USER GUIDE - EV Solutions
Contents
1. 21 Charge complete tractor 22 Interrupt a charging 23 Remove and return connector to Charging Dock 27 Auto Restart LLL T uuu u 29 Power Outage 30 Care and 32 Time of Use Metering 32 TROUBLESHOOTING INSTALLATION FOR ELECTRICIAN ONLY 47 Introduction 48 Safety Instructions u uu uu uu uu uuu uu 49 Personal Protection Equipment PPEL 51 Package Contenits 52 Front Panel and 54 TABLE OF CONTENTS Installing the Charging Dock Obtain permits Building codes Check parts in the package 57 IL e e S Location REIR DO Choose wiring entry 60 Route wiring and or conduil 61 Use mounting plate as template 61 Install mounting plate 62 Drill OD Pull wires out Of wall2. 68 Remove cover and hang on rim of Charging Dock 64 Attach Charging Dock to mounting plate Upper mounting hole Lower mounting hole Connect conduit to Charging Dock 68 Connect utility wires and 68 Final ASSEMDIy ssescsssescsssesecsssecsssesessssssssecsssseesssseserssess 70 Mount cable hanger to wall stud or dry wall 73 TABLE OF CONTENTS Install a 40 amp circuit breaker Turn the power ON Self test E 78 To Re Open the Charging Dock electrician only 79 APPENDIX SPECIFICATIONS etie 83 WARRANTY tenens 84 GETTING STARTED GETTING STARTED Thank you for purchasing the AeroVironment Charging Dock Model EVSE RS for use with your Nissan LEAF all electric vehicle This user guide shows how to use the Charging Dock and contains installation instructions for the electrician AeroVironment recommends that your Charging Dock be installed by a licensed qualified electrician To avoid serious injury or death installation must be in accordance with the A WARNING manufacturer s installation instructions and must comply with the provisions of the National Electric Code NEC and all local codes In cases of conflict between local codes and the NEC local codes shall take precedence GETTING STARTED CHAPTER 1
3. ELECTRIC VEHICLE COMPATIBILITY The Charging Dock is designed Electric Vehicles EVs and Plug In Hybrid Electric Vehicles PH electric vehicles charging standard that has been developed by the Socie Automotive Standards in the USA Engineers t The Chargin he governing body g Dock requires eith a 208 VAC 2 phases and neutra the power d FEATURES e SAE J1772 Compliant Auto restart in event of power outage or Breakaway safety cable ground fault Integrated cable stowage with cable hanger o charge all SAE J1772 compliant vehicles including er a 240 VAC split phase and neutral grounded circuit or grounded circuit This circuit must be routed directly from istribution panel to the Charging Dock location e Underwriters Laboratory UL compliant Optional pedestal mount CHAPTER 1 EVs SA E J1772 is an e Quick read status indicators y of Automotive GETTING STARTED GETTING STARTED IMPORTANT SAFETY INSTRUCTIONS Please read these Important Safety Instructions and the charging instructions in your vehicle owner s manual before charging your electric vehicle Failure to do so can result in death or serious injury Save this user guide for future reference There are many safety features built into the Charging Dock Read all the safety informa tion and warnings in this guide to be aware of any hazards and risks associated with instal
4. the way you move USER GUIDE Installation Instructions for Your Electrician AeroVironment EV Solutions Charging Dock Model EVSE RS NOTICE TO ELECTRICIAN Leave this User Guide with the EVSE RS customer for future reference 2010 2011 AeroVironment Inc All rights reserved AeroVironment EVSE RS EV Solutions and the AeroVironment logo are trademarks of AeroVironment Inc Nissan the Nissan logo the Zero Emission logo and LEAF are trademarks or registered trademarks of Nissan Motor Co Ltd used with permission Corporate names trademarks registered trademarks service marks symbols and logos stated herein are property of their respective companies Specifications are subject to change without notice Images of the Charging Dock Model EVSE RS are repre sentative production models may vary No portion of these materials may be duplicated used or disclosed without prior written permission from AeroVironment Inc Disclaimer This user guide includes the latest information available at the time of printing AeroVironment Inc reserves the right to make changes to this user guide and or product without further notice Changes or modifications to this product not completed by an authorized service provider could void the product warranty AeroVironment Inc 181 W Huntington Drive Suite 202 Monrovia CA 91016 Phone 626 357 9983 or 888 833 2148 Fax 626 359 9628 www avinc com evsolutions
5. The Charging Dock is intended to be used by licensed drivers only Children should not be allowed to use this Charging Dock DO NOT allow children to play in or around the Charging Dock Close supervision of children is necessary when the Charging Dock is used CHAPTER 1 Use this Charging Dock to supply power to Electric Vehicles equipped with a compatible WARNING vehicle receptacle only For more information see the vehicle owner s manual State of California Proposition 65 Warnings Thi t tai hemical k to the State of California t is product contains a chemical known to the State of California to cause cancer WARNING This product contains a chemical known to the State of California to cause birth defects or other reproductive harm CHAPTER 1 GETTING STARTED Important Changes or modifications to this product by anyone other than an authorized service provider will void FCC compliance 10 GETTING STARTED FCC Information This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 This device may not cause harmful interference 2 This device must accept any interference received including interference that may cause undesired operation This product has been designed to protect against Radio Frequency Interference RFI However there are some instances where high powered radio signals or nearby RF producing equipment i
6. Up to 90 non condensing NEMA Type 3 enclosure Raintight with mounting plate UL listed FCC part 15 subpart B CHAPTER 5 APPENDIX 83 84 AV INSTALLATION CHARGING DOCK MODEL EVSE RS LIMITED WARRANTY The AeroVironment Inc AV Home Charging Dock Model EVSE RS Charging Dock is warranted to be free of defects in material and workmanship for a period of thirty six 36 months from the date of original installation In addition if a Charging Dock is installed by AV or a certified member of AV s licensed independent electrical contractor installation network AV warrants that the original installation of the Charging Dock shall be free of defects in workmanship for a period of thirty six 36 months from the date of installation THIS IS THE SOLE AND EXCLUSIVE WARRANTY GIVEN BY AV WITH RESPECT TO THE CHARGING DOCK AND INSTALLATION THEREOF AV UNDERTAKES NO RESPONSIBILITY FOR THE QUALITY OF THE CHARGING DOCK AND INSTALLATION SERVICES EXCEPT AS OTHERWISE PROVIDED IN THE PURCHASE CONTRACT AND THIS WARRANTY OTHER THAN EXPRESS AND OR IMPLIED WARRANTIES REQUIRED BY APPLICABLE LAWS OR WHICH ARE REQUIRED TO EXTEND FORA LONGER PERIOD THERE ARE NO WARRANTIES THAT EXTEND BEYOND THIS LIMITED WARRANTY AND ANY REQUIRED WARRANTIES ARE LIMITED IN DURATION TO THE WARRANTY PERIOD To the extent permitted by applicable laws a AV s total warranty expense with respect to any Charging Dock and or its installation is limited
7. s Es the vehicle that verifies that the vehicle is READY TO CHARGE O x rower Present fully charged See the owner s manual that VEHICLE CONNECTED j pesce pe ceca came with the vehicle to find out where the gt VEHICLE CHARGING 3 mms Gs gauge is located TROUBLE O CHAPTER2 OPERATION POWER PRESENT READY TO CHARGE VEHICLE CONNECTED VEHICLE CHARGING TROUBLE OPERATION 000090 5 Charge complete When the vehicle has completed charging the VEHICLE CHARGING light turns OFF the POWER PRESENT READY TO CHARGE and VEHICLE CONNECTED lights turn ON as shown below zero Emission POWER PRESENT neavy ro START VEHICLE CONNECTED Q VEHICLE CHARGING QsroP trovere STOP NISSAN CHAPTER 2 6 Interrupt a charge cycle STOP You can interrupt charging at any time using one of the two following methods PAUSE METHOD 1 Preferred SIART Press the STOP button After pressing STOP the POWER PRESENT READY TO RESUME CHARGE and VEHICLE CONNECTED lights appear as shown The VEHICLE CHARGING light goes OFF Press the START button to resume charging POWER PRESENT senor ro OSTART VEHICLE CONNECTED VEHICLE CHARGING trouste STOP NISSAN POWER PRESENT BLINKING gt READY TO CHARGE u VEHICLE CONNECTED u OFF gt VEHICLE CHARGING O TROUBLE O CHAPTER
8. 2 OPERATION POWER PRESENT OFF READY TO CHARGE VEHICLE CONNECTED ON gt VEHICLE CHARGING TROUBLE OPERATION 00000 Once charging has resumed the POWER PRESENT VEHICLE CONNECTED and VEHICLE CHARGING lights are ON as shown below zero Emission POWER PRESENT Rin OSTART STOP NISSAN VEHICLE CHARGING mouere CHAPTER 2 METHOD 2 Press the latch release on the connector to stop the flow of electricity and remove from the vehicle as shown below Charging stops LATCH RELEASE CHAPTER 2 OPERATION 25 POWER PRESENT READY TO CHARGE VEHICLE CONNECTED VEHICLE CHARGING TROUBLE OPERATION 00066 The POWER PRESENT and READY TO CHARGE lights are ON as shown below zero Emission POWER PRESENT START TROUBLE STOP NISSAN CHAPTER 2 7 Remove and return connector to Charging Dock When the charge cycle is complete press the latch release and remove the connector from your vehicle Return the connector to the Charging Dock The VEHICLE CHARGING light will be OFF LATCH RELEASE CHAPTER 2 OPERATION ALWAYS position the Charging Dock output cable so that it will not be driven over stepped WARNING on tripped over or otherwise damaged or stressed while in use To prevent personal injury and damage to the Charging Dock
9. Corporate email ev avinc com OWNER S RECORD MODEL E SERIAL NUMBER S N on label underneath left side of Charging Dock enclosure housing CUSTOMER SUPPORT Before contacting Customer Support write down the Serial Number of the Charging Dock As you stand facing the Charging Dock look for the Serial Number underneath left side of the enclosure Customer Support Phone 1 877 NO GAS EV 1 877 664 2738 Customer Support email evscs avinc com This user guide is also available in Spanish French Chinese and Japanese For more information AeroVironment Inc 181 W Huntington Drive Suite 202 Monrovia CA 91016 Phone 626 357 9983 or 888 833 2148 Fax 626 359 9628 www avinc com evsolutions Corporate email ev avinc com Document Number EVSE RS_UG_ENG_rev A 2 17 11 TABLE OF CONTENTS GETTING STARTED 1 Electric Vehicle 3 Features odere ase tansa Aa 3 Important Safety Instructions 4 SYMMONS GG 4 High Voltage Warning iene 6 FCC Information i 10 Safety Features 11 Ventilation 13 OPERATION 15 Overview Key Features Charging your vehicle Check indicator lights Disengage the connector Connect to vehicle Automatic charge starts
10. NISSAN r STOP PAUSE Interrupts the charging cycle at any time If vehicle is connected to the Charging Dock press START to resume charging m CONNECTOR Communicates between Charging Dock and vehicle and delivers power to vehicle CABLE HANGER When cable is not being used coil the cable over the cable hanger START RESUME To resume charging after the STOP button was pressed Also to override a random time delay after a utility power outage STORAGE DOCK Connector inserts into Charging Dock here and stays in place for storage when not in use LATCH RELEASE Press to release connector Then remove connector from Charging Dock Also when connector is plugged into vehicle press latch release to stop power flowing to vehicle Then remove connector from vehicle The connector will not disengage unless you depress the latch and stop the flow of electricity CHAPTER 2 KEY FEATURES FRONT PANEL LATCH RELEASE CONNECTOR CABLE HANGER CABLE OPERATION 17 CHARGING YOUR VEHICLE 1 Check indicator lights First make sure the POWER PRESENT and READY TO CHARGE lights are ON as shown below This means that the Charging Dock is ready to charge your vehicle POWER PRESENT Zero Emission If the POWER PRESENT and READY TO CHARGE eee READY TO CHARGE lights VEHICLE CONNECTED O w OTOP are not ON please see the
11. Ratchet Set 8 Allen Head Adapter Channel Lock Pliers 1 8 Hole Saw Wire Stripping Pliers Electric Drill Cutting Pliers CHAPTER 4 5 Location Decide the location to install the Charging Dock Find the vertical stud in a wood frame wall suitable masonry wall or optional post mounting to drill holes to attach the mounting plate for the Charging Dock The Charging Dock is supplied with lag bolts for a stud mounting Suitable fasteners may be needed for other mounting types CHAPTER 4 INSTALLATION 59 6 Choose wiring entry HOLE IN REAR OF Only one service wiring entry point into the Charging Dock is permitted Identify the Copie ING OPER preferred wiring entry location in the Charging Dock and drill the hole at the dimple for the wiring entry The hole in the rear allows rear wiring entry and the hole on the underside allows for lower wiring entry Do not exceed the maximum limit on conduit size HOLE ON UNDERSIDE OF CHARGING DOCK Rear View Bottom View 60 INSTALLATION CHAPTER 4 7 Route wiring and or conduit Route wiring and or conduit between the power distribution panel and the Charging Dock as required Do not install a circuit breaker in the power distribution panel at this time This will be done later in step 19 on page 75 8 Use mounting plate as template Hold
12. into the opening at location as shown on page 80 72 INSTALLATION CHAPTER 4 18 Mount cable hanger to wall stud or dry wall Use 2 painted head fasteners to attach the output cable hanger to the wall stud dry wall masonry wall surface or pedestal recommended 12 inches 31 cm below the Charging Dock so that it is in line with the Charging Dock mounting location The hanger is supplied with screws for a wall stud mounting Suitable fasteners may be required for other mounting types Select and drill mounting holes through as required from the rear of the hanger CHAPTER 4 INSTALLATION 74 CHARGING DOCK CABLE HANGER INSTALLATION Front view CHAPTER 4 Mounting holes Back view 19 Install a 40 amp circuit breaker Install a 40 amp circuit breaker in the power distribution panel 20 Turn the power ON Turn the power ON at the circuit breaker and disconnect switch if applicable Turn the power ON at the Charging Dock dedicated circuit breaker at the power distribution panel to avoid electric shock Observe all safety precautions CHAPTER 4 INSTALLATION 75 Notice the POWER PRESENT and READY TO CHARGE lights are ON VEHICLE CONNECTED VEHICLE CHARGING and TROUBLE lights are OFF zero Emission POWER PRESENT READY TO CHARGE OSTART VEHICLE CONNECTED venicLe cHARGING O trovere STOP NISSAN POWER PRESENT READ
13. pushing a flat blade screwdriver into the access slot at the bottom tunnel of the enclosure Gently remove the outer ring all the way around the front panel Remove all nine 9 screws from the outer perimeter of the cover Pull the cover off the enclosure Hang cover as shown in the pictures on page 64 Put the cover back on the Charging Dock after inspection is complete as shown in the Final assembly on pages 70 72 INSTALLATION Access hole CHAPTER 4 Outer ring SPECIFICATIONS Model Connector Car charging dock communication protocol Dimensions Voltage Current output power Circuit breaker rating Frequency Power draw on idle Cable length Optional cable length Weight with 15 ft cable Weight with 25 ft cable Temperature Operating Temperature Storing amp Transporting Humidity Environmental rating Regulatory compliance Specifications are subject to change without notice EVSE RS SAE J1772 compliant SAE J1772 compliant 12 H x 12 W x 8 D approximately either a 240 VAC split phase and neutral grounded or a 208 VAC 2 phases and neutral grounded 30 Amp maximum 40 Amp Do NOT use a Class A circuit breaker with the EVSE RS Charging Dock 50Hz 60Hz less than 5 watt hours 15 ft 4 57 m Up to 25 ft 7 6 m 14 0 Ibs 6 35 kg 17 5 lbs 7 94 kg 22 F to 122 F 30 C to 50 C 40 F to 140 F 40 C to 60 C
14. turn ON 1 Turn the circuit breaker in your power distribution panel OFF and then back ON 2 If the problem persists contact Customer Support for service CHAPTER 3 TROUBLESHOOTING 37 VEHICLE CONNECTED light does not turn ON when the Charging Dock is connected to the vehicle 1 Unplug the Charging Dock connector and reinsert it fully into the electric vehicle receptacle ake sure the connector latch engages in the receptacle 2 Inspect the Charging Dock cable and connector terminals for damage If damaged discontinue using immediately and contact Customer Support for service 3 Inspect vehicle receptacle for damage If damaged discontinue using immediately and eport the problem to your nearest Nissan service dealership 38 TROUBLESHOOTING CHAPTER 3 VEHICLE CHARGING light does not turn ON 1 Ifthis occurs when the vehicle is connected and is charging contact Customer Support for service 2 If this occurs when the vehicle is connected but is not charging Attempt to charge using the Emergency Portable Cord Set that came with the vehicle as shown on page 36 in the Troubleshooting section of this user guide gt Ifa charge cycle starts contact Customer Support for service gt Ifa charge cycle does not start report the problem to your nearest Nissan service dealership CHAPTER 3 TROUBLESHOOTING 39 40 TROUBLESHOOTING TROUBLE light is ON solid The Ch
15. E CONNECTED STOP TROUBLE NISSAN POWER PRESENT READY TO CHARGE O VEHICLE CONNECTED Aly E VEHICLE CHARGING A TROUBLE O START RESUME VEHICLE CHARGING CHAPTER 2 OPERATION 32 OPERATION Care and Maintenance To clean the Charging Dock module wipe the Charging Dock with a clean cloth dampened with water or a mild detergent solution suitable for use on automobile paint Do not use chemicals or solvents Do not submerge the Charging Dock Time of Use Metering Many electric utilities have been actively promoting the use of EVs and have developed specific utility rates to promote off peak charging of these vehicles This approach typically requires a second meter to separately monitor the electrical use of the Charging Dock This allows the utility to charge rates on a Time of Use TOU basis typically providing savings for overnight off peak charging and penalties for daytime on peak charging Consult your local electric utility to determine Time of Use availability and cost CHAPTER 2 TROUBLESHOOTING 34 TROUBLESHOOTING If you experience difficulty with your Charging Dock or your vehicle battery does not charge properly please read this Troubleshooting section for possible solutions before contacting Customer Support for service Do not attempt to repair or service the Charging Dock yourself There are no user serviceable parts inside O
16. N The AV Home Charging Dock Model EVSE RS Charging Dock is warranted to the original purchaser to be free of defects in material and workmanship for a period of thirty six 36 months from the date of shipment THIS IS THE SOLE AND EXCLUSIVE WARRANTY GIVEN BY AV WITH RESPECT TO THE CHARGING DOCK AV UNDERTAKES NO RESPONSIBILITY FOR THE QUALITY OF THE CHARGING DOCK EXCEPT AS OTHERWISE PROVIDED IN THE AGREEMENT AND THIS WARRANTY OTHER THAN EXPRESS AND OR IMPLIED WARRANTIES REQUIRED BY APPLICABLE LAWS OR WHICH ARE REQUIRED TO EXTEND FOR A LONGER PERIOD THERE ARE NO WARRANTIES THAT EXTEND BEYOND THIS LIMITED WARRANTY AND ANY REQUIRED WARRANTIES ARE LIMITED IN DURATION TO THE WARRANTY PERIOD To the extent permitted by applicable laws a AV s total warranty expense with respect to any Charging Dock is limited to a maximum of the original purchase price of that Charging Dock as applicable to a warranty claim b AV s liability under this warranty shall be limited to the repair or replacement at AV s option of defective Charging Docks or defective component parts and c AV will not be liable for repair replacement service call de installation or installation costs for Charging Docks not covered by this warranty which shall be the responsibility of the Buyer Coverage under the terms of this limited warranty is not transferable to any other party This limited warranty does not cover service calls to correct the installation
17. TTING STARTED 12 DANGER GETTING STARTED W dri is ot wires in the cable and connector eliminate the possibility of electric shock when not nnected to a vehicle or if an unintended disconnect occurs during a charge en the Charging Dock connector is properly connected to the vehicle receptacle the vehicle ve system is disabled The output cable has a safety break away feature in case the vehicle moved or unintentionally rolls away from the parking location with the cable connected to the ve icle The safety break away feature will allow output cable separation from the Charging Dock if the output cable is yanked or pulled with excessive force Th po Ifthe e Charging Dock cable should be coiled up on the hanger when not in use to minimize tential cable damage and to eliminate the possibility of tripping over the cable cable becomes separated from the Charging Dock DO NOT attempt to repair or service the Charging Dock and cable assembly yourself There are no user serviceable components inside CHAPTER 1 Only a service technician authorized by AeroVironment can perform repair or service on the Charging Dock or the Charging Dock Warranty may be invalidated Contact Customer Support for service Ventilation The AeroVironment AV Charging Dock will not work with Electric Vehicles EVs that require an external ventilation system If the Charging Dock is connected to this typ
18. VEHICLE CHARGING O s Troubleshooting chapter for TROUBLE O possible solutions on page 34 18 OPERATION CHAPTER 2 2 Disengage the connector Press the latch release and remove the connector from the Charging Dock zero Emission OSTART STOP zero Emission Power present VEHICLE CONNEC VEHICLE CHAR LATCH RELEASE OPERATION CHAPTER 2 20 3 Connect to vehicle Plug the connector into your vehicle s charging receptacle and let go of the connector Latch release will click to indicate proper connection The connector should not disconnect without pressing the latch release The connector stays in place The VEHICLE CONNECTED light turns ON when a proper connection is made LATCH RELEASE zero Emission POWER PRESENT READY TO CHARGE gt VEHICLE CONNECTED VEHICLE CHARGING TROUBLE POWER PRESENT OSTART VEHICLE ae STOP NISSAN 00000 OPERATION CHAPTER 2 4 Automatic charge starts The vehicle automatically starts charging and the Charging Dock supplies power as needed POWER PRESENT VEHICLE CONNECTED and the VEHICLE CHARGING lights stay on when charging VEHICLE CHARGING light blinks when the vehicle is approaching the end of the charging cycle VEHICLE CHARGING light goes out when vehicle is fully charged Look for a gauge on POWER PRESENT Bees
19. Y TO CHARGE gt VEHICLE CONNECTED OFF VEHICLE CHARGING TROUBLE 00066 INSTALLATION CHAPTER 4 21 Self test Check to see that each light turns ON as follows 1 Press and hold the START and STOP buttons at the same time for three seconds The POWER PRESENT light stays ON If all lights do not turn ON contact Customer Support 2 3 The READY TO CHARGE light goes out 4 The VEHICLE CONNECTED VEHICLE CHARGING and TROUBLE lights turn ON and for assistance OFF one at a time going down Then they turn ON and OFF going back up They cascade going down then up 5 When the test completes the READY TO CHARGE light turns ON Service Tool testing AeroVironment recommends that an AV Service Tool is used to test installation of the Charging Dock Authorized AV thechnicians will have access to this tool CHAPTER 4 INSTALLATION 77 78 22 Inspection Schedule an appointment with an electrical inspector for your local permitting authority INSTALLATION CHAPTER 4 TO RE OPEN THE CHARGING DOCK electrician only Inspection may require opening and reclosing Charging Dock to visually inspect wire termination Turn the power OFF at the Charging Dock dedicated circuit breaker to avoid electric shock Observe all safety precautions CHAPTER 4 WARNING DANGER INSTALLATION 79 Remove the Outer Ring by
20. Y TO CHARGE OSTART O SE R VEHICLE CONNECTED zero Emission POWER PRESENT O VEHICLE CHARGING DSTART NISSAN OPERATION POWER OUTAGE RECOVERY If there is a power outage the utility grid might experience a large surge from multiple Charging Docks in your area attempting to resume charging simultaneously when power is restored This would cause additional stress to the utility grid The Power Outage Recovery feature avoids this scenario by resuming charge with an automatic delay after restoration of power Power Outage Recovery ensures that Charging Dock users in your area will resume charging in a staggered fashion to avoid stressing the grid If a utility power outage occurs while your vehicle is being charged the charging dock will automatically resume charging once power POWER PRESENT is returned The VEHICLE CHARGING light READY TO CHARGE O a blink d charai ill re start aut ti READY To CHARGE OSTART inks and charging wi ie star au oma E VEHICLE CONNECTED ecu cally after a randomly assigned time ranging Sn STOP n QNS gt VEHICLE CHARGING u POWER IS TROUBLE O RESTORED 30 OPERATION CHAPTER 2 To override the automatic random delay after utility power is restored press the START button on the Charging Dock to resume charging zero Emission POWER PRESENT 4 READY TO CHARGE OSTART VEHICL
21. all safety precautions 68 INSTALLATION CHAPTER 4 J Connect AC Power Phase wires Line 1 and Line 2 to the respective Terminal Block locations matching the labeled wires inside the Charging Dock Torque the AC Power Phase Wire screws to 20 in Ib 2 2 Nm Connect green Ground Utility wire to the Ground Strip Torque the ground strip screw to 20 in Ib 2 2 Nm Terminal Block Ground Strip Ground Wire Two power wires CHAPTER 4 INSTALLATION 69 17 Final assembly 1 Complete inspection To avoid having to reopen the Charging Dock panel AeroVironment recommends having the electrical inspector complete inspection of the Charging Dock wiring before closing the Charging Dock and power distribution panel 2 Install the Charging Dock cover and torque all nine screws to 12 1 in Ib 1 36 Nm A WARNING Do not over or under torque screws Use calibrated torque wrench 70 INSTALLATION CHAPTER 4 Verify that the wires from the front cover circuit board are routed to prevent pinching WARNING between the housing and cover during assembly Tighten cover screws by hand Do not use power screw driving equipment CHAPTER 4 INSTALLATION 71 3 Install the trim ring by snapping it into the groove in the Charging Dock faceplate Nine screws Outer ring Front cover To remove the trim ring insert a flat head screw driver
22. and cable ALWAYS stow the output cable after use STRANGULATION HAZARD Small children could become entangled in the output cable A WARNING and be strangled Keep small children away from the Charging Dock and ALWAYS stow the output cable after use CABLE HANGER CABLE 28 OPERATION CHAPTER 2 AUTO RESTART Auto Restart feature helps ensure that your vehicle will be charged and ready for use when needed If a charge is interrupted due to a temporary error condition the Charging Dock automatically clears any error codes when the cause of the temporary error condition returns to normal and then attempts to restart the charge The TROUBLE light remains lit while the cause of the temporary error condition is active or awaiting a time out delay The exception to immediate Auto Restart is when the interrupt is due to a GFCI event To allow charging after GFCI events caused by line surges or other disturbances the Charging Dock will restart 15 minutes after a GFCI event assuming the event did not occur immediately upon connecting power to the vehicle The Charging Dock is limited to four automatic restarts after a GFCI event during a charge cycle After the fourth attempt the Charging Dock will shut down and the TROUBLE light will be ON POWER PRESENT READY TO CHARGE VEHICLE CONNECTED O O VEHICLE CHARGING TROUBLE THIS LIGHT GOES OUT WHEN AUTO RESTART IS SUCCESSFUL CHAPTER 2 H READ
23. arging Dock and prepare to attach the Charging Dock to the mounting plate First at the upper hole then the lower hole in the back of the Charging Dock Upper mounting hole Lower mounting hole CHAPTER 4 INSTALLATION 65 14 UPPER MOUNTING HOLE Attach the Charging Dock through the upper mounting hole as follows Insert the supplied socket head screw and flat washer through the upper hole in the back of the Charging Dock into the upper hole of the mounting plate Upper mounting hole Flat washer Socket head screw 66 INSTALLATION CHAPTER 4 14b LOWER MOUNTING HOLE Insert screw washer at lower hole Insert a socket head screw and flat washer through the lower mounting hole of the Charging Dock into the lower mounting plate hole Tighten both screws to 40 in Ib 4 52 Nm CHAPTER 4 Lower mounting hole INSTALLATION 67 15 Connect conduit to Charging Dock Connect conduit and or cord grip to enclosure using appropriate hardware 16 Connect utility wires and conduit Connect utility wires and conduit to the internal connections and to the Charging Dock enclosure as follows DANGER Turn the power OFF at the Charging Dock dedicated circuit breaker at the power distribution panel to avoid electric shock Observe
24. arging Dock is one part of the Electric Vehicle s charging system A charger on board the vehicle is the other part TROUBLE indicators may be triggered by several sources including the Charging Dock the utility service the vehicle or temperature extremes See Troubleshooting tips below The Trouble light turns on when the Charging Dock detects an error whether the vehicle is connected or not With the Trouble light on the Charging Dock will not deliver power to the vehicle The error must be corrected before charging starts or resumes There are two scenarios for a solid TROUBLE light CHAPTER 3 Scenario 1 VEHICLE IS NOT CONNECTED POWER PRESENT READY TO CHARGE zero Emission POWER PRESENT O READY TO OSTART gt VEHICLE CONNECTED VEHICLE CONNECTED VEHICLE CHARGING STOP TRousLE NISSAN VEHICLE CHARGING TROUBLE 00000 CHAPTER 3 TROUBLESHOOTING 41 42 TROUBLESHOOTING Scenario 2 VEHICLE IS CONNECTED POWER PRESENT READY TO CHARGE VEHICLE CONNECTED VEHICLE CHARGING TROUBLE CHAPTER 3 00000 zero Emission POWER PRESENT READY TO OSTART VEHICLE CONNECTED VEHICLE CHARGING STOP Trouvere NISSAN 1 Turn the circuit breaker or the disconnect switch if installed OFF then ON 2 If the fault persists DO NOT USE the Charging Dock Contact Customer Support for service TROUBLE light blinks two times rep
25. e digital phones RF communications equipment etc could affect operation If you suspect your Charging Dock is receiving interference take the following steps before contacting Customer Support for service 1 Relocate nearby electrical appliances or equipment during charging 2 Turn off nearby electrical appliances or equipment during charging CHAPTER 1 SAFETY FEATURES The Charging Dock is designed with your safety as the highest priority and includes the following convenient safety features to protect against the risk of electric shock The Charging Dock is designed with a permanent grounding system for personal safety The Charging Dock constantly checks for the presence of a service ground connection If the service ground ever fails the Charging Dock TROUBLE light turns ON and shuts power OFF to the vehicle The Charging Dock is equipped wi th a Ground Fault Circuit Interruption GFCI reaction system to protect against electric shock If the module detects an output ground fault it will shut off power to the output cable and illuminate the TROUBLE light The Charging Dock enclosure and cable assembly are completely insulated no exposed live parts to protect against electric shock The Charging Dock connector and EV coupler are designed to minimize unintentional disconnection and to prevent exposing the user to live power if an unintentional disconnection occurs CHAPTER 1 GE
26. e of EV the Charging Dock will illuminate the TROUBLE light and not provide power to the vehicle Contact Customer Support for additional information CHAPTER 1 GETTING STARTED 14 CHAPTER 1 OVERVIEW All the lights on the front panel are green when they turn on except the TROUBLE light which is red POWER PRESENT Light turns on when power from your local utility is at the Charging Dock This light should always be on if the circuit breaker and disconnect switch are both ON Disconnect switch may be required by local permitting authority but may not always be present VEHICLE CONNECTED This light turns on when the Charging Dock is communicating with your vehicle and the connection was made properly TROUBLE This light turns on when Charging Dock has detected an error and requires you to take action See the Troubleshooting chapter on page 33 OPERATION zero Emission O READY TO CHARGE This light turns on when the Charging Dock is ready to be connected to your vehicle O VEHICLE CHARGING This light turns on when power from the utility company is being provided to your vehicle The light may stay on solid in the early stage of the charging cycle if vehicle battery is low then blinks later in the charging cycle then finally goes out when charging is complete CHAPTER 2 POWER PRESENT O a OSTART og STOP
27. eating 1 Caused by an error having to do with your electric vehicle 2 Turn the circuit breaker or the disconnect switch if installed OFF then ON If the fault persists contact Customer Support for service TROUBLE light blinks three times repeating 1 Caused by a utility problem 2 Turn the circuit breaker or the disconnect switch if installed OFF then ON 3 If the fault persists report issue to utility company CHAPTER 3 TROUBLESHOOTING 43 44 TROUBLESHOOTING TROUBLE light blinks four times repeating 1 Caused by the Charging Dock mounted near an external heat source furnace water heater etc or in direct sunlight 2 Remove the heat source 3 Provide shade from direct sunlight 4 fthe fault persists contact Customer Support for service TROUBLE light is rapidly blinking Press STOP A TROUBLE light goes OFF 1 Press START 2 TROUBLE light OFF Charging Resumes CHAPTER 3 3 If TROUBLE light turns ON a Turn power OFF at circuit breaker or disconnect switch if applicable b Disconnect from vehicle c Contact Customer Support for service B If TROUBLE light stays ON 1 Turn power OFF at the circuit breaker or disconnect switch if applicable 2 Disconnect cable from vehicle 3 Contact Customer Support for service CHAPTER 3 TROUBLESHOOTING 45 46 CHAPTER 3 INTRODUCTION Read these installatio
28. he Charging Dock is wired improperly INSTALLATION 49 WARNING This is a single phase device Do not connect all three phases of a three phase feed 50 INSTALLATION ELECTRICAL CAPACITY REQUIREM The Charging Dock requires either a 240 VAC split phase and neutral grounded or a 208 VAC 2 phases and 1A 240 V split phase single phase 3 wire system 1B 240 V split phase 3 phase 4 wire system delta system ENTS neutral dedicated grounded circuit 2 208 V 2 phases and neutral grounded made from 3 phase 4 wire wye system 2 EZ 4 High leg 08 V t CHAPTER 4 PERSONAL PROTECTION EQUIPMENT PPE The installer service technician must wear Personal Protection Equipment PPE that meets current ANSI ASTM and OSHA safety standards For this section PPE is defined as Safety Glasses or Goggles to prevent eye injury Safety Shoes designed to gt Prevent an electrical path to earth ground in the event of accidental contact with high voltages Protect the feet from injury due to falling objects During the installation procedure the installer should also wear a hard hat for areas with low overhead clearances or confined spaces and gloves for areas where potential for exposure to unfinished lumber exists CHAPTER 4 INSTALLATION PACKAGE CONTENTS Please check all the par
29. latch release 17 19 25 27 M model ii mounting plate 61 N NEMA Type 3 83 owner s record P pilot wires 12 power outage recovery 30 R regulatory compliance 83 re open the Charging Dock 79 repair 12 13 34 52 s SAE J1772 compliant 3 83 serial number ii single phase 50 specifications 83 START Resume 17 23 31 storage dock connector 17 T temperature 83 template 61 terminal block 69 tools 58 tripping 12 trouble light 11 29 40 V ventilation 13 w warranty i 13 34 49 84 85 weight 83 INDEX Customer Support Phone Number 1 877 NO GAS EV 1 877 664 2738 SHIFT the way you move
30. ling and using the Charging Dock Note any missing parts and contact AeroVironment Customer Support for assistance with obtaining replacement parts Symbol Usage Take special note of all information marked with the following symbols CHAPTER 1 Indicates information about safety practices which if not followed will result in death or DANGER serious injury Indicates information about safety practices which if not followed could result in personal WARNING injury or are necessary to prevent fire or equipment overheating Indicates helpful information for installation or usage but does not contain personal injury or equipment safety related information These symbols may also be found on labels affixed to your Charging Dock CHAPTER 1 GETTING STARTED DANGER WARNING GETTING STARTED High Voltage Warning High voltage is present in your electric meter housing and power distribution service panel Contact with high voltage can cause death or serious personal injury AeroVironment recommends that your Charging Dock be installed by a licensed qualified electrician To avoid serious injury or death installation must be in accordance with the manufacturer s installation instructions and must comply with the provisions of the National Electric Code NEC and all local codes In cases of conflict between local codes and the NEC local codes shall take precedence CHAPTER 1 T
31. n instructions completely and carefully They will save you time and effort and help to ensure optimum performance Be sure to observe all listed dangers and warnings Use only the screws nuts bolts and washers included in the package AeroVironment recommends that your Charging Dock be installed by a licensed qualified electrician To avoid serious injury or death installation must be in accordance with the WARNING manufacturer s installation instructions and must comply with the provisions of the National Electric Code NEC and all local codes In cases of conflict between local codes and the NEC local codes shall take precedence 48 INSTALLATION CHAPTER 4 SAFETY INSTRUCTIONS ELECTRIC SHOCK CAN KILL cal parts can cause fatal shocks or severe burns Touching live elect The input power circuitry and internal circuits are live whenever input power is on An incorrectly installed or improperly grounded unit is a hazard GROUNDING INSTRUCTIONS This unit is to be connected to a grounded metal permanent wiring system or an equip ment grounding conductor is to be run with the power circuit conductors and connected to an equipment grounding terminal or lead on the Charging Dock ground strip Connections to the Charging Dock shall comply with all local codes and ordinances CHAPTER 4 A DANGER Read all instructions and cautionary markings on the Charging Dock assembly Warranty is void if t
32. nly a service technician authorized by AeroVironment can perform repair or service on the Charging Dock or the Charging Dock Warranty may be invalidated Contact Customer Support for service CHAPTER 3 Charging Dock is not available If the Charging Dock is not available use the the vehicle as follows Use of an Emergency Portable Cord Set will charge your vehicle at a much slower rate than the Charging Dock Connect the Emergency Portable Cord Set from a dedicated 120 Volt wall outlet with Ground Fault Circuit Interrupt GFCI protection to the vehicle as shown below The battery charger in the vehicle automatically detects low or high voltage inputs Emergency Portable Cord Set that came with CHAPTER 3 TROUBLESHOOTING 35 36 WARNING Use only an Emergency Portable Cord Set that is approved by the vehicle manufacturer or you could damage the charger in the vehicle or the vehicle might not charge A WARNING Use only the approved receptacle for the Emergency Portable Cord Set TROUBLESHOOTING WALL OUTLET WITH GFCI a EMERGENCY PORTABLE CORD SET CHAPTER 3 POWER PRESENT light does not turn ON 1 Turn the circuit breaker in your power distribution panel OFF and then back ON 2 Make sure the disconnect switch is ON if present If the problem persists contact Customer Support for service READY TO CHARGE VEHICLE CHARGING and TROUBLE lights do not
33. o clean the Charging Dock wipe the Charging Dock with a clean cloth dampened with wa ter or a mild detergent solution suitable for use on automobile paint Do not use chemicals WARNING or solvents Do not submerge the Charging Dock Turn off the power to the Charging Dock at the circuit breaker and disconnect switch if applicable before cleaning it Do not operate your Charging Dock with a visibly damaged output cable or module housing Visually inspect the output cable including the connector and module housing for dam DANGER age before each use If you detect any damage stop using the Charging Dock and contact Customer Support for service If at any time you think the equipment is unsafe shut off the electricity at the circuit breaker or disconnect if applicable and immediately contact Customer Support for service DO NOT use your Charging Dock until the problem is identified and corrected CHAPTER 1 GETTING STARTED A WARNING A WARNING A WARNING GETTING STARTED ALWAYS position the Charging Dock output cable so that it will not be driven over stepped on tripped over or otherwise damaged or stressed while in use To prevent personal injury and damage to the Charging Dock and cable ALWAYS stow the output cable after use STRANGULATION HAZARD Small children could become entangled in the output cable and be strangled Keep small children away from the Charging Dock and ALWAYS stow the output cable after use
34. of your Charging Dock instruction to you on how to use your Charging Dock costs associated with de installing the Charging Dock shipment of the Charging Dock to AV for repair or replacement and shipment of the repaired or replaced Charging Dock back to your home or re installation of the repaired or replaced Charging Dock This warranty shall be voided by damage or excessive wear to the Charging Dock caused by abnormal operating or environmental conditions including exposure to acid chemical fumes metallic dust or extreme temperatures accident abuse damage misuse vandalism unauthorized alteration or repair utility surges or if the Charging Dock was not installed operated serviced or maintained in strict compliance with the Home Charging Dock Model EVSE RS User s Manual and other printed instructions provided by AV No installation services warranty applies under these Terms Any evidence of an attempt to disassemble or reverse engineer the Charging Dock will void this warranty WARRANTY 85 INDEX A AeroVironment Inc ii appendix 82 auto restart 29 C cable hanger 73 74 cleaning 7 connector 12 17 19 customer support ii D document number ii E electric shock 11 49 68 75 79 emergency portable cord set 35 36 environmental rating 83 F features 3 front panel cover 17 54 G GFCI 11 29 36 ground fault circuit 11 35 36 H hook 64 I installing 55 insulated 11 L
35. rhood community and homeowners associations have or are implementing Covenants Conditions and Restrictions CC amp Rs which may affect or prohibit external device installations Review any CC amp Rs to ensure compliance and avoid any potential conflicts CHAPTER 4 Power Disconnect switch Charging Dock distribution if applicable Wall stud INSTALLATION 55 A WARNING Do not use the Charging Dock with a Class A circuit breaker AeroVironment recommends that the Charging Dock not be installed in a location that exceeds the operating temperature specified 56 INSTALLATION CHAPTER 4 3 Check parts in the package Check all the parts in the package to ensure that nothing appears to be broken damaged or missing Save the shipping cartons and packing materials in case the Charging Dock or cable was damaged in shipping File a claim with the freight carrier and or insurance company in the event of shipping damage Note any missing parts and contact AeroVironment Customer Support for assistance with obtaining replacement parts CHAPTER 4 INSTALLATION 57 58 INSTALLATION 4 Tools Have the following tools ready to use Standard Screwdriver Torx Drive Screwdriver amp adapters for Torque Screwdriver Phillips Screwdriver easuring Tape Electrician Screwdriver Utility Tape Torque Screwdriver ultimeter Torpedo Level Small Hammer Torque Wrench Duct Tape
36. the mounting plate up against the wall with the two small holes over a wall stud as shown Ensure that the mounting plate straight edges are plumb Use the mounting plate as a template to mark lag bolt location Example of wood frame construction installation CHAPTER 4 Mounting plate Large hole for conduit utility wires Charging Dock mounting holes Small holes for mounting plate to wall stud Wall stud INSTALLATION 61 62 9 Install mounting plate Mount the plate to the wall with the supplied lag bolts and flat washers as shown below Torque the lag bolts until the mounting plate is securely fastened Flat washer Lag bolt Wall stud INSTALLATION CHAPTER 4 10 Drill holes Use appropriate anchors for masonry wall installation 11 Pull wires out of wall Pull utility wires out of the wall if rear hole of charging dock is used for wire entry and through the mounting plate CHAPTER 4 Utility wire INSTALLATION 63 64 12 Remove cover and hang on rim of Charging Dock Gently hook the front cover into the two slots at the rim of the Charging Dock Hook on back of cover INSTALLATION CHAPTER 4 The front cover hangs safely with the cable out of the way for the next step 13 Attach the Charging Dock to mounting plate Pull utility wires through the service entry point in the Ch
37. to a WARRANTY maximum of the original purchase price of that Charging Dock and or its AV certified installation as applicable to a warranty claim b AV s liability under this warranty shall be limited to the repair or replacement at AV s option of defective Charging Docks defective component parts or defective installation workmanship together with any service call required to make repairs or replacements covered by this warranty and c AV will not be liable for repair replacement or service call costs for Charging Docks or installation workmanship not covered by this warranty which shall be the responsibility of the purchaser This warranty shall be voided by damage or excessive wear to the Charging Dock caused by abnormal operating or environmental conditions including exposure to acid chemical fumes metallic dust or extreme temperatures accident abuse damage misuse vandalism unauthorized alteration or repair utility surges or if the Charging Dock was not operated serviced or maintained in strict compliance with the Home Charging Dock Model EVSE RS User s Manual and other printed instructions provided by AV No installation services warranty applies if the Charging Dock is not installed by AV or a certified member of AV s licensed independent electrical contractor installation network Any evidence of an attempt to disassemble or reverse engineer the Charging Dock will void this warranty NON AV INSTALLATIO
38. ts in the package shown below to ensure that nothing appears to be broken damaged or missing Note any missing parts and contact AeroVironment Customer Support for assistance with obtaining replacement parts Save all packaging materials in case of service or repair needs in the future Please use the screws nuts bolts and washers that came in the package 52 INSTALLATION CHAPTER 4 OUTER RING FOR FRONT PANEL CABLE HANGER 5 CHAPTER 4 CHARGING DOCK USER GUIDE HARDWARE KIT WITH SCREWS NUTS BOLTS WASHERS INSTALLATION 53 FRONT PANEL AND ENCLOSURE ENCLOSURE HOUSING FRONT PANEL COVER 54 INSTALLATION CHAPTER 4 INSTALLING THE CHARGING DOCK 1 Obtain permits Obtain all required permits from your local permitting authority before installing the Charging Dock 2 Building codes A representative Charging Dock installation as shown on the right is connected to the resi dential utility power distribution panel The Charging Dock is designed for a permanently wired installation indoors in a garage or outdoors in a carport or on a pedestal While the Charging Dock is designed to be weatherproof the customer may wish to consider adding personal protection from wet weather for his her convenience For more information on temperature ranges see the Specifications section on page 83 In addition to local building codes and ordinances certain neighbo
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