Turbo Cord User Guide
Contents
1. modify the plug provided with the product if it does not fit in the outlet Have a proper outlet installed by a qualified electrician If the output cable becomes separated from the charger module or the charge coupler DO NOT ATTEMPT TO REPAIR THE CABLE YOURSELF Contact AV Customer Support for assistance When using your charger basic precautions should always be followed including the following e See warnings on charger cord label Read warnings before operating the unit the first time Read all instructions in this guide before using this product e Never use the charger with an extension cord e Shock hazard make sure the plug is fully inserted into the wall outlet so that there are no exposed blade surfaces e Children should be supervised when in the vicinity of the charger while plugged in Do not put fingers into the electric charge coupler e To reduce the risk of fire connect only to a circuit provided with 20 amps maximum branch circuit overcurrent protection e Do not use a commercial garage classified for internal combustion engine vehicles due to vapors of flammable liquids gasoline being present TurboCord will not charge and will give a fault indication if ground is not present TURBOCORD CHARGER COMPONENTS CHARGE MODULE 240 V ADAPTER CLIP 240 V ADAPTER Release button CHARGE COUPLER REQUIRED OUTLETS Any electrical socket should checked by e2. charge your vehicle Contact AV Customer Support 11 CHAPTER 3 TROUBLE SHOOTING TROUBLESHOOTING Please refer to this Troubleshooting Guide for possible solutions to common errors or difficulties with charging your vehicle using your portable charger A RED TROUBLE Indicator may be triggered by several sources including the charger the utility service or the vehicle See Troubleshooting tips below Do not attempt to repair or service the charger yourself NOTE There are no user serviceable parts inside The RED TROUBLE Indicator turns on when the charger detects an error whether it is connected to your vehicle or not With the RED TROUBLE Indicator on the dual charger will not deliver power to the vehicle The error must be corrected before charging begins or resumes Problem Possible Cause Solution BLUE STATUS Indicator does not illuminate No power to unit 1 Check circuit breaker and other circuit loads 2 Try another wall outlet 3 Ensure charger module and adapter if operating in 240 VAC mode is fully inserted into the wall outlet Charger internal failure Contact AV Customer Support for assistance Vehicle will not charge RED TROUBLE Indicator remains solid Charge coupler is not inserted into the vehicle 1 Inspect the charge coupler 2 Remove the charge coupler from the vehicle then reinsert it into the vehicle receptacle until it clicks Vehicle is
3. information about safety practices which if not followed may result in serious injury or death Indicates information about safety practices which if not followed could result in personal injury or are necessary WARNING to prevent fire or equipment overheating Indicates helpful information for installation or usage but NOTE does not contain personnel or equipment safety related Y information ABOUT YOUR TURBOCORD CHARGER Thank you for purchasing the AeroVironment AV TurboCord Dual Voltage Charger our easy to use compact and portable power supply for your electric vehicle s on board charger The charger supplies and manages AC power to your electric vehicle and is compatible with a variety of battery electric and plug in hybrid electric vehicles The charger will operate from either a 120 VAC or a 208 240 VAC 60 hertz power source The included adapter is required for 208 240 VAC operation KEY FEATURES e Dual voltage capability e Compact portable design Overheating protection e Quick read status indicators e Underwriters Laboratories UL listed e SAE J1772 compliant e Auto restart in event of ground fault or power outage N The adapter is designed for use with the charger in 208 240 VAC operating mode only DO NOT connect other devices to the adapter NEVER use the charger with any AC adapter except for the adapter supplied by the manufacturer specifically for use with this charge
4. not ina state to accept charge Verify vehicle charge timer is set to permit charging Refer to the vehicle owner s manual for charge timer instructions Communication error between charger and vehicle Contact AV Customer Support for assistance 13 Problem Possible Cause Solution RED TROUBLE Indicator is blinking rapidly Utility fault 1 Disconnect the charger module from the wall outlet then reconnect to the wall outlet 2 If the condition persists have a qualified electrician inspect the wall outlet ground circuit integrity 3 Repair as required Above temperature limit Cases 1 Temperature is too high The charger will restart charging when it cools down 2 House socket wiring may be faulty 1 Inspect charger module for overheating hot to the touch a Carefully unplug charger module from the wall outlet and allow to cool b If the condition persists contact AV Customer Support for assistance 2 Disconnect the charger and adapter if operating in 240 VAC mode from the wall outlet 3 Have a qualified electrician inspect the wall outlet and adapter integrity a Repair as required RED TROUBLE Indicator is on solid when connected to vehicle RED TROUBLE Indicator is off and BLUE STATUS Indicator is on when you unplug from vehicle Vehicle problem Contact your vehicle service department RED TROUBLE Indicator is on
5. solid NOT connected to vehicle RED TROUBLE Indicator and BLUE STATUS Indicator are both on 14 Charger internal failure Charger trying to resolve internal error Contact AV Customer Support for assistance Charger will return to normal operation within 1 minute If problem persists contact AV Customer Support for assistance APPENDIX SPECIFICATIONS Model Line input power Output power Circuit breaker rating Frequency Power draw at idle during charging Cable length Weight Temperature operating Temperature storing and transporting Environmental rating Vehicle Dual voltage charger communication protocol Charge coupler Direction of charge Dual voltage 120 VAC 240 208 VAC 12 amps continuous 120 VAC 16 amps continuous 240 208 VAC 15 amps 120 VAC 20 amps 240 VAC 60 Hz lt 2 watts lt 4 watts approximately 20 ft 6 1 m 4 lb 1 81 kg module 0 2 Ib 0 09kg adapter 40 C to 50 C 40 F to 122 F 40 C to 70 C 40 F to 158 F NEMA 6P watertight SAE J1772 compliant SAE J1772 compliant Grid to vehicle Specifications are subject to change without notice 16 INSTALLING THE CABLE HANGER CABLE HANGER MOUNTING INSTRUCTION 1 Choose a location to install the cable hanger hanger should be located in practical proximity to both the utility service and the location of you
6. SOLE AND EXCLUSIVE WARRANTY GIVEN BY AV WITH RESPECT TO THE TURBOCORD CHARGER OTHER THAN EXPRESSED 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 the charger is limited to a maximum of the original purchase price of the charger 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 component parts and c AV will not be liable for repair replacement or service call costs for the charger 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 charger 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 charger was not operated serviced or maintained in strict compliance with the charger User s Manual and other printed instructions provided by AV and applicable building codes Any evidence of an attempt to disassemble or reverse engineer the charger will void this warranty 21 INDE
7. USER GUIDE TURBOCORD PORTABLE CHARGER 120V 240V DUAL VOLTAGE AeroVironment EV Solutions 2013 AeroVironment Inc All rights reserved AeroVironment EV Solutions and the AeroVironment logo are trademarks of AeroVironment Inc 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 Dual voltage charger are representative production mod els may vary Dual voltage charger may be branded under different names 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 Corporate Headquarters AeroVironment Inc EV Solutions 181 W Huntington Drive Suite 202 Monrovia CA 91016 Phone 626 357 9983 or 888 833 2148 Fax 626 359 9628 Email ev avinc com Website www evsolutions com OWNER S RECORD model TurboCord Dual Voltage Charger A NOTE ON CUSTOMER SUPPORT To ensure superior service please take note of your Serial Number when contacting AeroVironment Customer S
8. X A adapter 3 5 10 13 14 16 18 20 adapter 5 10 11 BLUE STATUS 8 9 10 11 13 14 6 charge coupler 5 9 1 13 18 20 charge module 5 8 9 10 circuit breaker 3 6 13 16 5 customer support D dedicated circuit 3 document number i E electric shock 3 4 19 20 environmental rating 16 F feature Surroi 3 19 G 20 11 H 17 18 indicator light 8 9 10 insulated 20 22 M 9 10 11 13 14 output ground 20 pilot signal wire 20 R RED TROUBLE indicator 8 11 13 14 19 20 release button 5 9 10 11 S SABINA Discs 3 16 18 safety 19 serial i service ground 19 STATUS indicator 8 9 10 13 14 T 16 21 TROUBLE indicator 5 8 11 13 14 19 20 wall 6 WATAN esirinnas 21 weight 16 AeroVironment EV Solutions Customer Support 1 888 833 2148 evscs avinc com Corporate Headquarters AeroVironment Inc EV Solutions 181 W Huntington Drive Suite 202 Monrovia CA 91016 Corporate phone 626 357 9983 or 888 833 2148 ev avinc com www e
9. following safety features to protect against the risk of electric shock e Service Ground Check The charger constantly checks for the presence of a service ground connection If the service ground ever fails the charger RED TROUBLE Indicator turns ON and shuts down power to the vehicle Thermal Event Sensor Charger module senses out of ordinary thermal events and will shut the unit down 19 20 GFCI Protection The charger is equipped with a Ground Fault Circuit Interruption GFCI reaction system to protect against electric shock If the charger module detects an output ground fault it will shut down power to the output cable and illuminate the RED TROUBLE Indicator Insulation The charger module adapter cable assembly and charge coupler are completely insulated no exposed live parts to protect against electric shock Unintentional Disconnection The charge coupler is designed to minimize unintentional disconnection A pilot signal wire in the cable and charge coupler eliminates the possibility of electric shock when not connected to a vehicle or if an unintended disconnect occurs during a charge Disconnection during charging is safe LIMITED WARRANTY TURBOCORD CHARGER LIMITED WARRANTY KEEP RECEIPT FOR WARRANTY CLAIMS The AeroVironment Inc AV TurboCord EV charger is warranted to be free of defects in material and workmanship for a period of thirty six 36 months from the date of original purchase THIS IS THE
10. he solid BLUE STATUS Indicator and the RED TROUBLE Indicator turns off WARNING A constant or blinking RED TROUBLE Indicator indicates an actual problem CHARGING YOUR VEHICLE Your charger is designed for easy charging in two modes 120 VAC and 240 VAC 120 VAC MODE When used WITHOUT the ADAPTER the charger connects to a 120 V outlet and charges your vehicle in Level 1 charging mode The Level 1 120 VAC charge regimen takes longer to charge than the Level 2 240 VAC mode however 120 VAC wall outlets are typically more readily available 1 Insert the CHARGE MODULE into the appropriate 120V wall outlet 2 The BLUE STATUS Indicator on the CHARGE MODULE should be ON This means that the charger is ready to provide power to your vehicle 3 Plug the CHARGE COUPLER into your vehicle s charging outlet until it clicks If inserted properly the BLUE STATUS Indicator will blink once Once latched the CHARGE COUPLER will not disengage unless the release button is pressed manually 4 Automatic charge begins Power will be delivered in accordance to vehicle demand If the vehicle is charging the BLUE STATUS Indicator will blink on and off approximately every two seconds Always verify that the vehicle charging status indicator agrees 5 When fully charged the BLUE STATUS Indicator light illuminates solid blue Your vehicle has a dashboard gauge which can verify that the vehicle is fully charged Refer to the vehicle
11. lectrician 120 VAC operation a NEMA 5 15R wall outlet is required NEMA 5 15R receptacle 120 V A dedicated 120 VAC single phase circuit and 15 amp NOTE rated circuit breaker are required 208 240 VAC operation a NEMA 6 20R wall outlet is required NEMA 6 20R wall receptacle 240 V Ba A dedicated 240 VAC split phase circuit or a 208 VAC NOTE Y two phase circuit and a 20 amp rated circuit breaker are required SECTIONE USING YOUR TURBOCORD CHARGER KNOW YOUR INDICATOR LIGHTS The indicator light on your dual voltage charger is the first thing you will notice when you are about to plug or unplug your vehicle Before we get started here is asimple explanation of the indicators CHARGE MODULE INDICATOR LIGHTS Red TROUBLE Blue STATUS Indicator light Indicator light BLUE STATUS When plugged into the wall outlet the BLUE STATUS Indicator illuminates to communicate that the charger is ready to use RED TROUBLE The RED TROUBLE Indicator illuminates when the charger has detected an error If the RED TROUBLE Indicator is illuminated the charger will not deliver power to the vehicle The error must be corrected before a charging cycle can begin or continue Refer to the Troubleshooting Guide in Section 3 for more information A momentary blink of the RED TROUBLE Indicator at first 5 plug in to the wall socket is normal and functions as a NOTE Y startup safety check This momentary blink is followed by t
12. ore cleaning it To clean the charger wipe it 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 charger STATE OF CALIFORNIA PROPOSITION 65 WARNINGS This product contains a chemical known to the State warning N of California to cause cancer or birth defects or other reproductive harm FCC INFORMATION This device complies with Part 15 ofthe FCC Rules Operation is subject to the following two conditions e This device may not cause harmful interference e 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 some instances where high powered radio signals or nearby RF producing equipment i e digital phones RF communications equipment etc could affect operation If you suspect your charger 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 Important Changes or modifications to this product by anyone other than an authorized service provider will void FCC compliance SAFETY FEATURES The charger is designed with your safety as the highest priority and includes the
13. owner s manual to find the gauge location on your dashboard 6 Disconnect when the charge is complete by pressing the release button on the CHARGE COUPLER and removing it from the vehicle 240 VAC MODE When used WITH the ADAPTER the charger can charge in Level 2 240 VAC mode 10 Charge Module Adapter Clip Adapter Snap the ADAPTER CLIP to the lower end ofthe CHARGE MODULE lining up the appropriate symbols AA and O on the clip and module Insert the CHARGE MODULE into the ADAPTER make sure it is fully inserted or the clip will not slide into the lock position Slide the ADAPTER CLIP up to the top of the CHARGE MODULE to lock in place Insert the CHARGE MODULE with the attached ADAPTER into the appropriate 240 VAC wall outlet The BLUE STATUS Indicator on the CHARGE MODULE should be ON This means that the charger is ready to provide power to your vehicle Plug the CHARGE COUPLER into your vehicle s charging receptacle until it clicks Once latched the CHARGE COUPLER will not disengage unless the release button is pressed manually Automatic charge begins Power will be delivered in accordance to vehicle demand If the vehicle is charging the BLUE STATUS Indicator will blink on and off approximately every two seconds Always verify that the vehicle charging status indicator agrees When fully charged the BLUE STATUS Indicator light illuminates solid blue Your vehicle has a dashboard gauge which can verif
14. r 120 VAC Operation the charger requires a 120 VAC single phase dedicated circuit lt draws a maximum of 12 amp continuous current and requires a 15 amp rated circuit breaker 240 VAC Operation the charger requires either a 240 VAC split phase or a 208 VAC two phase dedicated circuit lt draws a maximum of 16 amp continuous current and requires a 20 amp rated circuit breaker warning N warune N It is recommended that electrical outlets for use with your charger be installed by a licensed qualified electrician To avoid serious injury or death installation must comply with the provisions of the National Electric Code and all local codes In cases of conflict between local codes and the NEC local codes shall take precedence This product must be grounded If it should malfunction or break down grounding provides a path of least resistance for electric current to reduce the risk of electric shock This product is equipped with a cord having an equipment grounding conductor and a grounding plug The plug must be inserted into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances warnine N warnine N DANGER warnine N NOTE Improper connection of the electrical outlet grounding conductor might result in a risk of electric shock Check with a qualified electrician if you are uncertain whether or not the electrical outlet is properly grounded Do not
15. r vehicle s charge receptacle Preferably mounted to a wall stud Dry wall and masonry wall installations require the use of appropriate inserts 2 Measure up approximately 36 from the floor and mark the location 3 Drill out the preferred mounting holes through the back of the cable hanger using 32 inch drill bit 4 Using a Phillips Screwdriver tighten the screws for the cable hanger 17 HIGH VOLTAGE WARNING DANGER warnine N warning N warning AN 18 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 DO NOT operate your charger with a damaged output cable charge coupler adapter or module Visually inspect the output cable charge coupler adapter and charger module for damage before each use If you detect any damage stop using the dual voltage charger and contact AV Customer Support ALWAYS position the charger output cable so that it will not be driven over stepped on tripped over or otherwise damaged or stressed To prevent personal injury and damage to the charger ALWAYS stow the charger and adapter on hanger or in stowage bag after use Use the charger only to supply power to electric vehicles equipped with an SAE J1772 compliant vehicle receptacle For more information refer to the vehicle owner s manual Disconnect the charger from the wall outlet bef
16. upport Write down the Serial Number of your charger in the Owner s Record above The Serial Number can be found on the bottom of the charger s plug in module AeroVironment EV Solutions Customer Support 1 888 833 2148 evscs avinc com P22603 03 1 SAVE THESE INSTRUCTIONS This manual contains important instructions for the TurboCord Dual Voltage Charger that shall be followed during installation operation and maintenance ofthe unit TABLE OF CONTENTS SECTION 1 1 Symbol net 2 About Your TurboCord 3 TurboCord Charger 5 Reg ired OUT 6 SECTION 2 USING YOUR DUAL VOLTAGE CHARGER 7 Know Your 63 8 Charging Your Vehicle cvs euer nannten 9 120 VAG rai 9 240 Mode 10 Manual topico ar sang 11 A Noten Aut Restart u 11 SECTION 3 12 APPENDIX u en 15 7 16 Installing the Cable et 7 High Voltage caricia iia 18 State of California Proposition 65 19 at ita 19 Safety 19 Warranty rd 21 anne 22 SECTION 1 INTRODUCTION SYMBOL USAGE DANGER Indicates
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18. y that the vehicle is fully charged Refer to the vehicle owner s manual to find the gauge location on your dashboard Disconnect when the charge is complete by pressing the release button on the CHARGE COUPLER and removing it from the vehicle When plugging into an unfamiliar wall outlet it is good practice to let the vehicle charge for several minutes N before leaving it unattended to ensure it is in fact NOTE supplying the expected AC charging power The RED TROUBLE Indicator will illuminate if not charging The unit will turn OFF if breaker or infrastructure GFI is tripped MANUAL STOP To safely stop charging at any time before charge completion just press the CHARGE COUPLER release button and remove it from the vehicle Charging will automatically and safely stop BLUE STATUS Indicator remains ON solid A NOTE ON AUTO RESTART The Auto Restart feature helps ensure that your vehicle will be charged and ready for use when needed A charge may be interrupted if an error is detected Charging will resume once the error is no longer detected The RED TROUBLE Indicator illuminates during an error condition The exception to immediate Auto Restart is when the interruption is due to a charger event The charger will attempt to restart 15 minutes after a event After the fourth attempt to restart the charger will shut down and the RED TROUBLE Indicator will stay ON If the fault persists do not continue to try to
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