Charging Infrastructure

Saturn 22kW
Installation Manual
 Legal Notice

Company: Wanbang Digital Energy Co., Ltd

Company address: No. 39 Longhui Road, Wujin District, Changzhou, Jiangsu, China

Customer service: 400 828 0768

Website: www. starcharge. com/en

Wanbang Digital Energy Co., Ltd All rights reserved

This document is one of the “charging infrastructure” technical documents of Star

Charge and is protected by copyright. Without written consent, any use outside the strict

limits of copyright law is prohibited.

This also applies to files that are copied, translated, and photographed, and files that are

stored and processed using electronic media.

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Any party who violates this regulation is obliged to compensate for the loss!

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 Contents 3.2 Equipment installation and connection........................................................13
3.2.1 Wall-mounted installation......................................................................13

Legal Notice.......................................................................................................... 1 3.2.2 Column-mounted installation................................................................16

3.2.3 Wire connection.....................................................................................20
1 Genera................................................................................................................ 4
1.1 Document purposes....................................................................................... 4 4 Post-installation inspection..............................................................................22
1.2 Scope of application...................................................................................... 4 4.1 Clean up ......................................................................................................22

1.2.1 Types of equipment applicable to this manual........................................ 4 4.2 Inspection ...................................................................................................22

1.2.2 Personnel applicable to this manual....................................................... 4 5 Completion information....................................................................................22

1.3 Definition of warning symbols....................................................................... 4
Appendix 1..........................................................................................................23
2 Preparation before installation......................................................................... 5
2.1 General construction tools............................................................................. 5 Appendix 2..........................................................................................................24
2.2 Construction materials.................................................................................. 6
2.2.1 Cable splice terminal............................................................................... 6
2.2.2 Other materials....................................................................................... 6
2.3 Installer requirements................................................................................... 6
2.4 Handover of construction drawings.............................................................. 7
2.5 Inspection of electric power cables............................................................... 7
2.6 Requirements for concrete foundation (Column-mounted)........................... 7
2.7 Equipment spacing requirements.................................................................. 9
2.8 Power supply requirements.........................................................................10
2.9 Ground/insulation resistance requirements.................................................11
2.10 Installation environment.............................................................................11

3 Installation procedure......................................................................................12
3.1 Unpacking and unpacking inspection..........................................................12
3.1.1 Equipment unpacking list........................................................................12
3.1.2 Inspection of unpacking..........................................................................12
3.1.3 Notes of unpacking.................................................................................13
3.1.4 Check before installation......................................................................... 13
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 1 General 2 Preparation before installation
1.1 Document purposes 2.1 General construction tools

The purpose of this document is to guide the construction personnel to complete the on-site Table 2 General construction tools
installation of Saturn 22kW WallBox . No. Category Name Use Picture
Cable preparation Stripping of insulation
1.2 Scope of application 1 Electrician knife
tools sheath
• 1.21 Types of equipment applicable to this manual Stripping of insulation
2 Installation tools Wire stripping pliers
layer
European standard Saturn 22kW WallBox Installation personnel
3 Installation tools Wire pressing pliers Terminal bonding
• 1.22 Personnel applicable to this manual

Professional installers of Saturn 22kW WallBox Component

4 Installation tools Percussion drilling
installation
1.3 Definition of warning symbols
Electric air pick
Table1 Definition of warning symbols 5 Installation tools Notching
machine
No. Symbol Content

"Warning" symbol indicates danger

6 Installation tools Cutting machine Tube Cutting
Failure to pay attention to the procedures, practices or improper
1 implementation may cause installer injuries and death. Only after the
conditions referred to are fully understood and fulfilled, the operation
accompanied the "electrical hazard" symbol can be performed. Thermal shrinkage of
7 Installation tools Heat gun
insulating materials
"Caution" symbol indicates warning
Failure to pay attention to the procedures, practices or improper
2 implementation may cause product damaged or destroyed. Only 8 Installation tools Fuse machine Welded PE pipe
after the conditions referred to are fully understood and fulfilled, the
operation accompanied the "caution" symbol can be performed.
Hexagon socket Install and remove
9 Installation tools
wrench (set) screw
"Prompt" indicates usage tips or useful information
3 Tips and useful information are marked with "prompt" . It does not Open End Wrenches
contain information to warn about dangerous or harmful functions. 10 Installation tools Install and remove nut
(set includes No.13)

"Garbage disposal" symbol indicates electrical and electronic 11 Installation tools Angle grinder Polishing of materials
waste
This symbol is located on the product, in the instruction manual, or on
the packaging, indicating that electrical and electronic equipment and Cross screwdriver Install and remove
4 its accessories should be separately disposed from ordinary household 12 Installation tools
(full set) screw
waste.
Materials can be reused according to this symbol. By reusing old
equipment, materials and other forms of reuse, you can make a Measuring Horizontal
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13 Laser level meter
significant contribution to the environment. instrument measurement

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 Measuring Horizontal 7. Those who use mobile power tools must master their use skills and precautions. Wear
14 Horizontal rule
instrument measurement insulated shoes and insulated gloves as much as possible. Metal shell must have ground

Measuring Measure voltage, protection or zero connection protection.

15 Multimeter
instrument current, etc. 8. Temporary on-site electricity, electricity box should be kept intact, damaged electrical
components must be replaced in time.
Measuring
16 Megger Measure resistance 9. Rubber cable shall be used for the temporary electric wires on the site. No plastic splines are
instrument
allowed. No wires shall be directly inserted into the socket.
Place the
17 Assistive devices Insulation mat 10. Do not do electrical installation and wiring when power on about temporary power supply on
disassembled parts
site.
NOTEICE
11. If enter the edge of foundation pits, roofs, and other openings, and concentrate to prevent
The above tools should be selected according to the actual situation on site.
falls from falling.

12. Pay attention to the ground environmental conditions such as nails and steel bars, and
2.2 Construction materials prevent sticking, bumping, hanging, falling and other injuries.

• 2.2.1 Construction materials 13. The on-site construction protective facilities, safety signs, warning signs, etc. cannot be
9AWG wire corresponding terminals (22kW). removed without authorization.

• 2.2.2 Other materials 14. Strengthen on-site maintenance of construction equipment to maintain intact rate, and
prohibit operation with problems and overloading.
Heat shrinkable tube, electric tape and other accessories .

2.4 Handover of construction drawings

2.3 Installer requirements
After the installer arrives at the site, first ask the store staff for a drawing of the installation
1. Entering the construction site shall comply with the construction site safety management
location of the equipment, and check that the cables and concrete foundation of each
regulations.
equipment meet the requirements.
2. Entering the construction site must wear a safety helmet (fasten your jaw strap, and the
helmet is intact), do not wear unsafe clothes such as loose clothing, slippers, etc. It is 2.5 Inspection of electric power cable
strictly forbidden to work under the situations (such as smoking, drinking and etc.) at the
The recommended type of power cable to be laid in the 22kW WallBox is not less than 5*AWG9,
construction site.
Please check and verify the cable type before installation.
3. Operators at high altitude must wear safety helmets, hang up safety belts, wear non-slip
shoes, and fasten labor tools.
2.6 Requirements for concrete foundation (Column-mounted)

4. If the work site is dusty or has spray paint work, protective masks must be worn. The concrete foundation for column-mounted charger needs to be poured before the charger
is installed. The size of the concrete foundation is 500mmx350mmx600mm, the buried depth of
5. Do not enter dangerous areas such as the hoisting area and below the vertical operation to
the foundation is 400mm, and the height above the ground is 200mm. The top view is shown
prevent objects from striking.
in Figure 1. The dimension of concrete foundation can be adjusted according to customer’s
6. Keep as far away as possible from various mechanical equipment, electrical circuits, and
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requirements and actual conditions on site.The concrete foundationi nspection requirements
prevent mechanical and electrical injuries.
are as follows:
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 1. Pay attention to the level correction when pouring the foundation. Figure 2 The three-view drawing of construction

2. The foundation installation is higher than the ground level, and necessary maintenance
walkway are reserved on site depending on the specific space.

3. The drainage outlet on the foundation surface is slightly inclined to avoid accumulation of
water.

4. The foundation is filled with C20 concrete.

5. Reserve an outlet hole on the foundation for cable, as shown in the Figure1.

6. After the foundation is completed, use a level to test the levelness.

7. According to the drawing positioning, 4 screws of M10 are embedded in the concrete
foundation in advance and expose 30-40mm on the upper surface of the concrete foundation.

Figure 1 Top-view drawing of concrete foundation

500

200
200
0.00 0.00
500

400
400
100 300

350
Embedded PVC Φ100 tube

500 350
100

175

2.7 Equipment spacing requirements

350
150

Embedded PVC Φ100 tube 1. Maintenance distance requirements.

When the back or side of the charger to be installed is near a wall or other obstacles, a certain
Embedded anchor bolt 4-M10, L=150, exposed part=30 maintenance distance needs to be left, please refer to Figure 3 below:

250 Figure 3 Charger maintenance distance diagram

Wall Wall
800 800

800
The three-view drawing of construction is as follows: Wall-mounted
800 800
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Column-mounted

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 2. Single or back-to-back parking spaces distance requirements. 2.9 Grounding / insulation resistance requirements
When the charger is installed in the parking space, it is recommended to leave a space of 1. Check the civil grounding resistance test report to ensure that the resistance of the grounding
1200mm between the wheel stop and the charger, as shown in Figure 4. grid produced on site must be ≤ 4Ω.

Figure 4 Parking space distance diagram 2. Check the civil insulation resistance test report to ensure that the insulation resistance of the
cable is ≥ 10MΩ.

1200mm NOTE
the above requirements are the minimum requirements of the equipment. The specific
standards shall be subject to local laws and regulations.

2.10 Installation environment

The recommended installation environment is as follows:

1200mm Table 4 installation environment

Environmental conditions Recommended range

The environment temperature -25℃ ～ ﹢ 45℃

Altitude ≤ 2000m
2.8 Power supply requirements
humidity 5% ~ 95%RH, no condensation inside the product;
1. The power supply mode of the 22kW AC charger is AC three-phase power supply, and the
Degree of dust ≤ 1mg/m3
input electrical requirements are showed as follow:
Corrosive substance No pollutants, such as salt, acid, smoke, etc.
AC working voltage: AC 400V ±10%
Vibration ≤ 1.5mm/s
AC working frequency: 50Hz/60Hz
Insects, pests, vermin, termites No
2. It is recommended that customers install a miniature circuit breaker on the power supply
Mold No
circuit of the charging pile. The miniature circuit breaker needs to meet local regulations. The
recommended specifications of the circuit breaker are as follow: Damp Rainproof

Table 3 Power supply requirements No inflammable material at the top and bottom of the
Fireproof
cabinet
Tripping
Power Series Rated voltage Rated current Quantity
characteristics

22kW 3P+N 400V 40A B/C 1

22Kw+22kW 3P+N 400V 40A B/C 2

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 3 Installation procedure • 3.1.3 Notes for unpacking

(1) The installer shall unpack the container in the presence of the owner and fill in the unpacking
3.1 Unpacking and unpacking inspection
record in detail. See appendix 1 for the unpacking record.
• 3.1.1 Equipment unpacking list
(2) After unpacking, please ask the owner's representative to confirm and sign on the equipment
Table 5 Equipment unpacking list
unpacking record sheet.
Equipment
No. Quantity Comments (3) If any problem is found in the process of unpacking and acceptance of the equipment, it
component

1 AC charger 1 / shall not only record the accident, but also wait for the negotiation between the owner and

E10-12(KST) *8 the supplier.

2 Terminal connectors
3 Wall mount
1
RV5-6(KST) *2
• 3.1.4 Check before installation
Wall mount*1
M4 Hexagon socket countersunk head screw *1 (1) The charger should not be installed close to dangerous locations such as water pipes, gas
1
M6 Phillips Hexagon Screw *4
M6 Expansion screw *4 pipes, and steam pipes.

Charging cable hook
4 1
(For CaseC version)
5 RFID Card
6 User manual
7 Column(Optional)
(2) The installation location should be convenient for charging. When laying the circuit, the wiring
Charging cable hook*2
M5 Cross Combination screw *4 length should be shortened to reduce consumption of resistance energy .
M6 Expansion screw *4
(3) The installation position of the vertical charging pile should not be set at a place where the
2 /
terrain is low and water or dripping is easy. The installation should be vertical and the center
1 /
of gravity should not be too high to prevent tipping or tilting. It should not be placed in a place
Column*1
Cable guard*2 with severe vibration or high temperature.
1
M10 Expansion screw *4
(4) The wall-mounted charging pile must be connected to the wall which can withstand the
M4 Hex socket pan head screw*2
weight of the charging pile and its accessories . The wall-mounted charging pile should not

be tilted after installation.

• 3.1.2 Inspection of unpacking
(5) It is recommended that the charger be installed in an environment with a sunshade or
(1) Check the packing list number and equipment quantity.
umbrella; the lighting and passage of the charger installation site must be guaranteed.
(2) Check equipment nameplate information.
(6) The installer needs to complete the pre-installation confirmation check before installation,
(3) Check whether the attachment paper are complete.
see Appendix 2.
(4) Check whether the spare parts and accessories are complete.

(5) Check the delivery inspection report and certificate. 3.2 Equipment installation and connection
(6) Check the appearance of the equipment is good, whether there is deformation, knock, stains • 3.2.1 Wall-mounted installation
and other conditions.
(1) Take the drill template from the carton packaging.
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(2) Place the drill template at the desired location.

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 (3) Use a spirit level to verify that the template is levelled. (9) Install the charger from top to bottom, hang the charger on the two expansion screws above,

(4) Use the drill template to mark the drill holes, shown as Figure 5. and then fix the bottom of the charger on the wall mount with two M6 hexagonal head

Figure 5 Marking the drill holes pattern screws, shown as Figure 7.

Figure 7 Hanging charger and bottom fastening

220
373

192

(5) Use φ8 drill to make the holes at the marked points.

(6) Push expansion tube into the four drill holes. (10) Use a φ6 drill to drill a hole at a suitable position under the charger, and fix the charging

(7) Attach the mounting block on the wall by expansion screw. cable hook on the wall with the expansion screws.

(8) After tightening the above two expansion screws, screw out 7mm, shown as Figure 6.
Figure 8 Fix the charging cable hook
Figure 6 Marking the drill holes

Wall mout
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 • 3.2.2 Column-mounted installation (2) Fasten the column to the concrete foundation with 4M10*120 screws, shown as Figure 11.

The general assembly drawing is shown in Figure 9.

Figure 11 Fasten the column to the concrete foundation

Figure 9 General assembly drawing of column-mounted charger

M10*120
expansion screw
Wiring compartment cover M6 Phillips Hexagon Screw
Charge Wall mout Column
Decorative cover

M4 Hexagon socket countersunk head screw

(3) Snap the front decorative cover of the base into the grooves on both sides of the base,
Rear decorative cover then buckle the rear decorative cover with the front decorative cover, and finally fasten the rear
Wire guard
decorative cover to the base with two M3*8 hex socket pan-head screws, shown as Figure 12.
Front decorative cover M10*120 expansion screw
Figure 12 Fasten the column to the concrete foundation

(1) Place the column horizontally, and insert the cable into the bottom hole and exit from the

middle hole, shown as Figure 10.

Front decorative cover
Figure 10 Cable incoming drawing

M3*8 Phillips pan Rear decorative cover

head screws

(4) Fasten the wall mount to the column with two M6 Phillips hexagon screws, shown as Figure

13.
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 Figure 13 Fixed wall mount (6) After completing wiring, hang the cable guard on the column, and fasten it with two M4 hex

socket pan-head screws to complete the installation , shown as Figure 15. If you need to hang

chargers on both sides, please remove the cover plate on the back of the column.

Figure 15 Cable guard installation

Wall mout

M6 Phillips Hexagon Screw

Cable guard mounting hole

Cable guard
(5) Install the charger from top to bottom, hang the charger on the two welding screws above

the column, and then fix the bottom of the charger to the wall mount with two M6 hexagon
M4 hex socket pan head screw
socket screws, shown as Figure 14.

Figure 14 Charger installation and fixing

(7) Fix the Charging cable hook on the cable guard with M5 screws, shown as Figure 16.

Figure 16 Charging cable hook installation

M6 Phillips Charging cable hook

Hexagon Screw
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 • 3.2.3 Wire connection Figure 19 Incoming wire connections

(1) Open the wiring decorative cover as Figure 17.

Figure 17 Open the wiring decorative cover

(4) If Ethernet communication is required, it should be connected with a network cable. Take out

the rubber plug and waterproof rubber ring, put the waterproof rubber ring on the network
(2) Insert the SIM card supported by the local operator into the slot as Figure 18.
cable, then pass the network cable through the gland and connect to the internal network
Figure 18 SIM card slot
cable interface, shown as Figure 20.

Figure 20 Network cable connection

SIM card

(3) The incoming power cable passes through the waterproof joint at the bottom of the charger. Rubber stopper Waterproof rubber ring

Wiring according to lettering mark (L3/L2/L1/N/PE), then use the cable hoop to fix the
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incoming wire, shown as Figure 19.

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 4 Post-installation inspection Appendix 1

4.1 Clean up Unpacking record sheet

1. Dispose of all shipping and packaging materials in accordance with local regulations.
Name of Unpacking
2. Clean the charger and surrounding debris, such as small cables, straps, screws/mothers, etc. dealership date
Do not leave the installation tools on site or in the pile (record the type and quantity of tools to
prevent omission). Name of The actual Qualified Equipment
No. Quantity Note
commodity commodity number situation
3. Wipe the insulation with an antistatic cloth. Do not use any corrosive solvents.

4.2 Inspection

1. Check that the base is secure and sealed.

2. Check that the internal components of the device are securely fastened.

3. Check that the electrical connections and wiring are correct and complete, that the
connections are secure, and that the grounding is reliable.

4. Check that the degree of protection of the equipment meets the requirements, especially at
the cable entry at the bottom of the pile.

5. View appearance, marking, integrity, cleanliness.

5 Completion information

No. Name Number of pages Document necessity

1 Unpacking record sheet 1 √

2 Pre-installation checklist 1 √

Unpacking Installation
Owner unit
conclusion unit

Signature
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block

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 Appendix 2

Pre-installation checklist

Project name:

Civil construction unit： Equipment installation unit：

Acceptance Treatment
Sub-project No. Main acceptance items
record measures

Whether the on-site equipment installation

Installation plan 1 complies with the construction plan design
drawings

Distribution box Meet the equipment installation requirements

1
circuit breaker in section 2.8

1 5*AWG9 (coopper)
Cable type
Network cable cat6a (if Ethernet
2
communication is required)

Concrete 1 Dimensions meet requirements

foundation
(Column-
mounted) Foundation bolts meet the requirements in
2
section 2.6

The maintenance distance meets the

Maintenance
1 equipment spacing requirements in section
distance
2.7

In conclusion：

Note:
(1) In the acceptance record, fill in " √ " or "×" according to the on-site situation;
(2) At the conclusion, fill in "qualified" or "need to rectify" according to the on-site situation
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Signature of person in charge of inspection：__________________

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Zone, Changzhou, Jiangsu, China
China Office: Building 5, Innovation and Research
Port, Changzhou, Jiangsu, China
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