Enclosures for charging infrastructure
& e-mobility

The technology behind the charging point

Every charging park has a second, invisible half: the grid connection with metering and instrument transformers, the power distribution to the charging points, the load management including communications technology — and increasingly the connection of a battery storage system that buffers peak loads. All of this stands on open ground: full sun in summer, frost in winter, road salt, impacts, vandalism.

For this, ZPAS manufactures outdoor enclosures of the SZD series in double-walled aluminium — passively insulated against solar radiation, actively climate-controlled where necessary, bayable for growing parks and in any special size up to 3,000 mm in height. The grid side is described in detail on the Energy & smart grid page.

Typical projects in charging infrastructure

Requirements for charging park enclosures — clearly classified

Standards for charging park enclosures

The technology behind the charging point is governed by the rules for low-voltage switchgear and controlgear assemblies: distribution boards are built to IEC 61439, the enclosures are tested to IEC 62208 and CE-marked. Outdoors, the degrees of protection according to EN 60529 (IP 54/55) and impact resistance IK10 according to EN 62262 are added — 20 joules that make the difference between everyday car park life and a cabinet that has been prised open.

The operating range of the double-walled SZD aluminium enclosures extends from −40 to +70 °C: the rear ventilation between the walls takes the edge off the summer sun, a thermostat-controlled enclosure heater counters condensation and frost, and filter fans or a cooling unit deal with the waste heat from load management and power electronics.

Which enclosure for which task in the charging park?

Custom housings to customer specification: DC chargers, AC charging posts & wallboxes

Besides the technology behind the charging point, ZPAS also manufactures the housing of the charging point itself — as a custom design to customer drawings for manufacturers of DC chargers, AC charging posts and wallboxes. Sheet metal processing, welding, powder coating and assembly come from a single source — in corporate colours and the design of your choice, from prototype to series production.

Typical features of such housings: prepared cut-outs for display, charging sockets and cable management, separate compartments for power and billing technology, ventilation or climate control for each power class — and an outer skin that matches the manufacturer’s brand. An enquiry with a drawing or sketch is enough; the quotation arrives within 2 working days at most.

Typical project: DC rapid chargers at a truck stop

Starting point: a truck stop is adding several DC rapid charging points. The chargers themselves come from the charger manufacturer — but grid connection, metering and load management need a home outdoors, right next to the access road: weatherproof, vandal-resistant, temperature-controlled all year round and with reserve for expansion.

The solution: double-walled SZD outdoor enclosures in a special size — one section for the LV main distribution board and metering, one section for load management, cable entry from below with reserve. IK10 version with three-point locking, a thermostat-controlled heater against condensation in winter, filter fans against the summer load. Delivery is wired ex works, the foundation is agreed in advance as a drawing — on site, all that remains is positioning, connecting and commissioning.

Depot & fleet: charging away from public charging points

Bus depots, haulage yards and company car parks charge more predictably than public spaces — but in rows: many charging points, one shared grid connection, central load management. The distribution and control technology then moves into a few larger cabinet sections: bayable SZD cabinets on the yard or SZE rows in the plant room, both wired ex works.

As the fleet grows, the installation grows with it: reserve spaces in the cabinet, bayability and a cable route with room to spare cost little with the initial order — and avoid conversion work during expansion. A buffer storage system relieves the grid connection when the connected load becomes a bottleneck. For operational management, metering and communications technology go into a separate, separately lockable section — so access for the grid operator, billing and maintenance stays cleanly separated, without anyone having to get past the power section.

Planning checklist: enclosures for charging infrastructure

These points should be clarified before ordering:

• Installation: foundation or plinth mounting, collision protection, clearances to chargers and driveways — and cable entry with reserve.
• Heat load: quantify the power loss of load management and power electronics — it determines ventilation or cooling unit.
• Winter operation: plan a heater with thermostat against condensation and frost, especially for electronics and meters.
• Access protection: IK10, concealed hinges, profile half cylinders or electronic locking — depending on the site risk.
• Expansion: allow for bayability and spare space for additional charging points from the outset.
• Lead time: custom outdoor enclosures take 8–10 weeks (new drawing), repeat orders approx. 6 weeks.

Why ZPAS for charging infrastructure

Because rollouts need speed and repeatability: project-specific initial design with drawing approval, then identical cabinets for every further site — direct from our own production, with prepared cut-outs, mounting plates and climate control. The outdoor enclosure configurator delivers the first configuration in minutes; the cooling capacity calculator takes care of sizing the cooling.