electric Vehicle Charging Equipment Installation

It is the responsibility of the person(s) carrying out the installation work to ensure all instructions and methods described in this guide are followed at all times.
Pod Point cannot accept any responsibility where this installation guide has not been followed.

Standards, specifications and designs change from time to time, information contained within this guide may be subject to change without notice.
To ensure electrical safety, this product must be maintained in accordance and in line with recommendations made in this guide.

This product must not be adapted or modified in any way, doing so could result in personal injury or damage to the equipment. Adaptations, modifications or other unauthorised interference with the product may void your warranty. Please see our Warranty Terms and Conditions for more details on this.
Physical damage to the product may result in unsafe conditions, ensure electricity supplies are isolated and the product is not used if damaged consult Pod Point for further information and repair.

DANGER! Hazardous Voltage – Never make any unauthorised amendments to the internal components of this product. Ensure that the supply to the Array Circuit is isolated and locked off before installation and maintenance activities are carried out.

Earthing Arrangements

The Array Circuit must be connected to a permanent, metallic earthing system in accordance with the current version of BS 7671 and any other applicable local and National regulations.

The Array Circuit is suitable for connection to the following earthing systems:

The installer is responsible for ensuring that the earthing system used is adequate and meets the requirements detailed within the current version of BS 7671.

* Any circumstances where a Solo Charger is to be installed externally, an open PEN protection device must also be installed at the source of supply.

** Additional considerations should be made when the Array Circuit is connected to a TT earthing system. An RCD will always be required at the source of supply where a TT earthing system has been used – either for the whole installation or locally for the charger only.
Where an RCD is required for a TT earthing system, the RCD must be a Type B >100mA time delayed.

Electrical connection

Cables being terminated to the Array Circuit must be done so to avoid unintentional damage -appropriate cable glands must be used at the point of entry to the cable connection enclosure, cables must be stripped to the correct length to avoid excess copper showing at the termination. Terminations must be tightened within the specified torque of:

Component	Torque (Nm)
All EAE Components	See EAE Documentation
PP-E-170094 – 100A Input MCB	3.5
PP-E-210410 – 100A Output RCCB	2.5
PP-E-210414 – Earth Terminal	10
PP-A-170103 – Array Controller	0.5

Cables must be correctly identified by colour within the connection enclosure.

This system should not be installed without a project specific design produced by Pod Point, to be read in tandem with this guide.

This install guide details the installation procedure for the Array Circuit 1.0 (Solo). The Array Circuit version 1.0 consists of:

Pod Point’s Array Circuit Distribution Board
Elbagate’s MK E-Line Busbar
Elbagate’s Tap-off Box
Pod Point’s Data Box

Dependant on the electrical supply, this system can provide a modular increase from 3 to 27 installable units by using a smart load monitoring system. The modularity of this system is due to the Tap-off Points and Boxes, where the maximum capacity infrastructure is installed in one go and each additional Solo can be wired into the pre-existing infrastructure., The Array Circuit 1.0 is compatible with the original Solo and Solo 3 only.

Included materials:

Array Circuit Busbar & Busbar Components (site specific)
Array Circuit Distribution Board

Materials required to complete this installation:

Description	Qty
(PP-M-170167-1) 40mm Armoured cable gland	Site specific
(PP-M-170166-1) 20mm Armoured cable gland	Site specific
5-core cable	Site specific
2-core cable	3x per siteLength – site specific
Unistrut / Basket Tray	Site specific
PVC Conduit 20mm2	Site specific
20mm2 Steel Saddle Clamps	Site Specific
(PP-K-220074) Data Box Kit	[Ideally] 1x per Chargepoint installed[Min.] 0.5x per Chargepoint installed
(PP-K-220073) Tap-off Box Kit	1x per Chargepoint installed

Information

Description	Value
Weight of Distribution Board (incl. packaging)	16.3 kg
EMC Environment Classification	Class A – ImmunityClass B – Emissions
Maximum input short-circuit current (Supply PFC)	10 kA
Rated conditional short-circuit current (Icc)	10 kA*
Upstream short-circuit protective devices necessary	Min. 100AMin. 10kA

The prospective fault current at the supply input to the Array Distribution Board must not exceed 10kA

Reference list of Terms

Feeder Unit
Tap-off Point & Cover
Bracket
Tap-off Box

Busbar Trunking
Data Box
Distribution Board (DB)

Installation of EAE Busbar Components/System
All components provided by Elbagate (EAE) should be fitted and installed as per their specifications and in accordance with their guidelines. Pod Point does not take ownership or responsibility of their product or methodology. This guide only provides detail on using the product to fit the purpose of the Array Circuit and its related components. The Busbar Trunking used is the Elbagate E-Line MK version, details can be found here: https://www.eaeelectric.com/busbar-systems/e-line-mk-busbar

Primary Installation and Secondary Installation Overview

The Array Circuit installation is to occur in two distinct stages:

Stage 1 – The entirety of the passive infrastructure (Distribution Board, Busbar, Tap-off Boxes and Data Boxes) is installed. No Chargepoints are installed at this time.
Stage 2 – Upon a specific request, a Chargepoint is installed in the typical fashion. This then gets fitted into its own dedicated Tap-off Box along the Busbar.
Note: The reference notation of the following steps (i.e. X.Y.Z.) refer to Stage X, Phase Y and Step Z.

Distribution Board

Stage 1

Phase 1: Installation of Distribution Board – AC-DB-01-UAA ONLY

Measure and cut the trunking (and conduit if necessary) where the Distribution Board (DB) will be installed. Unlock the lid and unscrew the cover.

Mark 4 holes using the locations identified in Figure 2. Drill the 4 holes in the wall where the Distribution Board will be fitted.
Fit the Distribution Board on the wall using 4x appropriate screws.
Remove the appropriate knock outs from the side(s) of the Distribution Board where the incoming supply, outgoing supply and outgoing Data cables (via trunking, armoured cable and/or conduit) will be connected.

Strip the mains cables from the incoming supply, feed through knockout to Distribution Board using an appropriate gland. Care point: Make sure stripped cables reach the 100A MCB on Upper DIN Rail.
Connect the outgoing supply and Earth to the corresponding Busbar Feeder Unit, fixing to the wall/ceiling as appropriate. Use the EAE Install Manual for correct torque settings.
Feed the cable through the Distribution Board gland, then measure and strip the cables down to be fitted to their corresponding terminals.

Connect the Busbar supply to the Lower DIN Rail RCCB and Earth terminal, as seen in Figure 8 below. Figure 8. Distribution Board diagram of AC-DB-01-UAA -One-way busbar
Screw L1 (brown), L2 (black), L3 (grey) and Neutral (blue) at the bottom of RCCB(s) on the Lower DIN Rail. Fit the earth wire into the earth terminal on the Lower DIN Rail. Live and Neutral wires should be screwed to a torque of 2.5Nm, Earth to a torque of 10Nm.
Feed all 6 Data cables through appropriate knockout(s) using (a) gland(s). Label appropriately.
Care point: Ensure enough length to reach Array Controllers on Upper DIN Rail.
Care point: Ensure the Data cables are identifiable

Cut and strip Data cables to appropriate lengths and fit into the corresponding Array Controller “OUT 1” AND “GND”, see Figure 11.
Care point 1: Make sure that you are connecting the shielded wire to the correct Array Controller for that phase.
Care point 2: Ensure shielding is connected into the ground pin of the controller.
Care point 3: The grounds within the controllers are commoned. All Out connections should be connected separately to their associated phase, e.g. L1 controller must only connect to Chargers supplied from L1.Figure 11. Array Controller connections – showing only 1x per phase for simplicity
Feed Data cables through conduit(s) to the first Data Box, attached to the first bracket. Figure 12. Example Data Cable connection from Distribution Board to first Data Box
All Array controllers must each be connected to both wires (Live and GND) per Data cable.
Care point: Ensure that each Data cable is clearly identified in an appropriate manner.
Screw on the cover of Distribution Array Board.

Attach all stickers supplied with the boards on the cover.
After initial verification and testing, see steps and Figure 13 below for order of energisation.
1. Switch on main 100A MCB (see Picture 14 below)
2. Switch on 1-pole 2A MCB feeding the array controllers (see Picture 9 below)
3. Switch on lower DIN rail RCCB(s)(the number of RCCBs will depend on the SKU)
  Care point: All Solo Chargers must be connected to the Internet via Wi-Fi and must be configured for use with an Array system.

Phase 1: Installation of Distribution Board – AC-DB-01-UBA ONLY

DANGER! Hazardous Voltage – Never make any unauthorised amendments to the internal components of this product. Ensure that the supply to the Array Circuit is isolated and locked off before installation and maintenance activities are carried out.

This page has intentionally been left blank as a placeholder for the installation of the Array Circuit 1.0 Distribution Board AC-DB-01-UBA SKU variant. A later release of this this document shall detail the necessary installation steps once they are finalised and agreed by all relevant parties.

Preparation of Busbar

Phase 2: Preparation of Busbar Trunking

Care point: The Busbar Trunking can be installed in a number of methods; wall mounted, roof mounted and/or roof suspended, see Figures 16, 17 and 18.

Measure and mark distances along route so as to ensure a minimum of 2x Brackets per 2m length of Busbar Trunking is installed. Brackets should be installed in front of Tap-off Points where possible.
Care point: Ensure these Brackets do not cover Tap-off Points or Busbar joints and leave sufficient space for a Tap-off Box to be fitted.

Measure and mark distances along route where Data Boxes are to be installed. Data Boxes should be placed between 2 EV parking bays, so as to provide Data connection for 2 future Solo Chargers

Data cables

Phase 3: Recommended Installation of Data Cables

Due to the number of ways that the Busbar can be mounted, 3 methods are recommended by Pod Point. All use the same system of saddle clamps and Data Boxes fixed to Unistrut alongside the Busbar.
Install Data Boxes to Unistrut/Brackets in locations identified in Step 1.2.2.
Install saddle clamps at appropriately spaced distances to secure Conduit to Unistrut or Bracket.
Care point: Saddle clamps must be installed prior to busbar if using the same Bracket for both data and busbar fixation.

Fit conduit into saddle clamps and into Data Boxes as needed until end of Array Circuit, see Figures 19 and 20. Care point: Final length of conduit must terminate into a Data Box, regardless of EV bay location.
Feed and label the first set of Data cables, i.e. those connected to the far left hand side of the Array Controllers, through the first Data Box, as seen Figure 21.
Care point: Ensure each cable is correctly identified in a sensible fashion. For example, 1-L1 denotes the first pair “1-” of the “L1” Array Controller.
Feed the next set of Data cables into the Data Box. Loop once, zip-tie and mark these cables as the second pair per Live. See Figure 22 and 23. Care point: Ensure each cable is correctly identified in a sensible fashion in each box.

Phase 4: Installation of Tap-off Box

Tap-off Box

Phase 4: Installation of Tap-off Box

Identify the EV Charging Bay where the Chargepoint will potentially be installed.
Identify corresponding Tap-off Point to install Tap-off Box. This will be the closest, unless obstructed Point.
DANGER! Hazardous Voltage – follow the safe isolation procedure

Open Tap-off Box and fit RCBO to Neutral and appropriate Live wires.
Stick associated Live label onto RCBO.
Open busbar Access Cover exposing conductors within, as seen in Figure 25.

With the box open, fit the conductor points at the bottom of the Tap-off Box into the Tap-off Point and push straight into the Busbar. The Tap-off Box will click into place. Care point: Ensure the Tap-off Box is mounted so that the handle is on the same side as the Tap-off Cover relative to the conductors.
Remove knockout(s) from lid of Tap-off Box to expose RCBO, close lid and latch.
Fit sealing wire through holes alongside latch on Tap-off Box. Crimp into the ferrule (and tag if provided). Repeat with the flip-up latch, as seen in Figure 28.

Chargepoint Connection

Stage 2

Phase 1: Connecting Chargepoint to Tap-off Box & Data Cable

Identify EV Charging Bay where the Chargepoint will be/has been installed and the corresponding Data Box.
Identify corresponding Tap-off Box. This will be the closest, unless path is obstructed.
CAUTION: Ensure power is off and proved dead prior to install.

Cut wire sealing Tap-off Box, then feed Supply to Unit cable through side gland in Tap-off Box. Make a gland hole if necessary.
Cut Neutral, Live and Earth cables to length and fit into their corresponding terminals on RCBO and Earth Stud, as seen in Figure 29.Figure 29. Tap-off Box with L2 connected to RCBO
Feed the Data Cable to the Data Box through the appropriate knockout.

Strip and fit the incoming Signal and Ground into the 3-way terminal blocks, as seen in Figure 30.
1. Care point 1: Ensure the each terminal block contains exclusively Signal or Ground cables, with no cross-contamination.
2. Care point 2: All Ground cable(s) must be fitted alongside the wire shielding, as shown in the images.

Strip and fit the outgoing Signal and Ground into the 2-way terminal blocks. Each block should be fully populated with either Signal or Ground cables respectively as seen in Figure 31.Figure 31. Outgoing Data cables as if fitted to a unit, only showing 1 phase pair of Data Cables for clarity Figure 32. Incoming and outgoing Data cables wired into 3 and 2 lever terminals
Care point: All Ground cable(s) must be fitted alongside the wire shielding, as shown in the images.
Feed the two Data cables to and from the Chargepoint through an appropriate knockout in the Data Box. Label appropriately, i.e. “1-L1 IN”, “1-L2 OUT”.
Fit the Data cable to the Chargepoint into the incoming 3-lever terminals, as shown in Figure 33.Figure 33. Data cable to the Chargepoint fitted to the 3-lever terminals
Care point: Ensure that the Data cable being tapped off is identical to the Live fitted to the Tap-off Box.
Fit the Data cable from the Chargepoint into the outgoing 2-lever terminals, as shown in Figure 34. Care point: Ensure that all Data cables are correctly labeled.

Fit all wires and terminal blocks inside the Data Box, as seen in Figure 35.
To fit a second unit, repeat steps 2.1.5. to 2.1.9., using a second set of terminal blocks and a separate knockout.
Fit all wires and terminal blocks inside the Data Box, as seen in Figure 36.

Fit sealing wire through holes alongside latch on Tap-off Box. Crimp into the ferrule (and tag if provided). Repeat with the flip-up latch, as seen in Figure 37.
The Supply to Unit cable and Data Cable are now correctly connected to the Busbar and Distribution Board. The install now continues as per typical Domestic Install guidelines from this step onwards. See Figure 38 for reference.

Testing and Commissioning

Stage 3
Phase 1: Testing and Pre-Commissioning

Electrical testing
Upon the completion of the installation of the Array Circuit, the installer must carry out initial verification and testing of the supply circuit(s) and final circuit / busbar as set out in BS 7671. Certification should be issued to the client upon completion of the installation.

Pre commissioning
Visually inspect the Array Circuit installation to ensure:

The Array Circuit distribution boards are securely fixed and that IP ratings have been maintained
The busbar is securely fixed with all tap-off covers secured into position

Cable containment is securely fixed with lids where applicable fitted
All cables are adequately glanded and secured
There is no damage to supply conductors or the busbar

All supply and final circuits are identified at the distribution point
Warning labels have been fitted where required
Data cables have been identified and labelled

Data connection points are securely fixed with lids fitted where required

The Array Circuit system can now be powered on ready for commissioning.

Phase 2: Commissioning

Set-up:
Before testing of the Array system can commence, the individual Solo chargers must be connected to the supply and electrically tested (Ze, Zs etc.). Following this process each Solo must be connected to Wi-Fi (see instructions included in the box for this process). Commissioning of units require the PG number of each Solo and also the maximum supply the main distribution board has allocated to it.

The commissioning process allocates each Solo the maximum supply available, the commissioning data is then downloaded to each Solo and stored in its non-volatile memory. As this process may take 5 minutes to complete, all units should be done at once. Please note: when Wi-Fi and internet connection has been established the Solo status light will illuminate Blue with a Pink flash (Solo chargers with white LEDs cannot be commissioned).

Solid White
The Solo does not have a Wi-Fi signal or network access

Flashing Blue/Pink
The unit is communicating with Pod Point. (normal State)

Following online commissioning of all Solo Smart Chargers, a simple confirmation that all are receiving data from the Array Controllers can be conducted.

Check all Solo chargers are indicating normal operation (Blue/Pink). Any units that indicate a Red status LED should be checked to ensure cables are correctly fitted and rectified.

After confirming all are OK, switch the supply off to the Array control board (2A MCB).
All Solo chargers should error (red LED), confirming Array failsafe operation.

Turn MCB back on, Solo should recover and return to a normal state.

Solo Chargers per electrical phase
Approximate max Resistance at Array output (Ohms)	1	2	3	4	5	6	7	8	9
Approximate max Resistance at Array output (Ohms)	103	53	36	29	24	19	17	15	14

Fault checking of Array system:

If some or all of the Solo chargers error after commissioning (Red LED), check for 12VDC at the output of the power supply in the Array controller, if it is lower, isolate the 12V feeds to each Array module to determine if an excessive load is limiting the 12V supply.

If it is found one or more are causing the supply to limit, check the resistance of the output(s) of the Array module terminals (with 12V PSU switched off), typical resistances given above.
If a lower reading is obtained than expected it indicates either a short circuit on the data cable or one of the Solo chargers have been miswired (signal and ground terminals swapped), if the resistance is significantly higher it indicates an open circuit or one of the terminals inside the Solo is not correctly mated to the data cable (this failure usually only affects one or 2 units).
If DC voltages and resistances are in order -suspect a defective Array module.
Array controller PSU indicator lamp (normal).

Solo status light

Phase 3: Maintenance

Maintenance
The Array Circuit requires ongoing maintenance to ensure it remains safe for continued use and to ensure longevity. Maintenance tasks should only be carried out by Pod Point.

Pod Point recommends that RCDs fitted within the Array Circuit installation should be manually checked for operation every 6 months in line with recommendations within BS 7671.
Pod Point recommends that the Array Circuit is inspected and tested at least every 12 months, these checks will ensure the internal safety devices are operational.
In very high use locations, it is recommended to reduce the inspection frequency to every 6 months, it will be the responsibility of the installer to assess the requirement to inspect more frequently than every 12 months.

To arrange a service visit, please contact us via: www.pod-point.com/contact

Array Circuit 1.0 Install guide

FAQ

Q: Who should install the Array Circuit 1.0 – Solo 3?
A: The product should only be installed by suitably qualified and competent persons.
Q: Can the product be tampered with after installation?
A: No, the Array Circuit should not be opened, moved, modified, or interfered with after installation to ensure safety and warranty validity.

Documents / Resources

pod POINT 1.0-Solo-3 Array Circuit [pdf] Installation Guide
1.0-Solo-3, 1.0-Solo-3 Array Circuit, 1.0-Solo-3, Array Circuit, Circuit

References

User Manual

pod POINT 1.0-Solo-3 Array Circuit