Installation and Service Manual Dual AC Level 2 Electric Vehicle

Instruction Manual IM0EV00000E

Effective August 2013

Installation and Service Manual

Dual AC Level 2 Electric Vehicle

Supply Equipment (EVSE)

Contents

Description Page

1. Important Safety Instructions- Please Read . . 2

2. Symbols and Definitions . . . . . . . . . . . . . . . . . 2

3. About the Dual AC Level 2 EV Charging

Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4. Installing the Electrical Service . . . . . . . . . . . . 4

5. Instructions for Opening Door Latch . . . . . . . 5

6. Installing to the Premise . . . . . . . . . . . . . . . . . 6

7. Termination and Configuration . . . . . . . . . . . . . 9

8. Confirming Installation and First Use . . . . . . 11

9. Communications Connectivity for

ChargePoint . . . . . . . . . . . . . . . . . . . . . . . . . . 14

10. Specifications . . . . . . . . . . . . . . . . . . . . . . . . 15

11. Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

For more information, visit www.eaton.com/plugin, call

1-855-ETN-EVSE (1-855-386-3873), or call your local Eaton sales office.

Instruction Manual IM0EV00000E


1. Important Safety Instructions - Please

Read

WARNING ELECTRICAL

THIS EQUIPMENT SHOULD BE INSTALLED, ADJUSTED, AND SERVICED

BY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUC-

TION AND OPERATION OF THIS TYPE OF EQUIPMENT AND THE HAZARDS

INVOLVED. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN

DEATH OR SEVERE INJURY.

READ THIS MANUAL THOROUGHLY AND MAKE SURE YOU UNDERSTAND

THE PROCEDURES BEFORE YOU ATTEMPT TO OPERATE THIS EQUIPMENT.

THE PURPOSE OF THIS MANUAL IS TO PROVIDE YOU WITH INFORMATION

NECESSARY TO SAFELY OPERATE, MAINTAIN, AND TROUBLESHOOT THIS

EQUIPMENT. KEEP THIS MANUAL FOR FUTURE REFERENCE.

DO NOT USE THIS PRODUCT IF THE EV CABLE IS FRAYED, HAS DAMAGED

INSULATION OR ANY OTHER SIGN OF DAMAGE.

DO NOT USE THIS PRODUCT IF THE ENCLOSURE OR THE EV CONNECTOR

IS BROKEN, CRACKED, OPEN, OR SHOW ANY OTHER INDICATION OF DAM-

AGE.

DO NOT USE THIS PRODUCT IF THE EV'S CHARGING COUPLER/INLET IS

BROKEN/DAMAGED.

INTENDED FOR USE WITH PLUG-IN ELECTRIC VEHICLES ONLY.

PREMISE VENTILATION NOT REQUIRED.

THE INFORMATION CONTAINED IN THIS MANUAL IS SUBJECT TO CHANGE

WITHOUT NOTICE.

DO NOT DRILL HOLES OR MODIFY ENCLOSURE SUCH THAT THE NEMA/IP

RATINGS ARE COMPROMISED.

2. Symbols and Definitions




Definitions

AC – Alternating Current. The type of power available in most buildings and on utility poles. The Dual Level 2 EVSE protects Users and vehicles by allowing AC power to flow through it to the vehicle. The vehicle then converts the AC to DC (Direct Current) to charge the traction battery.

ADA – Americans with Disabilities ACT.

ALC – Available Line Current. The charger tells the vehicle through the J1772™ connector’s pilot pin how much current (in amperes) it is allowed to pull on the circuit. This allows the vehicle to not exceed the circuit’s maximum current rating.

EVSE – Electric Vehicle Supply Equipment. EVSE is a general term used for all of the equipment used to supply electricity to the vehicle, such as the Eaton Dual AC Level 2 EVSE.

GFCI – Ground Fault Current Interrupter. GFCI protects Users from faults involving leakage currents going to ground, rather than the proper return path of the circuit.

J1772™ – The SAE Recommended Practice for conductive charging of hybrid and electric vehicles. This standard spells out the physical dimensions of the J1772 connector and the pilot communication between the plug-in vehicle and EVSE.

Pilot – The signal through the J1772 connector. This signal tells both the vehicle and the EVSE when both are ready to charge and how much current it is allowed to pull. This signal is a SAE standard.

Plug Session – The time while the EVSE is plugged into a vehicle.

It starts by plugging in the J1772 connector and ends when unplugging the same connector.

SAE – Society of Automotive Engineers. The group that organizes and leads committees of transportation experts to create standards, such as J1772, for the transportation industry.

TB – The Terminal Block is where the incoming field power will be terminated in the EVSE unit.

Traction Battery – The large battery on a plug-in electric vehicle that is used to store and release energy for propulsion. This is different than the 12V battery that is used to start the vehicle initially and run accessories such as the radio.

UI – The User Interface part of the unit.


THIS SYMBOL INDICATES HIGH VOLTAGE. IT CALLS YOUR ATTENTION TO

ITEMS OR OPERATIONS THAT COULD BE DANGEROUS TO YOU AND OTHER

PERSONS OPERATING THIS EQUIPMENT. READ THE MESSAGE AND FOL-

LOW THE INSTRUCTIONS CAREFULLY.

 WARNING

INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT

AVOIDED, CAN RESULT IN SERIOUS INJURY OR DEATH.

 CAUTION

INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH, IF NOT AVOID-

ED, CAN RESULT IN MINOR TO MODERATE INJURY, OR SERIOUS DAMAGE

TO THE EQUIPMENT. THE SITUATION DESCRIBED IN THE CAUTION MAY,

IF NOT AVOIDED, LEAD TO SERIOUS RESULTS. IMPORTANT SAFETY MEA-

SURES ARE DESCRIBED IN CAUTION (AS WELL AS WARNING).

 IMPORTANT

INDICATES A PARTICULAR ITEM OR INSTRUCTION THAT IS IMPORTANT TO

CONSIDER.

Save These Instructions

2

EATON www.eaton.com




3. About the Dual AC Level 2 EV Charging

Station

Eaton’s Dual AC Level 2 charging station is Electric Vehicle Supply

Equipment (EVSE) and is compatible with the Society of Automotive

Engineers J1772™ standard for charging plug-in hybrid and all-electric vehicles.

The Dual Level 2 EV Charging Station has several safety features:

•

•

•

•

•

Protects Users with interlocked power – the cable and pins have no power on them until the connector is safely plugged into a vehicle.

Protects Users from temporary faults – and automatically resets* so no User interaction is needed.

Instructs the vehicle on how much current to draw – keeps the upstream circuit protection from ‘nuisance tripping.’

Allows integration into authorization and management systems

– keeping only authorized personnel able to use units and power usage levels to predefined levels.

See section ‘Specifications’ for more details.

* Automatic Reset feature must be enabled during installation – see page 12 for more information.

Moving, Transporting and Storage Instructions

Store this unit indoors and in its original packaging until it is ready to be installed. Storage temperature should be between -30° and

80° C. When moving or lifting the unit, always grasp the unit enclosure. NEVER attempt to lift, move, or carry the unit by the EV cable.

DO NOT carry the unit by the cable hook assembly.

Improper storage or handling may cause damage to the unit.

Before You Begin



ADA Standards for Accessible Design

It is very important to consider all STANDARDS FOR ACCESSIBLE

DESIGN for Americans with Disabilities when choosing the location and placement of all Electric Vehicle Supply Equipment.

The Department of Justice has assembled an online version of the official 2010 Standards to increase its ease of use. This version includes:

2010 Standards for State and Local Government Facilities

Title II; and

2010 Standards for Public Accommodations and Commercial

Facilities Title III.

For information about the ADA, including the revised 2010 ADA regulations, please visit the Department’s website www.ADA.gov; or, for answers to specific questions, call the toll-free ADA Information Line at 800-514-0301 (Voice) or 800-514-0383 (TTY).


WARNING – ONLY QUALIFIED PERSONNEL FAMILIAR WITH THE

OPERATION AND CONSTRUCTION OF THIS EQUIPMENT SHOULD INSTALL,

ADJUST, MODIFY, AND SERVICE THIS EQUIPMENT. FAILURE TO FOLLOW

THE INSTRUCTIONS COULD RESULT IN SEVERE BODILY INJURY OR DEATH.

 IMPORTANT

THE USER IS RESPONSIBLE FOR CONFORMING TO ALL LOCAL AND

NATIONAL ELECTRIC CODE® STANDARDS APPLICABLE IN THE ENVIRON-

MENT THAT THE EVSE IS BEING INSTALLED AND COMMISSIONED.

Replacement Parts List

Table 1. Replacement Parts List.

Part

Protection and Control Board PCBA

Part Number

Consult Factory

30A Cable / Connector Assembly 91C5363G02*

40A and 70A Cable / Connector Assembly 91C5363G04*

Ribbon Cable for User Interface 91C5361G01

Standard Dual User Interface Unit Consult Factory

Credit Card Dual User Interface Unit

Contactor 240V 30A

Contactor 240V 50A

Contactor 240V 70A

Consult Factory

91C5362G01

91C5362G02

91C5362G02

*consult with your local sales office to confirm availability


3



4. Installing the Electrical Service

Checking the Electrical Requirements

The National Electric Code

®

, Article 625.21 states “Overcurrent protection for feeders and branch circuits supplying electric vehicle supply equipment shall be sized for continuous duty and shall have a rating of not less than 125 percent of the maximum load of the electric vehicle supply equipment.” A load study of the location’s electrical service may be needed to determine the availability of adequate electrical service. Take the nameplate amperage rating of the Dual

Level 2 EVSE, and multiply by 125% for the minimum upstream circuit protection needed. This NEC article implies that the Dual will require 2 separate circuits.

Check your local jurisdictions for any other electrical requirements.

Running the Wires

Once the proper electrical overcurrent devices have been installed, wires need to be run from it to the Dual EVSE. For a typical installation, the only field wires will be for the incoming electrical service.

If the EVSE has a Level 1 option, additional service and wiring will be needed.

The Dual AC Level 2 EVSE operates on two single-phase service feeds each consisting of two hots and one ground.

N otee:

Use Copper Conductors ONLY.





WARNING – LOCKOUT/TAGOUT ALL ELECTRICAL SOURCE CIRCUITS

FEEDING THE UNIT(S) IN THE OPEN POSITION BEFORE BEGINNING

WIRING OR TERMINATIONS. FAILURE TO FOLLOW THE INSTRUCTIONS

COULD RESULT IN SEVERE BODILY INJURY OR DEATH.

 WARNING

DUAL LEVEL 2 UNITS WILL HAVE TWO SEPARATE FEEDS. THE TWO DIS-

TRIBUTION BREAKERS SHOULD BE INTERLOCKED UPSTREAM TO ENSURE

PROPER DE-ENERGIZATION OF BOTH SIDES.

 WARNING

THIS UNIT IS RATED FOR INDOOR OR OUTDOOR INSTALLATION. IF THIS

UNIT IS MOUNTED OUTDOORS, THE HARDWARE FOR CONNECTING THE

CONDUITS TO THE UNIT MUST BE RATED FOR OUTDOOR INSTALLATION

AND BE INSTALLED PROPERLY TO MAINTAIN THE PROPER NEMA 3R RAT-

ING ON THE UNIT.

 IMPORTANT

THE DUAL 30A LEVEL 2 EVSE REQUIRES TWO DEDICATED

208/240VAC 40A UPSTREAM BREAKERS.





THE DISTRIBUTION BREAKERS FOR THE DUAL EVSE SHOULD

BE INTERLOCKED. THIS WILL HELP ENSURE BOTH ARE

DE-ENERGIZED AT THE SAME TIME.

OPTIONAL DUAL LEVEL 1 OUTLET REQUIRES DEDICATED

120VAC 20A UPSTREAM BREAKER.

DO NOT USE GFCI BREAKERS. GFCI EXISTS IN EVSE AND ON

LEVEL 1 OUTLET.

Notese:

The end user is responsible for all arc-flash hazard category information.

For units with circuit breaker 60A or greater, end user must install disconnect means consistent with NEC requirements - article 625.23.

This EVSE is not suitable for location as identified in NEC article

500 (classified locations).

 IMPORTANT

CONFIRM WITH THE LOCAL ELECTRICAL REQUIREMENTS FOR THE GAUGE,

TEMPERATURE RATING, AND TYPE OF WIRE MATERIAL USED FOR THE

OVERCURRENT RATING FOUND BELOW. THE CHART SHOWS A GENERAL

RECOMMENDATION.

Table 2. Electrical Wire Chart

Style Nameplate Upstream

Breaker

Size

Wall-mount

SCR_B* 30A 40A

SCR_C*

SCR_D*

Pedestal

SDR_B*

48A

70A

30A

60A

90A

40A

SDR_C*

SDR_D*

48A

70A

60A

90A

*Additional catalog characters will follow

Suggested

Wire Type

Suggested Wire

Temp Rating

Copper

Copper

Copper

Copper

Copper

Copper

75 degrees C

75 degrees C

75 degrees C

75 degrees C

75 degrees C

75 degrees C

For detail on termination of Level 1 option see page 10.

4





5. Instructions for Opening Door Latch

Step 1.

Facing the charging station, locate the door latch on the right side of the unit as shown in Figure 1.



Step 3.

Rotate the handle counter-clockwise to release latch as shown in

Figure 3. The door should pop open.

Figure 1. Door Latch.

Step 2.

Insert key into lock and turn counter-clockwise (note: for new installations the key will come already in the lock). Once unlocked, the latch should pop outwards as shown in Figure 2.

.

Figure 3. Rotate Handle to Release Latch

Figure 2. Unlocked Door Latch.


5



6. Installing to the Premise

The three typical installation methods of installing Eaton's Dual AC

Level 2 EVSE’s to the premise are found below. Some installations require installing the wall-mount style of EVSE to a wall or unistrut.

Choosing a Location




Mounting to a Wall

Preparing the Site

Once a proper site has been chosen and the electrical service has been run to the location, you can begin installation.

 IMPORTANT

THINGS TO CONSIDER BEFORE CHOOSING A LOCATION TO MOUNT THE

UNIT:

1. STANDARDS FOR ACCESSIBLE DESIGN.

2. CONSULTATION WITH AN ARCHITECT MAY BE NEEDED IN ORDER

TO CONFORM TO ALL GOVERNING STANDARDS FOR LOCATION AND

PLACEMENT OF ELECTRIC VEHICLE SUPPLY EQUIPMENT.

3. LOCATION OF AN AVAILABLE MOUNTING SUPPORT - THE WALL-

MOUNT UNIT MUST BE ANCHORED INTO A MOUNTING SUPPORT

STUD OR SOLID CONCRETE WALL, USING MOUNTING HARDWARE

THAT IS APPROPRIATE FOR THE SURFACE ON WHICH YOU ARE

MOUNTING. DO NOT MOUNT THIS UNIT TO A STUCCO/DRYWALL/

WALLBOARD.

4. LOCATION OF AN AVAILABLE ELECTRICAL SOURCE - POWER WIRES

MUST BE RUN THROUGH AN APPROVED CONDUIT OR JACKET

FROM THE CIRCUIT PANEL TO THE UNIT.

5. LOCATION OF THE VEHICLE'S CHARGING INLET WHILE PARKED

-- THE UNIT MUST BE LOCATED SO ITS RESPECTIVE CABLE LENGTH

IS CORRECTLY SIZED TO WHERE THE VEHICLE'S INLET IS

ACCESSIBLE FOR PLUG-IN WITHOUT UNDUE MANEUVERING.

6. HEIGHT OF THE CONNECTOR DOCK MUST BE BETWEEN 24 AND 48

INCHES WHEN INSTALLED TO COMPLY WITH ADA AND NEC

STANDARDS.

7. COMMUNICATIONS CONNECTIVITY -- ENSURE EVSE WITH

CELLULAR COMMUNICATION CAPABILITY ARE INSTALLED IN

AREAS WITH A SIGNAL STRENGTH ABOVE -85DBM.

 CAUTION

DO NOT MOUNT UNIT TO ONLY STUCCO/DRYWALL/WALLBOARD. DO NOT

USE TOGGLE BOLTS, ZIP ANCHORS, NOR PLASTIC WALL ANCHORS MEANT

FOR THESE MATERIALS BECAUSE THEY DO NOT HAVE THE STRENGTH

NEEDED TO SUPPORT THE UNIT. THE UNIT MUST BE MOUNTED TO A

SOLID SUPPORT SUCH AS: WOOD, CONCRETE WALL, CONCRETE BLOCK

WALL, OR EQUIVALENT.

Step 1e: Remove the mounting plate from the back of the EVSE unit by placing the unit on a solid non-scratch surface and opening the unit by turning the latch on the side. Remove the three nuts on the 5-16 carriage bolts that attach the mounting plate to the unit. The location of these mounting studs can be seen in Figure 4. Save these nuts as they will be needed to re-attach the unit later in the installation.

Step 2e: Using the mounting plate as a template, mark the holes to be used for mounting. Make sure the mounting plate is level. If mounting on a wood stud wall, use the two center holes. If mounting on a solid wall such as concrete, brick, or concrete block, use the four outside square holes.

Step 3e: Pre-drill mounting holes if mounting into a wood stud or drill appropriate sized holes in a solid wall for use with the type of anchor you will be using.

Step 4e: Attach mounting plate to the wall as shown in Figure 5. If installing on a wood stud, use 5/16” or 3/8” x 3” long Lag screws and washers. These should be galvanized or stainless steel for weather protection if mounting outdoors. If mounting onto a concrete, block, or brick wall, use an appropriate anchor for the type of wall on which you are installing the unit. Again, these should be appropriate for weather conditions if mounting outside.

Figure 4. Unit and Mounting Plate.

6





N otee:

EVSE.

Single Level 2 EVSE shown, mounting is identical for the Dual Level 2



Figure 5. Typical Wall Mounting.

Step 5e: After the mounting plate is secure to the wall, mount the

EVSE unit to the mounting plate using the washers and nuts removed in Step 1.

Mounting to Uni-Strut


Step 1e: Remove the mounting plate from the back of the EVSE unit by placing the unit on a solid non-scratch surface and opening the unit by turning the latch on the side (for details, see

Section 5. Instructions for Opening Door Latch). Remove the three nuts on the 5-16 carriage bolts that attach the mounting plate to the unit. The location of these mounting studs can be seen in Figure 4. Save these nuts as they will be needed to re-attach the unit later in the installation.

Step 2e: Using the mounting plate as a template, determine where the anchors should be placed to be used for mounting.

Cross-arms should be used to avoid twisting which can occur in areas of high wind or in situations of heavy use.

Make sure the mounting plate is level. If mounting on a single pole use the two center holes. If mounting utilizing cross-arms use the four outside square holes.

Step 3e: Attach mounting plate as shown in Figures 6 and 7. Use appropriate hardware making sure it is galvanized or stainless steel for weather protection if mounting outdoors.

Step 4e: After the mounting plate is securely attached to the mounting structure, mount the EVSE unit to the mounting plate using the nuts removed in Step 1.


7






Figure 6. Typical Unistrut Mounting.

Figure 7. Dimensional Detail for Unistrut Mounting.

8







Figure 8. Base Detail Pedestal for EVSE.

Pedestal Floor Mounting

Preparing the Site


Step 1e: Open door using the latch on the side of the unit (see

Section 5. Instructions for Opening Door Latch, for details).

Step 2e: Remove the bottom pan by pulling upward and then angling outward. Best if performed when door is held opened.

Step 3e: The hole pattern for the base of the pedestal mount is shown below in Figure 8 Use six, 3/8 UNC Grade 5 stainless bolts torqued at 50 ft-lbs for mounting base to the ground.

N otee:

If using a concrete pad, please be mindful of the overall height of the unit due to ADA Compliance. Please reference www.ada.gov for more information.

7. Termination and Configuration


WARNING – LOCKOUT/TAGOUT ALL ELECTRICAL SOURCE CIRCUITS

FEEDING THE UNIT(S) IN THE OPEN POSITION BEFORE BEGINNING WIRING

OR TERMINATIONS. FAILURE TO FOLLOW THE INSTRUCTIONS COULD

RESULT IN SEVERE BODILY INJURY OR DEATH.

WARNING – ONLY QUALIFIED PERSONNEL FAMILIAR WITH THE

OPERATION AND CONSTRUCTION OF THIS EQUIPMENT SHOULD INSTALL,

ADJUST, MODIFY, AND SERVICE THIS EQUIPMENT. FAILURE TO FOLLOW

THE INSTRUCTIONS COULD RESULT IN SEVERE BODILY INJURY OR DEATH.

Wire Terminations

For a typical installation, the only field wire terminations will be the incoming electrical service wires. For a remote management system connection via Modbus, a 3-wire shielded cable for RS-485 communications will be required. For additional information on communication wiring configurations, reference the EVSE Complete Networking

Guide (IL0EV00005E).

Electrical Service Wires

Terminate the incoming electrical service wires to the Dual Level 2

EVSE’s provided terminal block, following the designations for each wire; L1, L2, and G (see Figure 9).


9




 






 

FEED 2

FEED 1

L1

L2

L1

L2





FEED 2 G2

FEED 1 G1

FEED 2

FEED 1

L1

L2

L1

L2

FEED 2 G2

FEED 1 G1





 







Figure 9. Dual Pedestal Contactor Installation Group (left 30A and right 70A).

 

MODEL FILENAME



91C5362G07.iam

MODEL REV

2





Figure 12. GFCI Receptacle Location - Reference Only

C

ALL REV. NOTES

LISTED ON SHT. 1

DWG NO

T.BLK

REV-4





91C5362

REV

8

3

Control Wires

A 2-wire shielded Belden cable for Modbus communication may be needed based upon the configuration of your EVSE. Terminate these wires before applying the electrical service wires. If none present, skip this step and go to the next section.

 

FEED 2 G2

FEED 2

L1

L2

FEED 1

L1

L2

FEED 1 G1

FEED 2 G2

FEED 2

FEED 1

L1

L2

L1

L2

FEED 1 G1



Figure 10. Dual Wall Component Mounting Plate Group (left 30A and right 70A).

MODEL FILENAME MODEL REV C

ALL REV. NOTES

LISTED ON SHT. 1

DWG NO

91C5362

REV

91C5577G02.iam

2

T.BLK

REV-4

8

   

3



N otee:

Torque for incoming field service wiring – 22.1 - 26.6 in-lb

(2.5 – 3.0 Nm) – Use Copper Conductors Only.

Grounding Instructions

This product must be connected to a grounded, metal, permanent wiring system; or an equipment-grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal.

Optional Level 1 - 120VAC Outlet

When the EVSE is equipped with a Level 1 - 120VAC Outlet perform the wiring instructions outlined below in Figure 11.

Figure 13. Control Wiring.

Figure 11. Optional Level 1 - 120VAC Outlet

10





8. Confirming Installation and First Use



Dual User Interface

Icon / Light

Dual User Interface - Credit Card Only

Steady Blink

Payment / Authorization Needed Unit Ready for Charge Session

Vehicle Connected, EVSE Ready,

Waiting on Vehicle

Vehicle Charging

Rate of Charge Controlled Remotely and Charging Set to INACTIVE

Rate of Charge Controlled

Remotely and Charging ACTIVE

Slow fading blink

Side Ready to be Selected.

Note: From this state, more time can be added if vehicle is actively charging by selecting the side again.

NA

Display states: Select a Side

Bright blink

Bright blink

Side #1 (Left) Selected. User has 5

Minutes to Provide Payment.

Note: User can still change mind and select other side if payment not made yet.

Side #2 (Right) Selected. User has 5

Minutes to Provide Payment.

Note: User can still change mind and select other side if payment not made yet.

NA

NA

Figure 14. Status Indication for Normal Operation.

Step 1e: Ensure that the electrical service wires are landed according to this manual. Make sure the station access door is closed and locked.

Step 2e: Power ON the Distribution Breaker.

Step 3e: During initial EVSE boot-up, the User Interface will cycle all

ICONs.

Step 4e: After boot-up, the Power ICON will be either STEADY or

BLINKING per above table. If this is not the case, please verify that all incoming service connections are landed appropriately and that the distribution breaker is in-tact. If the Power ICON still does not appear, please call technical support at 1-855-ETN-EVSE (1-855-386-3873).

Step 5e: If the Power ICON is BLINKING, Authorization is needed.

Please consult the Authorization section of this document below. If the Power ICON is STEADY, please proceed to the next step.

Step 6e: If a SAE J1772 Compliant Electric Vehicle is available, please connect the EV Connector to the Vehicle Inlet. You may also use an Eaton Vehicle Simulator, part number

"EVSETESTB".

Step 7e: The CHARGING INDICATOR will begin to blink.

Step 8e: Almost immediately, the vehicle will engage a charge session (the contactor will close and power will be supplied to the vehicle).

See Table 10: Normal Operation User Interface Indicators, in the Appendix, for more details.

Step 9e: When power is being supplied to the vehicle, the

CHARGING INDICATOR will move from a BLINK status to STEADY status signifying that current is flowing to the vehicle.

Step 10e: You may now remove the connector from the vehicle at your leisure.


11



Authorization Needede:

If Authorization is needed, the Power ICON will have a BLINK pattern. This signifies to the end User that either payment activation is needed or RFID authorization.

Ground Fault Test




Automatic Reset Feature

From the factory, the EVSE is set to automatically reset after a temporary fault. The User has to manually disable the automatic reset feature if desired.

The EVSE will automatically reset a limit of 5 times before the user is locked out.

Figure 15. Ground Fault Test.

The ground fault detection feature is self tested every time the unit starts a plug session to charge a vehicle. A User can manually test the ground fault feature at any time by pressing and holding the reset button for approximately seven seconds (each side should be tested independently). If the test passed successfully, the fault light will flash once. If it detects a problem, the power icon will turn off and the service light (wrench icon) will have a medium single blink until power is cycled to the unit. See Table 11: EVSE Fault or

Error User Interface Indicators, in the Troubleshooting Section in the

Appendix, for more details.

Dip Switch Settings

Figure 16. Enabling/Disabling Automatic Reset.

 CAUTION

MODIFYING THE DIP SWITCH CONFIGURATION OF THE UNIT COULD

CAUSE THE UNIT NOT TO OPERATE AS DESIRED. PLEASE ONLY MODIFY

DIP SWITCH SETTINGS IF YOU ABSOLUTELY UNDERSTAND THE IMPACT

TO THE UNIT.

Dual Level 2 EVSE has two Protection and Control Boards. Each of these has its own dip switch configuration. Each board dip switch configuration should be identical and is set at the Factory.

The following Dip Switch details should be followed for each

Protection and Control Board respectively.

During installation, the Automatic Reset setting can be either left enabled as it came from the factory, or the User can decide to disable the feature. To enable or disable this feature, a Service

Technician must change the position of a dip switch on the control board.

•

•

To Enable Automatic Reset: Dip Switch Block SW2, Position 6 must be ON.

To Disable Automatic Reset: Dip Switch Block SW2, Position 6 must be OFF.

12





For board replacements or basic confirmation of settings, Table 3 contains the explanation of the dip switch settings found in the corner of the Eaton Protection and Control Board (EPCB) near the

RS232 Serial port, labeled SW1 and SW2.

Table 3. Dip Switch Settings.

Dip

Switch

Block

SW2

Dip

Switch

Position

1

Feature

Voltage

Configuration

ON OFF

US 120V US

208/240V

SW2

SW2

SW2

SW2

SW2

SW1

SW1

SW1

Description

2

3, 4, and 5

6

7

8

1 Reserved for

Factory

2 and 3 RS485 Baud

Rate

4, 5, 6, 7, and 8

RS485

Address

Voltage Configuration of the Unit. For 120V

Configuration -

A Wire Jumper is included between

L2 and N as shown in Figure 15 of this

Document

North America is 60Hz Operating

Frequency

Reserved for

Factory Use

Auto-reset after fault

60Hz

Soft Start

Download

50Hz

Reserved for Factory Use.

Enabled Disabled Default in Disabled position.

A vehicle fault must be reset manually – the owner can easily enable this feature via this dip switch.

Doing so, will enable an auto-reclosure on a nuisance trip

Default in OFF position. If ON, the EVSE will perform a ramp up of current to the Available

Line Current (ALC) or Nameplate Rating over a

30 second time period. This is done through the SAE J1772 handshake with the vehicle by modifying the Duty Cycle on the Pilot Signal.

Default in OFF position, Used to install new firmware updates from the SD Card Slot. For more details, please reference IL0EV00026E.

Default in OFF position

Defaults in ON position.

See Baud Rate Dip Switch Table 4.

Defaults in OFF except for Position 8, i.e. 0x01.

Range 0x00 to 0x1F using binary addressing

(Most Significant Bit being SW1- Position 4).



Figure 17. Dip Switch Settings for a 208/240V, 60Hz, 30A Dual

Level 2 EVSE with Auto-reset Enabled.

Table 4. RS485 Baud Rate Dip Switch Table.

Baud Rate SW1 – Position 2 SW1 – Position 3

9600 OFF OFF

19200

38400

115200

OFF

ON

ON

ON

OFF

ON

There is a "Power Up Delay" that is a random amount of time between 3 and 10 minutes for units that are plugged into vehicles after a power outage. This ensures Charging Sessions are started at different times across your fleet.


13



9. Communications Connectivity for

ChargePoint

ChargePoint Connectivity

For ChargePoint enabled EVSE, connectivity to the ChargePoint network will need to be verified. Please complete the following steps.

Step 1

Please safely energize the unit. Locate the cellular modem on the door of the unit, behind the ChargePoint board (shown in Figure 18).

The "PWR", "TR", and "CD" indicator lights should be lit.

Step 2

Locate the Mac address and provisioning password located on a label above the wiring diagram on the sloped panel inside of the unit. Document these numbers for provisioning.

If you are not a ChargePoint certified installer, please proceed to

Step 3.

Step 3

Call 1-855-ETN-EVSE (1-855-386-3873), and provide them with the

Mac address and provisioning passwords, as well as the EVSE serial number (found on the white label on the outside of the EVSE) and station location.




Figure 18. ChargePoint Cellular Modem

14





10. Specifications

The Eaton Dual AC Level 2 EVSE is compliant with the following standards:

•

•

Society of Automotive Engineers (SAE) J1772™ EV Conductive

Charge Coupler and Station.

UL 2231 Personnel Protection Systems for EV Charging Circuits.

•

•

•

•

UL 2594 EV Supply Equipment (Outline of Investigation).

UL 1998 Software in Programmable Components.

FCC compliant, Part 15.

Canadian Standards Association (CSA) C22.2.107.

Table 5. Electrical and Mechanical Specifications.

Description

Incoming Voltage

30A 48A

Input Frequency

70A

208/240 VAC

120 VAC*

Line 1, Line 2, Earth Ground

50/60Hz

40 A 90 A Upstream Breaker Size

Output Voltage

Output Frequency

Output Amperage - Max Continuous 30 A

60 A

Same as Incoming

Same as Incoming

48 A 70A

Interlocked Power Output

Overcurrent Rating

Ground Fault Interruption

Yes

Output Amperage + 5%

20mA

(UL2231-1/UL2231-2 Personnel Protection)

DIP switch selectable Enable/Disable

(default Enabled)

Automatic Reset after Nuisance Trip

Feature

Randomized Restart On Power

Failure (delay before charging resumes after a power failure)

Mechanical Operations

Incoming Field Electrical Service

Terminal Block Torque in in-lb (Nm)

Incoming Modbus Connections

Terminal Block Torque in in-lb (Nm)

* when optional Level 1 receptacle is present

Yes

(randomized across a time range to stagger power up across deployments)

10,000 cycles (EV Connector, replaceable)

100,000 cycles (Contactor, replaceable)

22.1 – 26.6 (2.5 – 3)

4.4 – 5.3 (.5 - .6)



Table 7. I/O Specifications.

Description

J1772™ Pistol Grip EV

Connector

Wall-mount Pedestal

Same as Output Rating

Permissive Run Contact

Available Line Current

Control

RS-485

Memory

Field Diagnostics and

Upgrade Port

NC dry contact input

4 – 20mA analog input

Modbus-RTU 4-wire port

SD Memory Slot

RS-232 DB9 (HyperTerminalTM Support)

Table 8. Optional Specifications.

Description

Through-feed (Daisy Chain)

Compatible

Ethernet

Credit Card Processing

ChargePoint*

Wall-mount

No

Pedestal

Yes

RJ45, IEEE 802.3, TCP/IP, Modbus TCP

PCI-DSS

Available as ChargePoint only or as ChargePoint with contactless credit card reader.

CDMA, GSM/GPRS USA, GSM/GPRS Canada

Open Charge Point Protocol

(OCPP) Enabled.

Enables connectivity to OCPP 3rd party network service

* Not available on Dual Wall-Mount provider (Consult Factory)

Table 9. Optional Level 1 120VAC 20A Outlet .

Incoming Voltage

Input Frequency

Output Voltage

Output Frequency

Output Amperage - Max Continuous

120VAC

60 Hz

Same as incoming

Same as incoming

20A

Table 6. Physical and Environmental Specifications.

Description

Dimensions - H x W x D

Status Indicators

Push Buttons

Type Rating

Temperature – Operating

Temperature – Storage

Humidity

Wall-mount

30.13 x 15.37 x 11.23 in

(765.3 x 390.4 x 285.2 m)

Pedestal

50.03 x 16.41 x 8.35 in

(1270.8 x 416.8 x 212.1 m)

6 LEDs: ‘Power’, ‘Charging’, ‘Complete’, ‘Remotely

Controlled’, ‘Temporary Fault’, and ‘Service’

2 Buttons: ‘Override’ and ‘Reset’

3R

-30 to 50 degrees Celsius

-40 to 70 degrees Celsius

90% RH, non-condensing


15



Appendix

Table 10. EVSE Fault or Error User Interface Indicators




Notee: Shown below is right half of user interface only. The conditions are the same on both halves of the user interface.

*Credit Card only user interface not shown. Troubleshooting applies to all

Dual configurations.

What is Happening?

All indicator lights are off

Pattern

N/A

Cause

No electricity to unit

Secondary overcurrent device has detected a problem and tripped (for XX style units)

User interface cable unplugged

Control board damage from overcurrent or surge

Recommendation

Turn on circuit feeding the unit with the breaker or fuse in electrical panel

Service technician should inspect unit and reset internal overcurrent device

Service technician should plug in user interface

Call service technician

Only wrench indicator is lit Slow single blink

Medium single blink

Steady on

Lockout error—the same temporary fault has occurred three consecutive times or a more serious fault was detected

Ground fault detection failed self-test

Permanent error—installation wiring.

Internal contactor or control board has failed

Cycle power to the unit by turning off/on the breaker or fuse. Inspect the unit for damage to the cable, connector

Cycle power to the unit, but if continues, call a service technician

Call a service technician.

Confirm 120V between L1 and N.

Replace contactor or control board

Exclamation point and charging Exclamation point—slow single flash and charge—slow single flash

Exclamation point—fast double flash and charge—slow single flash

Exclamation point—steady ON and blue charge—slow single flash

Detected an overcurrent, currently not charging

Pilot signal error from a dirty connector or damaged cable or from a dirty vehicle inlet

Detected a ground fault, currently not charging

Wrench and charging is blinking Service wrench—slow single flash and blue charge—slow single flash

Vehicle’s pilot signal has a diode malfunction

Press Reset button (to right)

—or—

Wait for unit to automatically reset

Unplug and try again. If continues, call a service technician to clean or replace cable/connector and/or bring the vehicle in for service.

Press Reset button (to right)

—or—

Wait for unit to automatically reset

Unplug and try again. If continues, bring the vehicle in for service.

16

“Slow” equals a duration of about 1.5 seconds.

A Blink indicates that the light is instantly ON then OFF.

“Medium” equals a duration of about 1/4 of a second.

A Flash indicates that the light fades to ON and fades to OFF.


Automatic Reset feature must be enabled during installation— see the installation leaflet.

“Fast” equals a duration of about 1/8 of a second.




Notese:

Markings:

The physical unit must comply with NEC 625.15 and CEC 1.86.

A. "For use with Electric Vehicles"

B. "Ventilation Not Required"




17



Notese:




18





Notese:




19






For more information, visit www.eaton.com/plugin, call 1-855-ETN-EVSE (1-855-386-3873), or call your local Eaton sales office.

Eaton

Electrical Sector

1000 Eaton Boulevard.

Cleveland, OH 44122

United States

877-ETN-CARE (877-386-2273)

Eaton.com

© 2013 Eaton

All Rights Reserved

Printed in USA

Publication No. IM0EV00000E / TBG001077

August 2013

Electrical Sector

Canadian Operations

5050 Mainway

Burlington, ON L7L Canada

EatonCanada.ca

Eaton is a registered trademark..

All other trademarks are property of their respective owners.

Installation and Service Manual Dual AC Level 2 Electric Vehicle

Instruction Manual IM0EV00000E

Installation and Service Manual

Dual AC Level 2 Electric Vehicle

Supply Equipment (EVSE)

Contents

1. Important Safety Instructions - Please

Read

2. Symbols and Definitions

Definitions

Save These Instructions

3. About the Dual AC Level 2 EV Charging

Station

Moving, Transporting and Storage Instructions

Before You Begin

ADA Standards for Accessible Design

Replacement Parts List

4. Installing the Electrical Service

Checking the Electrical Requirements

Running the Wires

5. Instructions for Opening Door Latch

Step 1.

Step 3.

Step 2.

6. Installing to the Premise

Choosing a Location

Mounting to a Wall

Preparing the Site

Mounting to Uni-Strut

Pedestal Floor Mounting

Preparing the Site

7. Termination and Configuration

Wire Terminations

Electrical Service Wires

Control Wires

Grounding Instructions

Optional Level 1 - 120VAC Outlet

8. Confirming Installation and First Use

Authorization Needede:

Ground Fault Test

Automatic Reset Feature

Dip Switch Settings

Dual Level 2 EVSE has two Protection and Control Boards. Each of these has its own dip switch configuration. Each board dip switch configuration should be identical and is set at the Factory.

9. Communications Connectivity for

ChargePoint

ChargePoint Connectivity

Step 1

Step 2

Step 3

10. Specifications

Appendix

Notese:

Markings:

The physical unit must comply with NEC 625.15 and CEC 1.86.

A. "For use with Electric Vehicles"

B. "Ventilation Not Required"

Notese:

Notese:

For more information, visit www.eaton.com/plugin, call 1-855-ETN-EVSE (1-855-386-3873), or call your local Eaton sales office.

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