Installing an EV Charger

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EV Charger Install

I had some quotes for installing an EV charger and wondered about doing a self-install. I purchased the parts and my best friend came over to help me with the install (Thanks Phil!) It is worth having someone knowledgeable and trusted to act as the "competent" part of the installation team!

  1. 25m SWA 6mm2 three core cable (for single-phase install)
  2. EV Charger
  3. Type B RCD with DC voltage detection
  4. 20mm cleats
  5. 32mm stuffing gland black
  6. 4 x 20mm SWA Connectors (Brass) Exterior grade
  7. Screws and wall plugs for fixing
  8. 40 Amp dual pole isolator
  9. 5ft Earth Rod
  10. Earth pit
  11. 6mm Earth cable
  12. Conduit and connector for conduit
  13. Old loyalty cards to use as packing to level out wallbox mounting

EV Charger

For my make of charger/wall box, I need to check a couple of DIP switches and set the current via a rotary selector Position 6.


Positioning

We had purchased a tethered charger with a 7.5m cable and wanted to mount the unit on the side of the house. We also wanted an isolator nearby so we could disable power if needed.



For the Isolator we used one top entry (incoming power) which was not ideal. After a rainstorm, I did open the isolator after drying the unit and the internals wwew completely dry, so no water ingress! Power to the charger and earth leave via the base of the isolator.

The cable storage is just the top of the wall box. The unit is 14cm deep so does not stick out much. Make sure the fixings are strong as the cable can be heavy. Similarly with the isolator which not load-bearing needs to be well secured for safety



Earth

I used ferrules on the end of the earth as it was a multistrand 6mm2 cable. This prevents whiskers and allows more of the conductor to be in contact with the connector/connection. Earth Pit


I dug an Earth pit by hand using water looking for pipes as I dug. I hit the clay under the ground and then checked for pipes before installing the earth electrode, earth pit and cover.


RCD

The B type RCD with DC leakage detection was installed in an existing consumer unit with capacity.
As the unit was a dual pole unit the bus bar could not be used. Instead, a connection from the line came from the output of the isolator and the neutral supply from the neutral bus bar.

New regulations demand a sophisticated RCD with DC and AC detection.