Mennekes AMTRON, AMTRON Standard E, AMTRON Start E, AMTRON Basic, AMTRON Pro Installation Manual

AMTRON® Wallbox
Start (E), Light, Standard E, Pro, Basic (E/R)

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Installationsanleitung für die Elektrofachkraft

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Installation manual for qualified electricians

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Instructions d'installation à l’attention de l’électricien

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Istruzioni per l'installazione per l'elettrotecnico specializzato

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1

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About this Document

© Copyright MENNEKES Elektrotechnik GmbH & Co. KG
Content subject to changes without notice.
This document is protected by copyright. It helps to ensure

the device is used safely and efficiently by the user. The
contents may not be duplicated or reproduced, in whole or in
part, without the prior consent of the copyright holder.

Document symbols

 Listing
 Check / Result

Tip

 Reference to another page in this document
 Reference to another document

Table of Contents

1 General .................................................................. 2

1.1 Structure of the installation instructions .................. 2

2 Safety .................................................................... 2

2.1 General Safety Information ..................................... 2

2.2 Safety Information .................................................. 3

2.3 Intended Use ........................................................... 3

2.4 Qualification of Personnel ....................................... 3

2.5 Warranty ................................................................. 3

2.6 Returning Devices ................................................... 3

3 Product Description .............................................. 4

3.1 General information ................................................ 4

3.2 Optional equipment ................................................ 4

3.3 Identification Plate .................................................. 5

3.4 Delivery Contents .................................................... 5

3.5 Assembly................................................................. 6

3.5.1 Exterior view ............................................... 6

3.5.2 Interior view................................................ 7

3.6 Components ........................................................... 8

3.6.1 Front panel ................................................. 8

3.6.2 CPX communication box ............................. 8

4 Technical Data ...................................................... 9

4.1 General data ........................................................... 9

4.1.1 Maximum cable cross-sections at terminals . 9

4.2 Ambient conditions ................................................. 9

5 Installation .......................................................... 10

5.1 Choice of location ................................................. 10

5.2 Unpacking ............................................................ 10

5.3 Opening the charging station ................................ 11

5.4 Assembly ............................................................... 11

5.4.1 Minimum distances ................................... 11

5.4.2 Installing the supply cable ......................... 11

5.4.3 Installing the charger station on the wall ... 12

5.5 Electrical connection .............................................. 13

5.5.1 Voltage supply / supply

network connection .................................. 13

5.5.2 Safeguarding and personal protection ...... 13

5.5.3 Terminals .................................................. 14

6 Commissioning ................................................... 15

6.1 Setting the configuration switches ........................ 15

6.1.1 Setting the charging current upper limit .... 15

6.1.2 Setting the colour code of the LED info bar16

6.2 Switching on the device ........................................ 16

6.2.1 Checking the charging station .................. 16

6.3 Closing the charging station .................................. 17

7 Operation ............................................................ 17

7.1 Charing cable storage ........................................... 17

7.2 LED Info bar .......................................................... 18

7.3 Multi-function button ............................................ 18

7.3.1 Terminating an on-going charging process 18

7.3.2 Re-activating the residual current circuit

breaker and circuit breaker ....................... 19

7.3.3 Testing the integrated residual current circuit

breaker (RCCB) ......................................... 19

7.3.4 Acknowledging faults ............................... 19

7.4 Key switch ............................................................. 19

7.5 Charging the vehicle ............................................. 19

7.5.1 Starting the charging process .................... 19

7.5.2 Terminating the charging process ............. 20

7.5.3 Power failure during charging process ...... 20

8 Maintenance ....................................................... 21

8.1 Maintenance plan ................................................. 21

9 Troubleshooting ................................................. 22

9.1 Troubleshooting by a qualified electrician .............. 22

9.2 Emergency release of charging plug ...................... 24

9.3 System monitoring ................................................ 24

10 Disassembly, Storage and Disposal .................. 25

10.1 Disassembly ........................................................... 25

10.2 Storage ................................................................. 25

10.3 Disposal ................................................................ 25

11 Appendix ............................................................. 26

11.1 Accesories ............................................................. 26

11.2 Glossary ................................................................ 26

11.3 Index ..................................................................... 27

2

chapter.

1 General

This manual is an essential aid for trouble-free and safe
setting up and use of the device.

The specifications in this manual apply only to the device
stated in the product description.

Read this manual before setting up the device.

Using this manual will help you to:

 avoid any risks for the user;
 become acquainted with the device;
 achieve optimum functioning;
 promptly detect and rectify faults;
 avoid any malfunctions due to improper installation;
 cut down on repair costs and reduce the number of

downtimes;

 improve the reliability and increase the service life of the

system;

 avoid causing harm to the environment.
This manual is an important part of the product and must be

kept for later use. The complete manual must be kept
available for all authorised people.

MENNEKES Elektrotechnik GmbH & Co. KG accepts no
liability for any damage resulting from non-observance of the
information in this manual.

1.1 Structure of the installation

instructions

General Information

This chapter contains general information on the Installation
manual.

Safety

This chapter contains details on the presentation of safety
information, provisions for liability and warranty and
information on intended use.

Product Description

This chapter contains basic information on the device and its
construction.

Technical Data

This chapter contains details on the technical data for the
device and the components used.

Installation

This chapter provides information for correctly installing and
mounting of the device.

Operation

This chapter contains information on operating the device.

Maintenance

This chapter provides details on the required maintenance
work and instructions on exchanging components when
necessary.

Disassembly, Storage and Disposal

This chapter provides information on correctly disassembling
storing and disposing of the device.

Appendix

This chapter contains a list of the available accessories, the
glossary and the index of the this document.

2 Safety

2.1 General Safety Information

The device has been designed using state-of-the-art
technology and is safe to operate.

Nevertheless, there may be residual risks associated with the
device under the following circumstances:

 The device is not used as intended.
 The device is not maintained properly.
 Non-compliance with the safety information given in this

manual.

 The device is modified or converted improperly.
 The maintenance work specified in this manual is not

carried out in due time.

Danger

Risk of death resulting from non-compliance with
documentation!

Any person authorised to work on the system must have
read and understood this manual, in particular the "Safety"

The electrical installation, initial operation and servicing of
the device may only be performed by qualified electricians
who have been authorised by the operator.

In addition to the safety information in this manual,
compliance with the following rules and regulations is also
required:

 relevant accident prevention regulations;
 occupational health and safety regulations;
 generally recognised technical safety regulations;
 country-specific regulations;
 requirements regarding intended use.

Furthermore, these rules and regulations may be
supplemented by internal factory or company requirements.

3

This symbol in conjunction with the signal word "Danger"
indicates an imminent danger.
Failure to follow the safety instructions will result in death or
serious injury.

This symbol in conjunction with the signal word
indicates a potentially hazardous situation.
Failure to follow the safety instructions may result in death
or serious injury.

This symbol in conjunction with the signal word "Caution"
indicates a potentially hazardous situation.
Failure to follow the safety instruction may result in light or
minor injuries.

This note indicates a potentially harmful situation.
Failure to follow the safety instructions may result in
damage to, or destruction of the product and / or other
components.

2.2 Safety Information

To recognise safety instructions in this manual at a glance,
the following signal words and symbols are used:

Danger

Warning

"Warning"

Caution

Caution

2.3 Intended Use

The device may be used for the purpose described in 3
"Product Description" on page 4 and in conjunction with the
supplied and approved components.
Any use exceeding the aforementioned shall be deemed
unintended. MENNEKES assumes no liability for damage
resulting from non-intended use. The risk is borne solely by
the user / operator.
Intended use also includes:

 compliance with all the information in this manual;
 carrying out of servicing tasks according to schedule.

The device may present hazards, if it is not used as intended.

2.4 Qualification of Personnel

The electrical installation, setup and maintenance of the
device may only be performed by qualified electricians, who
have received authorisation from the system operator to
perform such tasks. Such persons must have read and
understood the operating manual and must comply with the
information therein.

Requirements of qualified electricians:
 Knowledge of general and special safety and accident

prevention guidelines.

 Knowledge of relevant electrical guidelines (e.g. DIN VDE

0100 section 600 DIN VDE 0100722), as well as valid
national regulations.

 The ability to recognize risks and avoid possible dangers.

2.5 Warranty

In the event of complaints regarding the product, please
contact your responsible service partner immediately and
provide the following information:

 type designation / serial number;
 date of manufacture;
 reason for complaint;
 duration of use;
 ambient conditions (temperature, humidity).

2.6 Returning Devices

In case you return the device to MENNEKES for repair, please
use the original packaging or a suitable, safe transport
container.

4

Start1)

Start E2)

Light1)

Standard E2)

Pro1)

Basic1)

Basic E2)

Basic R2)

LED info bar

processes

Multi-function button

 Stop function

Reset function

breaker

activating the residual current circuit

breaker

Residual current circuit breaker (RCCB)

Circuit breaker (CB)

from outside

3 Product Description

3.1 General information

The MENNEKES AMTRON® Wallbox is a charging station for
use in private and semi-public areas, such as company car
parks, depots or private land.
The charging station is used exclusively for charging
electrically powered vehicles.

 Mode 3 charging according to IEC 61851-1:2010.
 Plugs and sockets according to IEC 62196.

The charging station is operated as a stand-alone solution
without connection to a master control system.
The charging station is intended solely for fixed installation.

Features:

 Status information through LED info bar.
 MENNEKES CPX communication and control unit.
 Multi-function button (termination of charging process,

RCCB test, re-activation of RCCBs and CBs).

 Unlocking function in the event of a power failure when

charging with a type 2 charging plug (mode 3).

 Enclosure made of AMELAN.
 Integrated cable storage.
 Wired ready for connection.

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3.2 Optional equipment

Depending on the version of the charging station, the
following optional features are available:

Connector systems

Fig. 1

Depending on the version, the charging station is equipped
one of the following connector systems:

A Charging socket type 2 for use with separate charging

cable.

B Permanently connected charging cable with charging

connector type 2.

C Permanently connected charging cable with charging

connector type 1.

Key switch for authorising charging



 Testing the residual current circuit

 Re-

Calibrated digital energy meter, readable

1) Version for Germany

2) EU version

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       

— — —

    

  

—



— — —

       

— —

— —

— —
— —








—

—

—
—

— — — —

 

 

 
 

—

—

—
— —







   

5

1
2
3
4

connection

5
6

7

1
2
3
4

hardware (screws, dowels,
plugs)

5
6
7

3.3 Identification Plate

Fig. 2: Name plate (example)

Manufacturer
Protection class
Barcode
Supply network

Date of manufacture
Part number / serial

number

Type

3.4 Delivery Contents

Fig. 3: Delivery contents

Charging station

Key set for authorisation

1)

Allen key
Bag with installation

Operation manual
Installation manual
Quick guide

1) Only for versions Basic (E/R) and Standard E.

The keys can be reordered from the following address

quoting the code number on the key / lock:

Günter Ernsthäuser Sicherheitstechnik GmbH
Walsroder Straße, 2630851 Langenhagen, Germany
Phone: +49 (0)5 11 / 74 30 30 30
Fax: +49 (0)5 11 / 74 41 05
E-mail: [e-mail]

6

1
2
3
4
5

Fastening screws for front
enclosure part

6

1
2

Fastening screws for front

3

4
5
6

3.5 Assembly

3.5.1 Exterior view

Fig. 4: Front view (example)

Rear enclosure part

Front enclosure part
Window for counter

1)

Front panel

1) Only for versions Pro and Basic.

Predetermined breaking

point for supply line /
cable duct from below

Fig. 5: Rear view (example)

Rear enclosure part

enclosure part

Opening for cable duct
Fastening holes
Cable glands

Air outlet

The enclosure of the charging station has three parts and
consists of rear enclosure part, front enclosure part and the
front panel. The front panel has to be folded down to access
the internal components. The design of the front panel
depends on the version of the charging station.

 See Chapter 3.6.1 "Front panel" on page 8.

7

1
2

3

3.5.2 Interior view

Fig. 6: Interior view of rear enclosure part (example)

1 Counter
2 Circuit breaker (CB)
3 Multi-function actuator
4 Charging contactor
5 System monitoring
6 Cable glands

7 Controller (CPX

communication box)

8 Residual current circuit

breaker (RCCB)

9 Mains adapter
0 Terminals for mains

connection

k Actuator control

The charging station contains all required components for
controlling the charging process and communicating with the
vehicle.
The design of the components depends on the version of the
charging station.

Fig. 7: Interior view of front panel (example)

Configuration switches

Socket insert

Actuator (plug interlock)

The configuration switches are used to set the charging
current upper limit and the colour scheme of the LED info
bar.

 See Chapter 6.1 "Setting the configuration switches" on

page 15.

The actuator interlocks the charging plug in the charging
socket during the charging process (applies only to charging
stations with charging socket Type 2).

8

1
2

3
4

with hinged lid

1
2
3 Plug strip for low voltage DC

3.6 Components

3.6.1 Front panel

Fig. 8: Front panel (example)

Multi-function button

Key switch (optional)

LED info bar
Charging socket type 2

The control and display elements as well as the charging
socket of the charging station are located on the front panel.
The design of the front panel depends on the version of the
charging station.

3.6.2 CPX communication box

Fig. 9: CPX communication box

Plug strip for low voltage 230 V AC

Plug strip for front panel

The CPX communication box controls the charging process
fully automatically and performs the following functions:

 Detecting the current-carrying capacity of the charging

cable with resistance coding. Unsuitable charging cables
are rejected.

 Verification of the conditions for proper charging
 Communicating with the vehicle using the CP contact.

The charging current upper limit is communicated to the
vehicle with a PWM signal. The protective earth
connection to the vehicle is checked at the same time.

 Controlling the locking of the charging plug in the

charging socket (for devices with charging socket Type

2).

 Controlling the charging contactor.

9

Nominal voltage

230 / 400 V AC ±10 %

frequency

Nominal current

16 A

32 A

16 A

32 A

configuration

Mode 3

Mode 3

phase

phase

phase

phase

2 with shutter)

IP 54 (with charging socket Type 2)

Protection class

I

category

rigid

flexible

3.7 kW

3 x 6 mm²

3 x 4 mm²

7.4 kW

3 x 10 mm²

3 x 6 mm²

11 kW

5 x 6 mm²

5 x 4 mm²

22 kW

Ambient temperature

-25 to +40 °C

over 24 hours

Storage temperature

-25 to +40 °C

sea level

condensing)

4 Technical Data

4.1 General data

3.7 kW 7.4 kW 11 kW 22 kW

4.2 Ambient conditions

Average temperature

< 35 °C

Nominal

Maximum back-

50 Hz

according to name plate /

up fuse
Charging power

Max. charging
current

3.7 kW 7.4 kW 11 kW 22 kW

16 A,
single-

32 A,
single-

16 A,
three-

32 A,
three-

Protection class IP 44 (with permanently attached

charging cable or charging socket Type

Overvoltage

Dimensions

CAT III according to EN60664-1

474.8 mm x 259.2 mm x 220.1 mm

(H x W x D)
Weight 5 to 8.5 kg (depending on version)

4.1.1 Maximum cable cross-sections at terminals

Altitude max. 2,000 metres above

Relative humidity max. 95 % (non-

5 x 10 mm² 5 x 6 mm²

Refer to special instructions on charging stations without

integrated circuit breaker (EU variants) in Chapter 5.5.2
"Safeguarding and personal protection" on page 13!

10

met.

installation location:

Use a soft base to set aside the charging station.

5 Installation

Danger

Mortal danger posed by improper installation.

There is a risk of injury for persons performing tasks for
which they are neither qualified nor have received
appropriate training.

 The device may only be installed by persons who are

familiar with this task, have been instructed with
regard to the associated hazards and who possess the
necessary qualifications.

 Before installing, all safety requirements must first be

5.1 Choice of location

Warning

5.2 Unpacking

Caution

Damage to the charging station by improper
handling.

Collisions and impacts may damage the charging station.

 Move the charging station with utmost caution.



Risk due to unsuitable environmental conditions /
installation locations.

Unsuitable ambient conditions and installation locations
may lead to dangerous situations when dealing with
electricity.
Please observe the following points when selecting an

 Do not install in potentially explosive atmospheres (e.g.

gas refuelling stations).

 Do not install in flood-prone areas.
 Comply with local technical connection requirements and

safety rules.

 For ambient conditions, see Chapter 4.2 "Ambient

conditions" on page 9.

 The charging system must be protected from direct

exposure to water jets.

 The mounting surface must have sufficient strength to

withstand the mechanical stresses. When mounting on
plasterboard walls they must have at least two layers.

Fig. 10: Unpacking

Unpacking the charging station:

1. Remove the charging station

1 and the drilling jig 2

from cardboard box.

2. Place the charging station on a soft base.

11

transport support or handle.

5.3 Opening the charging station

Fig. 11: Opening the charging station

Caution

Damage to the device.

Damage to the device by improper handling.
Do not use the brass bolts for attaching the front panel as

When delivered, the front enclosure part is not attached

with screws. The screws
accessory bag.

Opening the charging station

1. Remove the screws
Make sure that the screws are not lost.

2. Remove the screws
the front panel

4. Make sure that the screws are not

lost.

After the installation of the charging station, the

enclosure screws on the back of the charging station can
be reached only with a shortened Allen key. The supplied
Allen key can be used.

1 are stored in the enclosed

1 and the front enclosure part 2.

3 for the front panel and fold down

5.4 Assembly

5.4.1 Minimum distances

Fig. 12: Minimum distances (mm)

Maintain the specified minimum distances for unrestricted
access during operation, maintenance and repair.

5.4.2 Installing the supply cable
On-wall installation of supply cable

If supply cable or cable duct comes from below, you have to
break out the pre-cut opening in the front enclosure part.

The charging station can be placed on an on-site

installed cable duct (H 30mm x W 45mm). Suitable
recesses can be found on the back of the rear enclosure
part.

 See also "Fig. 13: Wall mounting" on page 12.

Concealed installation of the supply cable

In a concealed installation of supply, data, and control lines,
their positions must be arranged in accordance with the
drilling jig.

12

A
1
2
3

B
4
5
6

5.4.3 Installing the charger station on the wall

For installation on concrete, brick and wood walls, use

the included installation hardware.

For other surfaces, a suitable on-site mounting method must
be chosen.
MENNEKES recommends the installation of the charging
station at a height (up to the top edge of the enclosure) of
approximately 1.50 metres above the finished floor.

 See also "Fig. 13: Wall mounting" on page 12.

1. Mark the mounting holes using the supplied drilling jig
and a spirit level.

2. Drill the holes in the wall with the diameter specified for
the selected installation hardware.

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3. Route the supply cable and possibly the data and control
cables to the positions specified on the frilling jig. A cable
of approx. 40 cm cable is needed for the electrical
connection inside the charging station.

4. Open the charging station (see Chapter 5.3 "Opening
the charging station" on page 11).

5. Run the supply cable and possibly the data and control
cables through the cable glands into the charging
station.

6. Secure the charging station to the wall by using dowels
and screws.

7. Check the charger for firm and secure fit.

Fig. 13: Wall mounting

Marking

Cable duct (for supply cable from above)
Cable duct (for supply cable from below)
Drilling jig

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Installation

Dowels
Screw
Plug (touch guard)

13

and secure the danger area.

installed behind RCCBs (type A) sensitive to pulse currents.

type A

type B

single-phase

phase

phase)

phase)

phase)

5.5 Electrical connection

5.5.1 Voltage supply / supply network connection

Danger

Risk of death by electric shock!

Components have voltage applied.
Contact with current conducting parts results in an electric
shock, burns or death.
When working with the electrical system, the following
points must be observed:

 Disconnect device from voltage.
 Secure device from being turned back on.
 Ensure that no voltage is applied.
 Earth and short-circuit the unit.
 Cover neighbouring componets that are under voltage

5.5.2 Safeguarding and personal protection

Danger

Danger to life by electric shock

RCCBs (type B) sensitive to universal currents may not

Depending on the equipment package, the charging stations
are fitted with the required safety equipment according to
the following table.

Version RCCB

Light, Pro, Basic

(3.7 kW / 7.4 kW)



RCCB

—

CB



During installation, the following points must also be
observed:

 The electrical installation, setting-up and maintenance of

the device may only be carried out by qualified
electricians and in compliance with the applicable
national regulations (see chapter entitled 2.4
"Qualification of Personnel" on page 3).

 Before connecting the device, caution must be taken to

ensure that it is free of voltage or the appropriate
protective measures have been taken.

Note the following points when connecting to the power
supply:

 Observe DIN VDE 0100 Part 530 for installation in

Germany.

 Observe the applicable national / local regulations when

installing in other countries.

 Ensure a clockwise rotating field for a three-phase

connection.

Light, Pro, Basic

(11 kW / 22 kW) three-

Start E, Standard E,
Basic E

(3.7 kW / 7.4 kW single­phase)
(11 kW / 22 kW three-

Basic R

(3.7 kW / 7.4 kW single-

Basic R

(11 kW / 22 kW three-

—

 

— — —



—

— —



—

14

not exceed the specifications on the nameplate.

Note the following points when connecting the charging
station:

 Each charging station must be connected using a

separate residual current circuit breaker (residual current
circuit breaker type A for single-phase versions, residual
current circuit breaker type B for three-phase versions).

 No other circuits may be connected to this residual

current circuit breaker.

 For versions Start E, Standard E and Basic E, the residual

current circuit breaker (RCCB) must be provided on site.

 For versions Start E, Standard E, Basic E und Basic R, the

circuit breaker (CB) must be provided on site.

Design of the on-site circuit breaker

Danger

Fire hazard due to device overload.

Fire hazard due to device overload in case of wrong design
of the on-site circuit breaker.
The nominal current of the selected circuit breaker must

5.5.3 Terminals

The EU versions of the devices (Start E, Standard E, Basic E
and Basic R) are supplied without integrated circuit breakers.
The circuit breakers must be scaled according to the
specifications on the name plate, the configuration switch
settings, the supply line (line length, cable cross-section) to
the charging station and national regulations.

 See Chapter 6.1.1 "Setting the charging current upper

limit" on page 15.

Fig. 14: Terminals for the supply line (example)

Connect the supply line:

1. Strip the supply cable over a length of 370 mm and
remove the core insulation over a length of 12 mm.

2. Connect the cores
terminal block

2 of the supply cable to the

1 according to the circuit diagram. The

protective earth conductor (PE) must be longer than all
other conductors!

3. Check that the individual cores are properly connected
and that the screws are tightened.

15

met.

2 Colour scheme

ON

ON

ON

OFF

OFF

7 A

OFF

OFF

OFF

ON

OFF

8 A

ON

OFF

OFF

ON

OFF

9 A … … … … … …

OFF

OFF

OFF

OFF

ON

16 A

OFF

OFF

ON

OFF

ON

20 A

OFF

OFF

OFF

ON

ON

24 A

… … … … …

…

6 Commissioning

Warning

Danger due to incorrect commissioning!

There is an increased risk of injury for persons performing
tasks for which they are neither qualified nor have received
appropriate instruction.

 The device may only be installed by persons who are

familiar with this task, have been instructed with
regard to the associated hazards and who possess the
necessary qualifications.

 Before installing, all safety requirements must first be

6.1.1 Setting the charging current upper limit

The charging current provided can be limited with
configuration switches 1 to 5 (S1 to S5). This allows, for
example, adapting the charging current to the power output
provided by the domestic installation.
The maximum charging current provided depends on the
device type (see name plate) and cannot be exceeded.
The adjustment is made by combining individual
configuration switch settings associated with current values.
The values of the configuration switch settings add up
accordingly. Example: S1 ON and S4 ON corresponds to 9 A.
Here are some examples of switch position for different
charging currents:

6.1 Setting the configuration switches

Fig. 15: Configuration switches

1 Settings of charging

current

3 Reserved, factory

setting: OFF

On the back of the front panel are eight configuration
switches. These configuration switches are used to set the
charging current upper limit and the colour scheme of the
LED info bar.

Changing the setting of the configuration switches takes

effect only after restarting the charging station. This is
achieved by turning the power supply at the control fuse
off and on.

The settings of configuration switches 7 and 8 should

not be changed; they are reserved for future expansions.

S1 S2 S3 S4 S5

1 A 2 A 4 A 8 A 16 A Max.

charging
current

OFF OFF OFF OFF OFF No limit
OFF ON ON OFF OFF 6 A

Setting a charging current of <6 A is not possible; this

would be considered a limitation to 0 A charging current.

16

Standard

Option

Operational (blue)

Operational (green)

Charging (green)

Charging (blue)

Waiting period (white)

Malfunction (red)

Risk of injury

Risk of injury due to damage to the charging station.
If it appears
not possible:




 See Chapter 9 "Troubleshooting" on page 22.

6.1.2 Setting the colour code of the LED info bar

The configuration switch 6 (S6) is used to set the colour
scheme of the LED info bar.
The luminous colour of the symbols "Operational" and
"Charging" can be adapted, for example, to requirements
typical for a country.

S6 OFF

S6 ON

6.2.1 Checking the charging station

Warning

that safe operation of the charging station is

Put the charging station out of service.
Determine and eliminate any faults / malfunctions.

 See Chapter 7.2 "LED Info bar" on page 18 for more

information about displays and flash codes.

6.2 Switching on the device

To turn on the charging station, proceed as follows:

1. Make sure that all protective devices (RCCBs and CBs) in
the charging station are turned on.

2. Turn on the power supply (back-up fuses, residual
current circuit breaker or circuit breaker).

3. Check the supply voltage at the charging station for
clockwise rotating field (see Chapter 9.3 "System
monitoring" on page 24).

 The LED on the power supply unit will light.
 The corresponding symbol on the LED info bar indicates

the operational readiness of the charging station.

Inspection in accordance with DIN VDE 0100 or national
regulations

Carry out an inspection of the charging station in accordance
with DIN VDE 0100 or the applicable national regulations
prior to the initial setting-up process and according to the
specified maintenance intervals.

System check

A test box is required for a systems check. The test box
simulates the communication with the vehicle.
Test boxes are available from MENNEKES.

 See Chapter 11.1 "Accesories" on page 26.
Carry out a system check with a test box before approving

the charging station for use.
 Carry out the system check according to the

documentation of the test box.

17

transport support or handle.

 See Chapter 9 "Troubleshooting" on page 22 .

6.3 Closing the charging station

7 Operation

Warning

Risk of injury

There is a risk of injury due to damage to the charging
system.
If it appears that the charging system cannot be operated
safely:

 Take the charging system out of service.
 Determine and eliminate any faults / malfunctions.

7.1 Charing cable storage

Fig. 16: Closing the charging station

Caution

Damage to the device.

Damage to the device by improper handling.
Do not use the brass bolts for attaching the front panel as

Closing the charging station

1. Fold up the front panel
the screws

2.

2. Fit the front enclosure part

4 (M5 x 35) and 5 (M5 x 16).

When delivered, the front enclosure part is not attached

with screws. The screws
enclosed accessory bag.

After the installation of the charging station, the

enclosure screws on the back of the charging station can
be reached only with a shortened Allen key. The supplied
Allen key can be used.

1. Secure the front panel with

3 and secure with screws

4 und 5 are stored in the

Fig. 17: Integrated charging cable storage

The design of the enclosure

18

station.

connected to the charging station.

vehicle.

permanently

deactivation.

vehicle.

Flashes red

7.2 LED Info bar

The LED info bar displays the operating status of the charging
station. The colour scheme (green / blue) for "Operational /
Charging" depends on the setting of the configuration
switches during the setting-up process.

LED info bar Description

Ready for operation

The charging station is operational; no

lit blue

vehicle is connected to the charging

permanently

Once-off authorisation (Standard E,
Basic (E/R) only)

flashes blue

The charging station is authorised for a
single charging process; no vehicle is

Ready to charge: vehicle pauses

All requirements for charging an electric

pulsating

green

vehicle are met.
A charging process is not taking place.
The charging process is paused due to a
vehicle feedback or was terminated by the

Charging enabled

All requirements for charging an electric

lit green

vehicle are met. Charging in progress.

Overtemperature warning

The charging station reduces the charging

flashes

current to prevent overheating and

green

Wait time

Connection to the vehicle is established.

flashes

white

Charging at the vehicle or at the charging
station has been terminated. Waiting for
removing the charging cable from the

Fault

A fault prevents the vehicle from charging.

lit red

permanently

 See Chapter 9 "Troubleshooting" on

page 22.

7.3 Multi-function button

Fig. 18: Multi-function button

The multi-function button has several functions:

A Terminating an on-going charging process (only for

charging stations without authorisation) and
acknowledging of errors.

B Re-activating the residual current circuit breaker (RCCB)

and / or circuit breaker (CB) in case of failure.

C Triggering the test-function of the residual current circuit

breaker (RCCB).

7.3.1 Terminating an on-going charging process

The charging process by charging stations without
authorisation (Start (E), Light and Pro) can be terminated with
the multi-function button.

 Press the multi-function button to terminate a charging

process.

19

1

2

 Use only undamaged charging cables.

7.3.2 Re-activating the residual current circuit

breaker and circuit breaker

The multi-function button can be used to re-activate the
residual current circuit breaker (RCCB) and circuit breaker
(CB) inside the charging station mechanically from the
outside without opening the enclosure.

1. Press the multi-function button until you feel resistance.

2. Now press the multi-function button firmly up to the end
position.

Residual current circuit breaker (RCCB) and circuit breaker
(CB) are re-activated and charging station is operational
again.

7.3.3 Testing the integrated residual current circuit

breaker (RCCB)

The multi-function button can be used to trigger the test­function of the residual current circuit breaker (RCCB) inside
the charging station from the outside without opening the
enclosure.

1. Insert a flat screwdriver with a blade width of 8 to
10 mm in the slot of the multi-function button.

2. Turn the multi-function button by 90 ° anti-clockwise.

3. Press the multi-function button briefly (about 2 seconds).

The residual current circuit breaker (RCCB) is triggered and
the fault display on the LED info bar flashes red.

4. Re-activate the residual current circuit breaker (RCCB)
(see Chapter 7.3.2 "Re-activating the residual current
circuit breaker and circuit breaker" on page 19).

7.3.4 Acknowledging faults

Faults are indicated by the "Fault" LED on LED info bar.
Some faults can be resolved by acknowledging.

 Press the multi-function button to acknowledge a fault.
 See also Chapter 9 "Troubleshooting" on page 22.

7.4 Key switch

Fig. 19: Key switch (only version "Basic")

Multi-function button

Key switch

The key switch can be used to control the authorisation of
charging processes.

 Position 0 (neutral position): charging function disabled.
 Position I (momentary): charging function enabled once-

off.
Only one charging process is possible. If another
charging process should be authorised, you need to key
to position I again.

 Position II (engaging): charging function is permanently

enabled.

The key can be removed in switch positions 0 and II.

7.5 Charging the vehicle

Warning

Risk of injury due to incorrect handling!

Using an extension cable or second charging cable may
result in electric shock or cable fire. Using extension cables
is not permitted.

 Never use more than one charging cable for

connection the electric vehicle to the charging station.

7.5.1 Starting the charging process

The charging station can be used without prior authorisation.
Charging stations with key switch require prior authorisation
by using the key switch.

 See Chapter 7.4 "Key switch" on page 19.

20

Fig. 20: Connecting the charging cable

the charging socket.

Make sure that vehicle and charging cable are suitable for
mode 3 charging.

1. Connect the charging cable to the vehicle.

2. Insert the plug of the charging cable completely into the
charging socket type 2 at the charging station (only for
charging stations with integrated charging socket
type 2).

The charging station performs now the following steps
automatically:

 Detecting the current-carrying capacity of the charging

cable with resistance coding. Unsuitable charging cables
are rejected.

 It checks that the requirements for proper charging have

been met.

 Communicating with the vehicle using the CP contact.

The charging current upper limit is communicated to the
vehicle with a PWM signal. The protective earth
connection is checked at the same time.

 The charging station interlocks the charging plug

mechanically (only for charging stations with integrated
charging socket type 2). The vehicle signals the charging
station that it is ready for charging. The charging process
starts.

 The symbol "Charging in Progress" lights up on the LED

info bar.

The maximum available charging current depends on the
following points

 Power rating of the charging station.
 Features / version of the charging station.
 Current load capacity of the charging cable.
 Configuration of DIP switches in the charging station.

7.5.2 Terminating the charging process

Caution

Damage to the charging cable.

Pulling the cable may cause cable breaks and other
damages.
Remove the charging cable only by pulling the plug from

1. Press the multi-function button on the charging station
or terminate the charging process at the vehicle (see
Chapter 7.3.1 "Terminating an on-going charging
process" on page 18).

2. Remove the charging cable by pulling the plug from the
charging socket.

3. Remove the charging cable from the vehicle.

7.5.3 Power failure during charging process

A power failure aborts the charging process.
The charging plug of charging stations with charging socket
type 2 is unlocked and removed.
If the charging plug cannot be pulled out, an actuator has
mechanically interlocked the charging plug.

 See Chapter 9 "Troubleshooting" on page 22.

21

to performing maintenance / repairs.

and secure the danger area.

damage.

fastening.

with damp cloth.

damage.

damage.

See Chapter 7.3.3 on page 19.

and connectors

damage.

damage.

Check function

16.

8 Maintenance

Danger

Risk of death resulting from improper maintenance /
repair.

There is a risk of injury for persons performing tasks for
which they are neither qualified nor have received
appropriate training.

 The maintenance / repair of the device may be

performed only by persons who are familiar with this
task, have been instructed with regard to the
associated hazards and who possess the necessary
qualifications.

 All technical safety conditions have to be satisfied prior

Maintenance interval every 6 months (biannually)

Part / component Maintenance work

Enclosure Visual inspection for defects or

Check the device for secure

Clean the outside of the enclosure

Front panel Visual inspection for defects or

Switching and safety

Visual inspection for defects or

devices

Check the function of the circuit
breaker (CB).

Danger

Risk of death by electric shock!

Components have voltage applied.
Contact with current conducting parts results in an electric
shock, burns or death.
When working with the electrical system, the following
points must be observed:

 Disconnect device from voltage.
 Secure device from being turned back on.
 Ensure that no voltage is applied.
 Earth and short-circuit the unit.
 Cover neighbouring componets that are under voltage

8.1 Maintenance plan

Carry out the following maintenance work at the specified
intervals.

Maintenance interval every four years

In addition, carry out all maintenance specified in
"Maintenance interval every 6 months (biannually)".

Part / component Maintenance work

Cable connections

Check for firm seat

Visual inspection for defects or

Charging station Visual inspection for defects or

System check Check the system

 See Chapter 6.2.1 on page

22

to performing maintenance / repairs.

and secure the danger area.

lit red permanently

station.

cooled down.

your service partner.

9 Troubleshooting

Danger

Danger

Risk of death resulting from improper maintenance /
repair.

There is a risk of injury for persons performing tasks for
which they are neither qualified nor have received
appropriate training.

 The maintenance / repair of the device may be

performed only by persons who are familiar with this
task, have been instructed with regard to the
associated hazards and who possess the necessary
qualifications.

 All technical safety conditions have to be satisfied prior

Wechsel ein-au f zweispalti g

9.1 Troubleshooting by a qualified electrician

Risk of death by electric shock!

Components have voltage applied.
Contact with current conducting parts results in an electric
shock, burns or death.
When working with the electrical system, the following
points must be observed:

 Disconnect device from voltage.
 Secure device from being turned back on.
 Ensure that no voltage is applied.
 Earth and short-circuit the unit.
 Cover neighbouring componets that are under voltage

Fault Cause Notes on troubleshooting

Self-test of the charging station is
faulty.

Thermal shutdown of the charging

Acknowledge the fault with multi­function button.

Wait until the charging station has

Internal system error. Acknowledge the fault with multi-

function button.
If you cannot rectify the fault, contact

23

Fault

Cause

Notes on troubleshooting

 See Chapter 7.3.2 on page 19.

again.

necessary.

 See Chapter 9.2 on page 24.

station.

tripped.

Residual current circuit breaker (RCCB)

flashing red

or circuit breaker (CB) in the charging
station has tripped.

Error in the power supply to the

Re-activate residual current circuit
breaker (RCCB) or circuit breaker (CB).

Check the power supply.
charging station (incorrect phase
sequence, missing phase, etc.).

Charging plug not interlocked. Acknowledge the fault with multi-

function button.

Disconnect charging cable and plug in

Incorrect or faulty charging cable. Acknowledge the fault with multi-

function button.

Disconnect charging cable and plug in

again.

Check charging cable and replace if

System monitoring indicates faulty
operating state.

Charging plug cannot be removed

E.g. incorrect phase sequence, missing
phase / neutral, undervoltage.

Check the power supply.

 See Chapter 9.3 on page 24.

Failure of the unlocking function. Unlock the charging plug manually.

from the charging station.

LED info bar does not light up. No power supply to the charging

Control fuse in the charging station has

If you cannot rectify the error or fault, contact your local service partner.

Wechsel ein-au f zweispaltig

Check the power supply.

Re-activate control fuse.

24

A

clockwise rotating field is applied.

B

The corresponding LED is off.

C

A flashing LED moves from L3 ... L1.

D

The corresponding LED flashes.

9.2 Emergency release of charging plug

If the unlocking function fails, the charging plug may be
mechanically locked in place in the socket panel by an
actuator.
The charging plug cannot be removed and must be
unlocked manually.

Fig. 21: Emergency release of the charging plug

1. Open the charging station, see Chapter 5.3 "Opening
the charging station" on page 11.

2. Attach the red lever
actuator

1.

2 to the square shaft of the

The red lever is attached with a cable tie close to the

actuator.

3. Turn the red lever on the actuator by 90 ° anti­clockwise.

4. Remove the charging plug.

5. Remove the red lever and attach it close to the
actuator with a cable tie.

6. Close the charging station, see Chapter 6.3 "Closing
the charging station" on page 17.

9.3 System monitoring

Fig. 22: System monitoring

The system monitor checks the three phases (L1, L2, L3)
and the neutral conductor (N) of the charging station's
power supply for correct phase sequence, phase failure or
undervoltage.

In single-phase charging stations (3.7 / 7.4 kW), the

system checks only for mains failure and undervoltage.

The operating status is indicated by three LEDs:

No. Description

All LEDs light up. All three phases are present,

Phase failure / power failure (only for three­phase units)

Anti-clockwise rotating field (only for three­phase units).

Undervoltage between two phases or between
phase and neutral conductor.
L - L = < 295 V
L - N = < 170 V

25

and secure the danger area.

10 Disassembly, Storage

and Disposal

10.1 Disassembly

Danger

Risk of death by electric shock!

Components have voltage applied.
Contact with current conducting parts results in an electric
shock, burns or death.
When working with the electrical system, the following
points must be observed:

 Disconnect device from voltage.
 Secure device from being turned back on.
 Ensure that no voltage is applied.
 Earth and short-circuit the unit.
 Cover neighbouring componets that are under voltage

10.3 Disposal

The disposal of old devices must comply with the common
national and regional laws and regulations. Ecological
considerations must be taken into account.

Old devices and batteries cannot be disposed of with
household rubbish.

 Dispose of the device in accordance with the

applicable environmental regulations of your country.

 Dispose of old devices through your specialised dealer.
 Dispose of old batteries in a recycling bin for old

batteries or through the specialised dealer.

 Dispose of the packaging material in the recycling bin

for cardboard, paper and plastic.

Disassemble as follows:

1. Make sure that the power supply is turned off.

2. Disconnect the supply line.

3. Remove the charging station.

10.2 Storage

The storage spaces must be dry and temperature
regulated. See chapter 4 "Technical Data" on page 9 for
ambient storage conditions.

26

On request

Channel adapter for cable ducts

3P+N+PE

320011

Test box

Designation of the plugs and

communicated.

charging controller.

to universal currents.

CB

Circuit breaker

the charging socket.

activating the immobiliser.

communication.

Term

Explanation

vehicle.

44 kW AC.

current load capacity.

11 Appendix

11.1 Accesories

Part number Description

36113 Charging cable Mode 3, 32 A,

11.2 Glossary

Term Explanation
CP Control pilot

sockets contacts / line, over
which the information is

CPX communication box MENNEKES designation of

the PWM module or

RCCB Residual current circuit

breaker
Type A = sensitive to pulse
currents, type B = sensitive

PWM module Element of the charging

station (in mode 3 charging)
for communicating with the

Type 2 (IEC 62196-2) Single- and three-phase

charging couplers with
identical plug geometry for
charging powers from 3.7 to

Resistance coding The charging cables feature

resistance coding that is
analysed by the charging
system.
The resistance value defines
the maximum allowable
current of the charging
cable.
The charging system will
reject cables with insufficient

Mode 3 (IEC 61851) Charging mode for vehicles

with a type 2
communication interface on

PP Proximity Pilot or Plug

Present

Contact for determining the
current load capacity of the
charging cable and

PWM Pulse-width modulation

Transmission type of data

27

11.3 Index

Glossary ......................................................................... 26

A

Accessories ............................................................... 16, 26

Ambient conditions .................................................... 9, 10

Appendix ........................................................................ 26

Assembly .................................................................... 6, 11

C

Charging cable storage .................................................. 17

Charging current upper limit .......................................... 15

Charging plug

emergency release ...................................................... 24

Charging process

power failure .............................................................. 20

starting ....................................................................... 19

terminating ........................................................... 18, 20

Charging station

closing ........................................................................ 17

opening ...................................................................... 11

Choice of location .......................................................... 10

Commissioning............................................................... 15

Configuration switches ............................................... 7, 15

Connector systems ........................................................... 4

CPX communication box .................................................. 8

D

Delivery Contents ............................................................. 5

Disassembly .................................................................... 25

Disposal .......................................................................... 25

E

Electrical connection ....................................................... 13

Emergency release .......................................................... 24

Emergency release of charging plug ............................... 24

Exterior view..................................................................... 6

F

Fault

acknowledging ........................................................... 19

Front panel ................................................................... 6, 8

G

General data .................................................................... 9

General Information ......................................................... 2

I

Identification Plate ............................................................ 5

Index .............................................................................. 26

Installation ..................................................................... 10

Intended Use .................................................................... 3

Interior view ..................................................................... 7

K

Key switch ...................................................................... 19

L

LED info bar ............................................................. 16, 18

switching colour scheme ............................................. 16

M

Maintenance .................................................................. 21

Maintenance plan .......................................................... 21

Minimum distances ........................................................ 11

Multi-function button ..................................................... 18

O

Operation ....................................................................... 17

P

Personnel qualification ............................................... 3, 13

electrician ..................................................................... 3

Product description ...................................................... 3, 4

R

Re-activating CB ............................................................. 19

Re-activating RCCB ........................................................ 19

Returning Devices ............................................................. 3

S

Safety ............................................................................... 2

Safety Information ............................................................ 3

Storage .......................................................................... 25

Switching on .................................................................. 16

System check ................................................................. 16

System monitoring ................................................... 16, 24

T

Technical Data ............................................................ 9, 25

Terminals ....................................................................... 14

28

Troubleshooting .............................. 16, 17, 18, 19, 20, 22

Turning on ..................................................................... 16

U

Unpacking ...................................................................... 10

Wechsel ein-au f zweispalti g

V

Voltage supply ............................................................... 13

W

Warranty .......................................................................... 3