MAHLE charging technology
with 6 x 11/22 kW and load management
In addition to MAHLE’s central charging solution for application areas of 15 charging points or more for fleet or employer charging, MAHLE chargeBIG offers a solution for smaller application areas in the residential sector and for workshops.
The chargeBIG6 charging system consists of a central control unit – the MAHLE chargeBIG6 charging distributor – with up to six three-phase charging points with permanently attached cable and type 2 plug. The charge distributor includes all necessary electronic components such as charge controller, residual current circuit breaker, and fuse. The power requirements possible for the system are 25kVA, 43kVA or 86kVA depending on the configuration, which the load management system distributes to the charging points as required. The charging infrastructure is easy to set up, cost-effective and is connected to the grid via the household electricity meter. Charging billing and connection to a charging infrastructure backend are not necessary. The charging points operate in plug-and-play mode and can be enabled via key switches if desired. The solution is also suitable for employers who do not require calibration-compliant billing.
The chargeBIG6 solution is based on the proven principle: intelligent control of the charging processes with load management in the case of limited grid connection and central arrangement of the electronic components in a small distribution box.
Complete system with 6 charging points (11 kW charging capacity):
Complete system with 6 charging points (22 kW charging capacity):
Connection is three-phase with neutral and PE conductor.
The power supply can be connected separately for each charging point.
Connection via household meter is possible.
Each charging point is dynamically regulated from 6 to 16/32 A.
Voltage 230 / 400 V 3NAC
Frequency 50 Hz / 60 Hz
50 Hz / 60 Hz
Three-phase 4 to 22 kW dynamically controlled depending on connected load, number of connected vehicles and control parameters
Residual current device and
DC fault detection
30 mA FI type A and 6 mA RDC-MD for each charging point
IP55 (charging distributor); plug (IP44)
5 x 6 mm² Rigid cable (32 A maximum current); N and PE separated. Supply line(s) for an installation with central power supply: Up to two lines 5 x 16 mm² rigid conductors. Between charging distributor and plug holder: 7 x 6 mm² rigid cable, see standard DIN VDE 0285-525-2-51, max. 90 m For example, 7 x 6 mm² rigid cable for three-phase charging points with a maximum of 22 kW NYM-J or NYY-J with / without empty conduit.
Operating temperature range
Charging point -25 °C to +70 °C (with direct sunlight)
Charging manifold -25 °C to +55 °C (without direct sunlight)
Central load management for 1 to 6 charging points
Parameterizable to 36 A, 63 A or 125 A
Pool-based charging strategy with equal charging current distribution without prioritization
Ethernet via RJ-45
Mechanical data complete system chargeBIG
Dimensions in mm (H x W x D)
Charging system (630 x 600 x 180) Wall mounting with 6 screw points.
Pedestal: square stainless steel tube (1200 x 100 x 100) Plug holder
(approx. 90 x 107 x 107) Wall mounting: plug holder (110 x 110 x approx. 100)
In the commercial context, the charging points are connected via a supply line.
The charging points in the apartment building can be connected to the respective electricity meter of the residential unit.
The charging system can be used at all six charging points simultaneously.
The charging points have a maximum three-phase charging power of 22kW, but can be throttled down to 11kW.
The chargeBIG6 solution includes central load management, whereby the system prevents overloading of the house connection. Due to the central design of the system, investment costs are reduced. Likewise, maintenance in the operational context can be carried out with reduced effort.
The system provides a single supply line for each charging point. This can be laid directly from the meter box of the respective user, for example.
Alternatively, the system can be connected with the expansion package chargeBIG6-AP01 with one or two common supply lines for all charging points.
The variant with six supply lines is ideal for apartment buildings. The six charging points can each be connected via the apartment meter. However, this requires modern building technology. The workshop/commercial package includes appropriate bridges/phase bars so that all six charging points can be connected via one supply line. Load management works with both variants.
Charging points that are not required can simply be left free. Further expansion of the charging points is possible at any time. However, the supply line for the first charging point must always be connected.
The chargeBIG6 charging station includes all the necessary technology for a charging process, as well as a type 2 charging cable with corresponding wall bracket. For the installation, only cables with fastening material and an appropriate pre-fuse are required (e.g. C40 for 32A charging current). The pre-fuse is installed in the sub-distribution. NYM-J or NYY-J 7x6mm² is recommended for the cabling. Depending on the location, conduits or cable trays may be required.
Yes, the charging system includes a central load management with total current limitation in the standard scope of delivery. The current limit or the total current can be parameterized to 36A, 63A or 125A.
These represent the permissible total current of all six charging points. If six electric vehicles are charging at the same time and the house connection is scarce, then they will each only charge with 6A. 6x6A = 36A total current. The default setting is 63A.
The system includes intelligent temperature derating. In addition, a potential-free normally closed contact can be used to switch off the system. Thus, fire alarm systems or emergency stop systems can be implemented easily.
In the user manual, you will find the troubleshooting procedure in the Error Management chapter. If you cannot find a solution to your problem in the user manual, contact support at support@chargeBIG.com.
A fuse protects the corresponding circuit against overload and short circuit. After a fuse has tripped, the circuit must be checked for faults. The fuse should not be switched on again until the circuit is fault-free.
The system should be regularly checked and maintained in accordance with the locally applicable regulations. For companies, we recommend a semi-annual inspection of the personal protection equipment by an electrotechnically instructed person and annual maintenance of the system by a competent installer.
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