Electric Vehicle Charging Installation Components you can Trust

By 2030 in the UK, the government has outlined plans to ensure that the sale of petrol and diesel cars are banned, meaning that all of the new cars constructed and sold in the UK will be ultra-low emission. This plan promises a rapid and vast expansion of the existing vehicle charging infrastructure in the UK that will obviously be needed to keep all these electric vehicles (EV) charged and mobile.

Plans include increasing the level of charge-points, with one every 20 miles along the strategic road network and charging points in all new homes and the retrofitting of lampposts with charging fixtures. There is certainly a vast amount of work to be carried out and all of those installations will depend on reliable and dependable electrical components to provide the power and protect the systems providing the electricity and of course the user.

Electric Vehicle charging station

IMO, a UK based global manufacturer of Industrial Control and Electronic Components have created a range of electrical system protection products that are ideally suited to the mammoth task at hand. This impressive range of IMO products, which are all available from Kempston Controls, are the ideal product solution for EV installers who are busy installing small domestic charge points to large commercial multiple charger installations. From the latest technology advanced RCDs specifically designed for use in EV applications to class leading surge protection devices IMO have created the perfect products for all those impending Electric Vehicle Charging installations.

Let’s have a look at some of the IMO EV installation range.


B6CR1N40-30-A – Type A Residual Current Circuit Breaker with Over-current

RCBOWithin an EV Charging installation reliability matters and this Type A 10kA Residual Current Circuit Breaker with Over-current protection (RCBO) has been cleverly designed to protect electrical installations from short circuits and overloads. Combining the functions of an MCB and an RCD providing all-round protection in a small form factor these RCBOs are ideal for use in EV charge points that have internal DC fault detection built in, manufactured in accordance with IEC 60898-1.

Type A RCBO Specification

  • Provides protection against earth fault and leakage current
  • Single pole + Neutral
  • Rated Current 40A, C Curve
  • Rated impulse withstand voltage 10kA
  • Compatible with IMO MCB accessories

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B10C1032A 10kA Miniature Circuit Breaker

Miniature BreakerWhen you need reliable electrical circuit protection in a compact package, this 10kA Miniature Circuit Breaker helps protect valuable charging installation circuits and their users from dangerous over-current and short circuits. When using an MCB within an electrical circuit an RCD should be used in unison for added protection.

MCB Specification

  • Protection against over-current and short circuits
  • Single pole
  • Rated impulse withstand voltage 6.2kA
  • Rated short circuit breaking capacity 4.5kA
  • Operating characteristic Type C
  • Rated current 32A

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All Metal Enclosures, DBM-04W and DBM-04WM

Electric Vehicle Component EnclosureTo house and protect your EV Charging Point installations electrical safety components you are going to need a robust and hard wearing enclosure that ensures your charging point and it’s electrical supply components are kept safe and operational. These durable IP20 rated enclosures have been designed to save space by keeping additional circuit protection devices external to the consumer unit.

Enclosure Specifications

  • Fully enclosed compact metal construction
  • 25mm circular cable entry knockouts
  • Integral 80mm DIN rail
  • IP20 rated
  • Dimensions 235x140x115mm – Model DBM-04W
  • Dimensions 175x110x90mm – Model DBM-04WM

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Residual Current Circuit Breakers, B10R2040-30-B and B10R4040-30-B

Electric Vehicle Residual Circuit Breakers

These Type B 10kA Residual Current Devices (RCDs) are the perfect addition to any EV charging installation, designed to offer protection against earth faults and leakage current. Versatile and dependable, the IMO Type B RCDs need to be used within EV charging installations when the charger circuit doesn’t have internal DC fault protection, covering all EV charging types regardless of any fault detection processes that may be built in. Offered in 1P+N and 3P+N versions, both with 30mA residual operating current they are manufactured in accordance with IEC 61008-1 & IEC 62423.

Type B RCD Specifications


Kempston Controls is the place to come to for all your IMO Electric Vehicle charging point installation components, just give us a call on +44 (0) 1933 411411 or email sales@kempstoncontrols.co.uk to discuss your EV installation requirements.

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Terra AC in use

Introducing the Terra AC Wallbox from ABB

With electric vehicles expected to make up for 57% of global passenger car sales by 2040, the need for smarter charging facilities is only growing. ABB, pioneers in electric vehicle infrastructure, have until now only used their Terra products for DC charging stations, but now they have expanded the range to include the Terra AC Wallbox for charging electric cars at home.

Did you know? A typical electric car (60kWh battery) takes just under 8 hours to charge from empty-to-full with a 7kW charging point.*

Passenger Electric Vehicles Sales Will Rise to 28m in 2030

ABB’s Terra AC Wallbox is designed to meet the surge in demand for quality yet affordable charging in homes and businesses and can even utilise a customer’s green energy, such as solar power. The Terra AC Wallbox is also equipped with an energy meter that can be integrated into intelligent building energy management systems and enables advanced load management functions.

Ultra-Low Emissions. Will you be Leading the Charge When it Comes to Electric Vehicle Supply Networks?

With a broad range of connectivity options, the Terra AC Wallbox can be configured and updated via a dedicated app or remotely via the cloud. This provides a lot of flexibility and minimises the need for onsite engineers to maximise uptime and efficiency.

View the Range

Please note that models: TAC-W22-T-RD-M-0, TAC-W22-T-RD-MC-0, TAC-W7-T-RD-MC-0 will be available from November.

Terra AC

Terra AC Wall Top Features:

High-value quality

  • A broad range of connectivity options including WiFi, Bluetooth and Ethernet
  • Space-saving design enables seamless installation on a wall or pedestal, which can accommodate two chargers back-to-back
  • With multiple connectors available, Terra AC Wallbox is compatible with the majority of electric vehicles
  • Dustproof and water-resistant to IP54, IK10

Future proof flexibility

  • Future-ready with simple software updated via the user app
  • Simplified authentication via either RFID or the App provides flexibility for public-use applications
  • Integrates seamlessly with ABB’s complementary building automation solutions

Safety and protection

  • Evaluated and tested by an independent third party to meet the highest standards
  • Current limiting protection allows maximum charging power without nuisance tripping
  • Integrated ground fault and overvoltage protection protects both user and car

Available in up to 22kW variants which ensures compatibility with electrical systems across the world, the Terra AC Wallbox offers a safe, smart and sustainable charging solution.

ABB is a world leader in electric vehicle infrastructure, offering the full range of charging and electrification solutions for electric cars, electric and hybrid buses as well as ships and railways. Kempston Controls, as a brand partner, has access to their entire range. Get in touch today on 01933 4114111 or email sales@kempstoncontrols.co.uk to see how we can support your application.

Enquire Now

Please note that models: TAC-W22-T-RD-M-0, TAC-W22-T-RD-MC-0, TAC-W7-T-RD-MC-0 will be available from November.

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* How long does it take to charge an electric car? From Pod Point

Top Ten Posts

Kempston Controls Top Ten Blog Posts of 2019

After publishing 65 posts this year, we’ve decided to take this time to reflect and round-up our most popular articles this year. Here are our top ten blog posts from 2019:

10. PROTECT PSC1 Safety Controllers – Total Control

By Rick Morgan – 21 October

The multifunctional PROTECT PSC1 safety controllers from Schmersal consists of a range of very capable freely programmable compact safety controllers with an impressive offering of I/O extension modules ideal for a wide range of industrial and commercial safety and control applications. Consisting of two comprehensive families, the PCS1-C-10 and the PSC1-C-100, these capable safety controllers can cover all your potential industrial signal processing and control requirements.

9. Important Update Concerning SICK Automation and Control Product Availability from Kempston Controls.

By Rick Morgan – 25 February

SICK, one of the World’s leading manufacturers and suppliers of automation and control products will be staging a phased removal of a number of ranges of their existing product portfolio during the Spring and Summer of 2019.

8. Switching Power – Craig & Derricott Automatic Transfer Switch Range

By Rick Morgan – 24 September

The Automatic Transfer Switch Range from Craig & Derricott is the perfect choice when you need to ensure that your power network is protected from outages.

7. Top 5 Inductive Proximity Sensors

By Rick Morgan – 27 August

Inductive Proximity Sensors are an essential addition to countless process automation and control installations in all manner of industries. Designed to ensure that your process, whatever it may be, from a heavy industrial robotic welding installation to managing warehouse conveyor systems performs the best it can at all times. Whatever your flavour of Inductive Proximity Sensor, from the toughest to the economical Kempston Controls has just what you need. Here, we get up-close and personal with our Top 5 Inductive Proximity Sensors.

6. Industry 4.0 – the Digital Backbone of Modern Manufacturing

By Rick Morgan – 29 April 2019

Industry 4.0 is known as the fourth industrial revolution, changing the way we manufacture an ever-increasing spectrum of products all thanks to the digitisation of the mechanism involved in their creation. The change is rapidly growing pace, due in part to increased demand for newer smarter products and with leaps in innovations in the manufacturing industry.

5. PRC Series Circular Connectors – A New Angle on Connectivity

By Rick Morgan – 19 August

When it comes to industrial connectors, the PRC Series of circular connectors from Phoenix Contact has been designed to enable robust, reliable and stable cable-to-cable connections that demand precision real estate management in a multitude of installations from industrial and outdoor to commercial buildings. Incorporating weatherproof materials in their construction and with an impressive IP69K rating, the PRC series of connectors are capable of high current transmission even in the most demanding environmental conditions.

4. Lighting Up Danger with ATEX Flashlights

By Joe Shipton – 29 October 2019

Kempston Controls is pleased to announce that we now offer a range of intrinsically safe flashlights ideal for hazardous areas from ecom – a Pepperl+Fuchs Brand.

3. IO-Link? Bi-directional Data Exchange? What’s that?

By Rick Morgan – 10 June 2019

IO-Link is an industrial communication network standard (IEC61131-9) that allows the easy extraction of data from process control and automation sensors that support the IO-Link protocol and are connected to a device master. IO-Link is the first globally standardised IO-technology that has been designed to allow communication from the primary controller down to a basic automation level.

2. Are you SIRIUS about Spring-Loaded Terminal Technology?

By Rick Morgan – 1 March 2019

Whether you are reversing a motor starter or building an infeed system, the Siemens SIRIUS range of modular low voltage products, available from Kempston Controls, is the ideal solution to the ever-accelerating world of modern industry. The SIRIUS modular system provides the most comprehensive switching device portfolio currently available in the marketplace, exceeding 50k tested and approved control set-up combinations.

1. Safety Handle Revolutionised with the new Pizzato P-KUBE Krome

By Rick Morgan – 13 June 2019

A revolutionary new product from Pizzato, the P-KUBE Krome series combines the functionality and characteristics of your typical enclosure safety handle, but with an ergonomic rounded grip, illuminated control button and unique customisable LED notification functionality. The multitude of signalling illumination options available (on the illuminated White P-KUBE Krome version) gives the end-user the added security of the safety guards status or any other processing condition.

Honourable Mentions outside of the Top Ten:

Our favourites from this year:

“I would have gotten away with it if it wasn’t for those meddling Data Loggers” Next level Data Logging.

By Mark Jansen – 31 October

With it being Halloween, we were struck by a Ghost Hunting project that we recently read about that has taken place at Motley County Jail, in Matador, Texas.

Ultra-Low Emissions. Will you be Leading the Charge When it Comes to Electric Vehicle Supply Networks?

By Rick Morgan – 8 April

In 2018 the UK Government launched its Road to Zero strategy, with ambitious targets of at least 50% and as many as 70% of new cars constructed to be ultra-low emissions by 2030 and by 2050 they want almost every car and van to be zero-emission. Outlined in the Government document, The Road to Zero, the plan promises a huge expansion of the vehicle charging infrastructure that will be needed to keep these electric vehicles moving efficiently. Plans are afoot to increase the level of charge-points, with one every 20 miles along the strategic road network by 2020, along with charging points in all new homes and the retrofitting of lampposts with charging fixtures.

Thank you for supporting our blog posts this year and we hope you enjoyed this top ten round-up. We look forward to bringing you more industry news and insights in 2020!

Industry 4.0 – the Digital Backbone of Modern Manufacturing

Industry 4.0 is known as the fourth industrial revolution, changing the way we manufacture an ever-increasing spectrum of products all thanks to the digitisation of the mechanism involved in their creation. The change is rapidly growing pace, due in part to increased demand for newer smarter products and with leaps in innovations in the manufacturing industry. The first industrial revolution was the use of water and steam power to drive the great industrial machines, the second step was the modernisation of those older processes through the use of electricity and the advent of production and assembly lines. The third came with the birth of computers and industrial process automation, this fourth revolution, took the computerised automation processes of the third revolution and enhanced it even further with the utilisation of smart data and advanced machine learning.

The computerisation and automation that led to the birth of the third industrial revolution were certainly disruptive, the computerised processes of the day could handle masses of data, perform multiple complicated tasks and so on. As Industry 4.0 unfolds, those computers and control systems are now more advanced and interconnected and can communicate with each other, make decisions based on data and act on them, taking human involvement out of the loop. With the Internet of Things and a rapidly expanding network of internet-enabled smart industrial devices, such as Robots, motor controllers and sensory technology means the smart factory is becoming the norm and the nearly human-free dark factory is destined to become a reality in some industries.

The Digital Backbone

The industry 4.0 revolution is built upon the backbone of these smart devices, and ultimately as they access more and more data and increase in their intelligence, productivity will improve even further and industrial processes will become less wasteful. The definition of wasteful will, in some cases, of course, include a reduction of employees, particularly when it comes to the human-free dark factories mentioned earlier.

This digital network of devices communicating with each other and sending valuable data and information back and forth will ultimately demonstrate the true power of Industry 4.0 in the coming years. And as the devices themselves become even smarter, the opportunity for localised intelligent data-based decisions reduces data traffic and speeds up decision making even further.

Some industries and companies may be reticent regarding how exactly Industry 4.0 could have any significant impact on their business while many others are embracing the march of Industry 4.0, seeing the prospects of increased productivity, lean manufacturing and intelligent maintenance.

Image credit: Iidefonso Polo

Network Enabled

One of the primary additions to Industry 4.0 is the Internet of Things (IoT), a thing in the IoT can be anything, a person with a heart monitor, a farm animal, an electric motor, basically anything that can be assigned an IP address and is network enabled.  These smart devices use embedded processors, sensors and communication hardware to collect, send and act on data they acquire from their environments.

With regards to industrial automation, IoT enabled devices not only assist with providing data about internal processes but through the use of cloud storage, equipment and operations can be optimised by leveraging the insights of others using the same equipment the world over.


Process Control, Process Flow

Modern factories depend on steadfast machinery, Industry 4.0 takes the concept of dependability, process improvement and cost reduction further, with smart machines that can independently communicate with each other, exchanging valuable data that in-turn can manage the production process itself and be sent for further analysis. Within industries that demand precise processing and data capture, such as the pharmaceutical industry, valuable information that forms part of the compliance of the products can be recorded for interpretation and analysis.


Maintenance and Operation

Industrial automation and control processes can be complicated affairs, multiple motors, conveyor belts, robots, press tools, packing machines etc. all of which, should they fail could prove a costly affair when it comes to repair and downtime. Maintaining your fleet of machines used to come in a few forms, planned, predictive, preventive maintenance and so on, but now maintenance can be interpreted differently.

With Industry 4.0 and the IoT, machinery and processes can report on their status, imagine a smart vibration sensor monitoring the bearings of an essential electric motor, once the smart sensor detects anomalies based around established parameters, this could flag a report to maintenance personnel informing them to prepare to change the failing component. The benefits of precision maintenance, when it is actually required instead of waiting for it to fail, or we will change this motor even though it’s perfectly functioning anyway methodology has numerous obvious benefits.

The Continued Rise of the Bots

The growth of robotics within industry is well known to most, rows of advanced robots working on a vehicle production lines performing various mechanical functions, or the pick and place robots assembling components on to a PCB. As a modern example, Amazon utilises robotics in some of their warehouses, bringing products to warehouse operatives instead of the operatives searching for the products themselves amongst the racking

All of these devices can be networked, sending valuable processing data upstream for analysis leading to a streamlining of processes, efficiency improvements, and as mentioned previously, help themselves to stay functional.

Autonomous Agriculture

With the human population increasing at an exponential rate the need for efficient farming will be required to feed all these people, as a result, the humble farm tractor, as the beating heart of any farm, is destined to be one of the earliest vehicles to become autonomous. Autonomous tractors will be fitted with various vision systems, accurate GPS for precision navigation, IoT connection for monitoring and data feedback, be able to monitor the weather and perhaps access LIDAR mapping for the detection of objects and terrain changes for avoidance purposes. People will still have a place, establishing areas for the tractors to operate in, boundaries and optimal paths to take using planning software and other baseline operating conditions along with maintenance when it’s detected.

It doesn’t stop there either, the accurate planting of seeds, on-time irrigation, crop maintenance and spraying, weeding and harvesting are all currently under development. Deepfield Robotics, a BOSCH start-up business, is busy developing their BoniRob farm-bot that is packed with advanced technology allowing it to navigate to a field, weed it, fertilise it, monitor crop condition and more besides.

Industry 4.0 – IoT – Industry 5.0?  Progression is fluid

Industry 4.0 and its essential counterpart the IoT are rapidly evolving, with billions of devices currently connected and growing rapidly in number, it may take a few short years before we have a clearer picture of its true and full potential. What is certain is that the companies and industries that are adopting and pioneering this technology are rapidly changing our traditionalist view of how things can be manufactured, maintained, farmed, monitored and controlled.  What could previously have taken considerable manpower and time can now be streamlined to perhaps a matter of hours, process times can be optimised and made leaner and can be run without human decision-making input.

One this is certain that this change, whether we like it or not, is upon us, and with the burgeoning population, their demands, and the needs for product and of course more food, there is no doubt that to be more efficient, and carefully utilise all our many resources to their fullest possible potential we need all the help our own innovation can give us.

Considering the rate of change within modern industry and the ever-accelerating nature of innovation and adoption of these advanced methods of managing and controlling a plethora of manufacturing processes, automated vehicles and just about anything else you can think of, what will the fifth industrial revolution be?

Will industry 5.0 herald the rise of A.I? Already outlined as the collaboration between man and machine – could Industry 5.0 (or industry 6.0?) eventually erase humanity from the production process, being solely employed to service and program machinery? All things considered, even that role would appear to be in question with the current ability of machinery to self-diagnose and act on smart data, it isn’t a big leap of the imagination to envisage self-diagnosis and analysis becoming self-repair and self-program. Time will tell as to just what path industry 5.0 (and the iterations destined to follow) will eventually take but what is certain is that that time will be upon us sooner rather than later.


Further Reading:

Industrial Ethernet

Ultra-Low Emissions. Will you be Leading the Charge When it Comes to Electric Vehicle Supply Networks?

In 2018 the UK Government launched its Road to Zero strategy, with ambitious targets of at least 50% and as many as 70% of new cars constructed to be ultra-low emissions by 2030 and by 2050 they want almost every car and van to be zero emission. Outlined in the Government document, The Road to Zero, the plan promises a huge expansion of the vehicle charging infrastructure that will be needed to keep these electric vehicles moving efficiently. Plans are afoot to increase the level of charge-points, with one every 20 miles along the strategic road network by 2020, along with charging points in all new homes and the retrofitting of lampposts with charging fixtures.

Picture credit: Joe Nomias, Pixabay

One thing is for certain, the Government’s plan offers an enormous opportunity for the many businesses and industries involved in its creation, development and upkeep.  Research and development teams will be constantly innovating, manufacturers will be building the devices required, the installation of the network and charging points and maintaining these systems will need a fleet of service personnel to fulfil the plan proposals.

It took over 20 years for electric cars to reach their first million in sales, fast forward to today and a million electric vehicles are being sold globally in a period of just a few months, the momentum is certainly gathering when it comes to the transition to electric vehicles.

The uptake of the outlined policy is certainly making headway, Oxford is planning on introducing the world’s first ‘Zero Emission Zone’ in its highly-congested city centre. In London, the Ultra-Low Emission Zone began on the 8th of April 2019, meaning drivers paying a healthy fee if they don’t drive an electric vehicle. Car manufacturers such as Jaguar Land Rover and Volvo recently announced that they will stop launching new models of car that feature just an internal combustion engine from 2020 onwards with other manufacturers likely to follow. One thing is certain a change in how we commute, or rather the vehicles we will be travelling in and how they are powered is coming and moving fast.

Driving Changes

Electric vehicles are obviously cleaner when it comes to producing emissions when in motion when compared to their petroleum-based counterparts, however, they do pose additional challenges.

  • In the UK and most other countries, the existing transmission and distribution networks will struggle to meet the expanding fleet of electric vehicles which will demand masses of additional power.
  • Although an electric vehicle may produce zero emissions, producing the energy used to charge it may not be the case, thus the energy grid will need to be powered by a much higher level of renewable energy and low-carbon methods.
  • Energy is generally produced according to demand, and renewable sources like wind and solar can be unpredictable, leading to instability in demand provision as the load increases further. Countries that depend on Hydroelectric power will be better placed environmentally.
  • The batteries used to power electric vehicles are rising in capacity, that coupled with their growth in use will equate to existing charging methods struggling to meet future demands.


Meeting the Demands

There is no doubt that the changes to the way we commute around our towns and cities are firmly headed in the direction of dependency upon electric vehicles, with natural gas, hybrid and fuel cell powered transport, both public and personal, making up a percentage as well.

Recent research suggests that fast-charging an electric vehicle battery in 10 minutes will require 300 to 400 kW of power, if you have several cars all charging at the same charging point you will need about 1MW of power. No 240V mains plugs here, a facility like this would need to be connected to an 11 or 33 kV grid. Primarily it is in this area where the infrastructure needs to be expanded and future proofed (along with the increase in green energy production), to make EV’s lend themselves to everyday life.

There are other considerations of course, such as how will people without their own parking area effectively charge their vehicles?  Will hybrid vehicles that feature a large electric motor that has its batteries recharged by a small petrol generator be more effective in the short term? Will the roads eventually incorporate induction charging in their construction so that your car can be charged just by being on the road itself? Time will tell.


Charging at home and on the road, safely

Electric vehicles charged at home will utilise the AC source found there and be charged using a cable, known as Mode 2 charging, with an integrated monitoring system and a dependence on the vehicles internal charging circuit to manage the charging process. Ultimately this means that AC charging at home is a relatively simple and safe process for those who possess their own parking facilities.

Picture Credit: Paul Brennan, Pixabay

Large scale quick-charging stations used to sustain an entirely electric vehicle network would usually be an unearthed DC system, known as Mode 4 Charging. Charging via DC would involve supplying an external DC voltage to a vehicles network of batteries connected in series with a governed voltage so that it is always slightly higher than the cell voltages of batteries. This process involves complicated control systems as the currents involved can be several hundred amps, which is also potentially dangerous. Unlike AC charging at home, this DC method is ideal for rapid recharging during a journey and depends on the insulation monitoring device in the car being deactivated with the entire charging process being monitored by the charger’s insulation monitoring device (IMD).

Companies like ABB, Phoenix Contact, Schneider, DOLD, Bender, Siemens and others offer a range of residual current monitoring sensors and insulation monitoring devices that are perfectly suitable for Mode 2 and Mode 4 vehicle charging methods.

To meet the growing need for these devices, Kempston Controls stocks an impressive range of products suitable for EV charging applications, and as ever, if we don’t have the products on our store shelves, we can certainly source it for you. Our dedicated technical and sales team are always happy to help please call +44 (0) 1933 411411, or email sales@kempstoncontrol.co.uk or technical@kempstoncontrols.co.uk for all your vehicle charging application requirements.