Wallbox Double — installation manual

1. INTRODUCTION

This manual guides installation of the AgeVolt Wallbox Double charging station, also called the wallbox or station. It covers positioning, wiring and initial startup. Every installation step must be followed correctly and performed by a qualified electrician. An electrical inspection technician must check the installation.

1.1 Safety information 

This document contains important instructions and warnings for station installation and maintenance.

 

• Read all instructions before installing this product.
• Only a qualified electrician may install, repair or maintain the charging station. Unauthorized repair or modification immediately voids the warranty.
• Unauthorized modifications or conversions are prohibited.
• Do not install or use the charging station near flammable or explosive materials, chemicals or vapours.
• Do not operate the charging station outside its operating temperature range.
• Connect the station to the earthing system, as specified by the site's charging system design.
• Protect the charging station from impacts.
• The charging station has no built-in power switch. Always follow rules and regulations applicable to the local electrical installation.
• Incorrect installation could damage the station or the connected electric vehicle.
• An electrical inspection technician must inspect Wallbox Double after installation.

 

This manual contains notes and safety warnings about potential hazards. The symbols have the following meanings:

DANGER — indicates an immediately hazardous situation that may cause death or serious injury unless appropriate measures are taken.

CAUTION — indicates that property damage may occur unless appropriate safety measures are taken.

 

2. CHARGING STATION DESCRIPTION 

2.1 Socket version 

• Wallbox Double has two charging points (EVSE), A and B.
• Wallbox Double may have cable-equipped charging points instead of sockets.
• Wallbox Double may be supplied without a display and RFID reader. Their presence depends on configuration.

 

2.2 Description of selected station components

The image below identifies internal charger components in the socket configuration.

1. Electricity meter
2. Residual-current circuit breaker with overcurrent protection (RCBO) / miniature circuit breaker (MCB), depending on station configuration
3. Contactor
4. EV module: communications unit
5. Input terminals for incoming power conductors
6. SmartSystem, if included in the station
7. Power supply, beneath the residual-current device
8. Input terminals for communication bus conductors
9. Type 2 socket
10. Socket lock
11. Surge protection beneath the incoming terminals, optional

3. CHARGING STATION SPECIFICATIONS 

3.1 Basic parameters 

Standard AgeVolt Wallbox Double AC 2x22 kW version

4. PLANNING INSTALLATION

Installing a Wallbox Double charging station requires:

• Calculating the existing electrical load to determine maximum operating current.
• Calculating cable distances to ensure minimal voltage drop.
• Obtaining required local authority permits, such as a building permit.
• Arranging a subsequent electrical inspection of the installation.
• Conductors must be sized in accordance with local standards.
• Cable insulation must comply with local standards.

 

Before installation, discuss all electrical equipment, including residual-current protection, overcurrent protection and wiring, with a certified electrician.

 

For maximum charging power, use a three-phase circuit breaker rated at 63 A. Where this current is unavailable, adjust the station's maximum available charging current accordingly.

4.1 Power cable requirements 

Minimum: reduced charging power, 2 × 11 kW

Incoming CYKY-J 5 × 6 cable providing 400 V / 32 A at the Wallbox Double installation location.

32 A circuit breaker upstream of the station*

Optimal: full charging power, 2 × 22 kW

Incoming CYKY-J 5 × 16 cable providing 400 V / 63 A at the Wallbox Double installation location.

63 A circuit breaker upstream of the station*

*Supply cable parameters below this minimum may be installed following individual discussion with an AgeVolt technician, but reduce the available charging output.

Vehicles have different onboard chargers and charging power. Although the station is rated at 22 kW, three-phase 32 A, your vehicle may charge more slowly depending on its onboard charger.

Maintain the correct phase sequence L1, L2, L3 (U, V, W) at the station input!

If your configuration has no RCBO, ensure the incoming cable is already RCBO-protected in the building's distribution board!

 

4.2 Communication and data cable requirements

J-Y(ST)Y communication cable  must connect the station to SmartSystem if external, and SmartSystem to SmartMeter in the distribution board. It must also be installed between multiple stations for communication. We recommend it even for a single station to simplify future expansion.

 

Optimal requirement: J-Y(ST)Y 2 × 2 × 0.8

FTP communication cable is required to connect the station to the local network/internet when SmartSystem is inside the station.

Optimal requirements: FTP CAT5e or higher + RJ45

 

4.3 Space requirements 

Wallbox Double can be wall-mounted or placed on a stand. We recommend a brick/concrete wall, a stand on a concrete foundation of at least 40x40x40, or SmartBase near the parking space, accounting for cable length and convenient access throughout charging. Do not mount it on an unstable or flammable wall, fence, pillar or stand, or near heat sources. It is approved for outdoor installation without additional weather protection.

 

Follow local electrical installation, fire protection and accident prevention regulations, and maintain escape routes at the site. Do not install where falling objects could damage the station.

 

Recommendations:

Height h = 1.2 m above ground

• Adjust height for convenient access if needed, always considering safe station access during EV charging.

Zone B, r = 3 m, depending on cable length

• Account for cable length when positioning the station. Park with the EV charging port in zone B, within cable reach. Maintain sufficient space between vehicle and station for easy access to both throughout charging.

5. INSTALLATION

5.1 Installation tools and materials

Before installing Wallbox Double, prepare the following tools and materials: 

5.2 Preparing the installation area

Run CYKY-J power cable to the solid wall or stand, with sufficient length for the correct wallbox height plus 0.5 m for internal and subsequent connections. Prepare J-Y(ST)Y and CAT + RJ45 cables to the same length.

5.3 Wall installation 

Warning: Before installation, switch off the incoming cable's circuit breaker and verify absence of voltage.

 

Place the WB Double bracket at the recommended height; see section 4.3. Mark four suitable positions within its mounting openings.

Installation steps:

 

1. Drill four holes, Ø 8 mm and 70 mm deep

2. Insert wall plugs flush with the wall
3. Fit glands in the designated WB Double bracket openings: 2x32, 2x16
4. Secure the bracket using the supplied screws.
5. Place WB Double on the bracket and secure its corners with four M5x12 DIN6921 A2 screws; see the image.
6. Feed power and communication cables through glands beneath the wallbox. For easier installation, feed them through the bracket glands before fitting the bracket. Use the designated separate gland for each cable.

5.4 Stand installation

Warning: before installation, switch off the incoming cable's circuit breaker and verify absence of voltage. 

1. Fit glands in the designated bracket openings: 2x32, 4x16
2. Feed power, communication and data cables through the bracket glands.
3. Secure the WB Double bracket to the stand with the supplied screws.
4. Fit WB Double to the bracket and secure its corners with four M5x12 screws.

5.5 Connecting cables 

Warning: before installation, switch off the incoming cable's circuit breaker and verify that the cable is not live. 

5.5.1 Connecting power conductors  

First connect PE to the PE terminal, then N, followed by L1, L2 and L3. 

Where two incoming supplies feed the wallbox, use the left terminals for the left cable and right terminals for the right cable. 

Connections must comply with local standards and be performed by an electrician. An electrical inspection technician must inspect the whole installation. 

5.5.2 Connecting CIB conductors

Connect the red J-Y(ST)Y conductor to CIB+ as illustrated and the black conductor to CIB−. Fold the spare yellow and white conductors back along the cable and insulate with electrical tape.

If Wallbox Double requires connection to SmartSystem or SmartMeter, connect the J-Y(ST)Y signal cable to the terminal. First check that the SmartMeter cable's red conductor is on CIB+ and black conductor on CIB−.

5.5.2 Ethernet connection

If Wallbox Double contains a control unit, connect Ethernet to it. Feed CAT cable, minimum Cat5e, through the gland and fit an RJ45 connector. Wire according to T568B, as illustrated. Test manually fitted connectors at both ends using an Ethernet cable tester according to its manufacturer's instructions.

Connecting CAT cable to RJ45

1 — white/orange 

2 — orange

3 — white/green

4 — blue

5 — white/blue

6 — green 

7 — white/brown 

8 — brown 

After a successful Ethernet cable test, connect RJ45 to ETH2 on the control unit's bottom, as illustrated. Do not connect Ethernet to ETH1 at the top.

5.6 Installing the Type 2 charging cable

For a cable-equipped Wallbox Double, connect the Type 2 charging cable if it is not already installed.

Only a qualified electrician may perform installation. First switch off the incoming Wallbox Double cable's circuit breaker in the building distribution board. Follow the installation instructions.

The charging cable uses these conductor insulation colours: 

L1 brown, L2 black, L3 grey, charging N blue, charging PE green/yellow, CP white

Installation procedure: 

1. Disconnect Wallbox Double from power and remove the front cover by undoing four screws.
2. Install the cable glands using four screws and four nuts.
3. Feed each charging cable's end without the TYPE 2 plug through the glands on either side, leaving enough length for conductors to reach terminals with spare length.
4. Start by connecting the green/yellow PE conductor to the PE terminal as illustrated.
5. Connect L1, L2, L3 and N to the electricity meter terminals with corresponding labels, and tighten using a PH screwdriver.

!!!For the right charging cable/EVSE, use the sequence L3, L1, L2, N!!!

6. Insert the charging cable's CP signal conductor into slot C1 of the communication unit and tighten with a flat-head screwdriver.
7. Check that every conductor is correctly connected and appropriately tightened.
8. After checking connections, secure the charging cable using its gland.
9. Refit the front panel.

After these installation steps, the charging cable is ready for charging.

6. Commissioning the charging station

Before switching on the incoming cable's circuit breaker, check for short circuits between conductors using a multimeter.

6.1 Initial startup 

Switch on the wallbox's internal RCBO/MCB and close the front panel. Switch on the distribution board's switch/circuit breaker. If SmartSystem is external, power it too. Wallbox Double starts with factory defaults; adjust charging power to the available upstream breaker capacity.

 

7. Troubleshooting

7.1 Possible problems and solutions 

7.2 Restarting the charging station

Disconnect Wallbox Double from power for 10 seconds, then switch it on again

 

 

 

V.2024-002

Text © AgeVolt Slovakia, s. r. o. 2024

Image © AgeVolt Slovakia, s. r. o. 2024

This manual is protected by copyright. Use without the creator's consent is prohibited. Copying, including partial copying, requires their permission.

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