Wiring & Installation Guide

This guide is intended for qualified electricians performing the electrical installation of a Thorium EV charging controller. It covers electrical requirements, wiring topology, per-channel connections, and critical safety considerations.

Electrical Requirements

Wiring Topology

The overall power path for each channel follows this sequence:

Distribution Board
  │
  ├— MCB (per channel) —→ RCD —→ Thorium Contactor —→ EV Charger
  ├— MCB (per channel) —→ RCD —→ Thorium Contactor —→ EV Charger
  ├— MCB (per channel) —→ RCD —→ Thorium Contactor —→ EV Charger
  ├— MCB (per channel) —→ RCD —→ Thorium Contactor —→ EV Charger
  │
  └— MCB (6A) —→ Thorium Controller Board (always-on 230V supply)

Key points:

• Each charger channel has its own dedicated MCB and RCD in the distribution board.
• The Thorium unit interrupts the supply between the distribution board and the charger using its internal contactors.
• The controller board has a separate always-on supply so it can operate the touchscreen, POS terminal, and network connection regardless of whether any channel is active.
• The earth (PE) conductor passes straight through — it is never switched by the contactor.

Per-Channel Wiring

Inside the Thorium enclosure, each channel has a clearly labeled terminal block set:

Input Terminals (from distribution board)

• L-IN — Line (live) input from the MCB/RCD.
• N-IN — Neutral input.
• PE-IN — Protective earth input.

Output Terminals (to charger)

• L-OUT — Line (live) output to charger, switched by contactor.
• N-OUT — Neutral output to charger.
• PE-OUT — Protective earth output to charger (direct pass-through).

For three-phase channels, the terminal block extends to L1-IN, L2-IN, L3-IN on the input side and L1-OUT, L2-OUT, L3-OUT on the output side. All three phases are switched simultaneously by a 3-pole contactor.

Current Sensor Installation

1. Open the split-core CT clamp by pressing the release tab.
2. Clip it around the live conductor only (L for single-phase, or L1 for three-phase — one CT per channel).
3. Ensure the arrow printed on the CT body points toward the charger (in the direction of current flow to the load).
4. Close the clamp until it clicks. The two halves must be fully mated with no air gap.
5. Plug the CT cable into the corresponding CT1–CT4 port on the controller board.

Network Connection

Ethernet

Connect a Cat5e or Cat6 Ethernet cable from your network switch or router to the ETH RJ45 port on the Thorium controller board. The unit supports 10/100 Mbps and will obtain an IP address via DHCP by default.

4G LTE (Optional)

If wired Ethernet is not available, insert a compatible 4G USB dongle into the USB1 port on the controller board. The dongle must have an active SIM card with a data plan. Thorium will detect the dongle on boot and use it as the primary network interface. Tested dongles include the Huawei E3372 and ZTE MF833V.

Safety Notes

• Always isolate before working. Turn off all upstream MCBs and verify zero voltage with a multimeter before touching any terminal inside the Thorium enclosure.
• Torque terminal screws to specification. Under-tightened connections cause heat buildup and are a fire risk. Recommended torque: 1.2–1.5 Nm for the terminal blocks used.
• Do not exceed cable ratings. Ensure that cable cross-sections are appropriate for the installed MCB rating and cable run length. Consult voltage drop tables for runs exceeding 20 meters.
• Earth continuity is critical. Verify end-to-end PE continuity from the distribution board through Thorium to the charger. The PE conductor must never be interrupted by the contactor.
• Label everything. Clearly label each channel's cables at both the Thorium unit and the distribution board. This simplifies future maintenance and troubleshooting.
• Test after installation. After completing all wiring, perform insulation resistance testing, earth continuity testing, and a functional test of each channel before handing over to the operator.