AV_EV_EVSE-RS UserGuide and Install
Contents
1. S o rtr rr gt S F o 7 o c et i o r o 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 e Safety Glasses or Goggles to prevent eye injury e Safety Shoes designed to 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 t H3ldVHOD NOILVTIVLSNI d31S A8 d341S Aluo sue1314131 104 t HJLdVHO NOI1VT11V1SNI d31S A8 d31S Aluo sue1314131 4104 PACKAGE CONIENIS Note any missing parts and contact AV customer Support for assistance with obtaining 3 d NOTE 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 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 damage2. owner s record ii P pilot wires 12 power outage recovery 30 power phase wires 69 power present 16 18 PPE 51 proposition 9 R regulatory compliance 83 re open the Charging Dock 79 repair 12 13 34 52 S SAE J1772 compliant 3 83 self test 77 serial number ii single phase 83 specifications 83 start resume 17 22 31 stop pause 17 22 stop a charging cycle 22 storage 17 storage dock 17 T temperature 40 55 56 83 template 61 tools 57 trouble 11 13 16 29 40 45 trouble light 11 13 16 29 40 45 troubleshooting 33 U utility wires 61 63 69 V vehicle charging 3 16 21 23 26 30 31 39 ventilation 13 warranty 13 34 49 78 84 warranty information 78 85 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 avinc com evsolutions PN 17315 03 Rev
3. LZ STOP PAUSE Interrupts the charging cycle at any time If vehicle is connected to the Charging Dock press START to resume charging 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 or vehicle The connector will not disengage unless you depress the latch KEY FEATURES FRONT PANEL LATCH RELEASE CONNECTOR CABLE HANGER HN CABLE N NOILVLS DNIDSYVHD YNOA ONISN d31dVHO NOILVLS DNIDSYVHD YNOA ONISN CHARGING YOUR VEHICLE 1 CHECK LIGHTS ON FRONT PANEL 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 READY TO CHARGE VEHICLE CONNECTED VEHICLE CHARGING TROUBLE OO Oe POWER PRESENT READY TO CHARGE VEHICLE CONNECTED VEHICLE CHARGING TRousLE NOTE If the POWER PRESENT and READY TO CHARGE lights are not ON please see the Troubleshooting chapter beginning on page 33 for possible solutio
4. DANGER 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 at the 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 t H3ldVHOD NOILVTIVLSNI d31S A8 d31S Ajuo sue1314131 4104 t HJLdVHO NOI1VT11V1SNI d31S A8 d31S Ajuo sue1314131 4104 Notice the POWER PRESENT and READY TO CHARGE lights are ON VEHICLE CONNECTED VEHICLE CHARGING and TROUBLE lights are OFF OFF Y POWER PRESENT READY TO CHARGE VEHICLE CONNECTED VEHICLE CHARGING TROUBLE Oooee NOTE If all lights do not turn ON contact Customer Support for assistance 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 2 The POWER PRESENT light stays ON 3 The READY TO CHARGE light goes out 4 The VEHICLE CONNECTED VEHICLE CHARGING and TROUBLE lights turn ON and 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 Itis highly recommended that AV Service Tool is used to test installation of Charging Dock An authorized AV technician will hav
5. Ensure that the mounting plate straight edges are plumb Use the mounting plate as a template to mark lag bolt locations Example of wood frame construction installation Mounting plate Large hole for conduit utility wires 4 48 Small holes for mounting plate to wall stud Wall stud NOILVTIVLSNI d31S A8 d341S Aluo sue1314131 104 NOILVTTVLISNI d31S A8 d31S Ajuo 1 11 2 104 8 INSTALL MOUNTING PLATE TO WALL AND TORQUE BOLTS Drill pilot holes and 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 Use appropriate anchors for masonry wall installation Flat washer Lag bolt Wall stud 9 PULL WIRES OUT OF WALL AND PLATE REAR CHARGING DOCK ENTRY ONLY Pull utility wires out of the wall Gf rear hole of Charging Dock is used for wire entry and through the mounting plate Utility wire NOI1VT11V1SNI d31S A8 d31S Ajuo sue132114131 104 NOI1VT11V1SNI d31S A8 d31S Aluo sue1314131 4104 10 PREPARE TO ATTACH CHARGING DOCK TO MOUNTING PLATE Prepare to attach the Charging Dock to the mounting plate as follows Lay the enclosure on a flat surface for the time being Remove the front panel from the enclosure ENCLOSURE HOUSING FRONT PANEL COVER 11 HANG FRONT PANEL ON RIM OF CHARGING DOCK Gently hook
6. available use the Emergency Portable Cord Set that came with the vehicle as follows Use of an Emergency Portable Cord Set will charge your vehicle at a much slower rate than the Charging Dock d31LdVHO ONILOOHSITENOUL 35 ONILOOHSITESNOYL 36 Connect the Emergency Portable Cord Set from a dedicated 120 Volt wall outlet with Ground Fault Circuit Interrupt GFCD protection to the vehicle as shown below The battery charger in the vehicle automatically detects low or high voltage inputs WALL OUTLET WITH EMERGENCY POTABLE CORD SET A N 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 N WARNING Use only the approved receptacle for the Emergency Portable Cord Set 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 3 If the problem persists contact Customer Support for service READY TO CHARGE VEHICLE CHARGING AND TROUBLE LIGHTS DO NOT TURNON 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 H31dVHO ONILOOHSITSNOUL 37 H31dVHO ONILOOHSITSNOUL 38 VEHICLE CONNECTED LIGHT DOES NOT TURN ON WHEN
7. is located POWER PRESENT READY TO CHARGE VEHICLE CONNECTED 1 VEHICLE CONNECTED POWER PRESENT mcn OSTART VEHICLE CHARGING trovere STOP VEHICLE CHARGING Oeeoe TROUBLE Zz dH31dVHO NOILVLS DNIDSYVHD YNOA ONISN H31dVHO NOILVLS 9D9NI983VHD2 YNOA ONISN TO STOP A CHARGING CYCLE You can interrupt charging at any time using one of the two following methods METHOD 1 Preferred ARE Press the STOP button After pressing STOP the POWER PRESENT READY TO CHARGE and VEHICLE CONNECTED lights appear as shown below The VEHICLE START CHARGING light goes OFF Press the START button to resume charging RESUME POWERPRESENT BLINKING gt READY TOCHARGE X OSTART stop VEHICLE CONNECTED anes OFF VEHICLE CHARGING O TROUBLE Once charging has resumed the POWER PRESENT VEHICLE CONNECTED and VEHICLE CHARGING lights are ON as shown below POWER PRESENT OFF gt READY TO CHARGE VEHICLE CONNECTED ON VEHICLE CHARGING TROUBLE Oeeoe POWER PRESENT READY CHARGE VEHICLE CONNECTED VEHICLE CHARGING OSTART 5 d31dVHO NOILVLS DNIDSYVHD YNOA ONISN 23 METHOD 2 Press the latch release on the connector and remove from the vehicle as shown below Charging stops and power stops flowing in the cable before the connector is fully NOILVLS 9NI9NUVHO YNOA ONISN 24 withdrawn from the vehicle in
8. live power if an unintentional disconnection occurs L 83L1dVHO NOILINGOUINI 1 Lu3ldVHOD NOILINGOUILNI 12 Pilot wires in the cable and connector eliminate the possibility of electric shock when not connected to a vehicle or if an unintended disconnect occurs during a charge e When the Charging Dock connector is properly connected to the vehicle receptacle the vehicle drive system is disabled The output cable has a safety break away feature in case the vehicle is moved or unintentionally rolls away from the parking location with the cable connected to the vehicle The safety break away feature will allow safe cable separation from the Charging Dock if the output cable is yanked or pulled with excessive force The Charging Dock cable should be coiled up on the hanger when not in use to minimize potential cable damage and to eliminate the possibility of tripping over the cable If the 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 DANGER components inside NOTE Only an authorized service technician can perform repair or service on the Charging Dock or the Charging Dock Warranty may be invalidated Contact Customer Support for service VENTILATION The AV Charging Dock will not work with Electric Vehicles EVs that require an external ventilation system If the Charging Dock is connected to this type of EV th
9. the front panel into the two slots on the lower rim of the Charging Dock Hook on back of cover The front cover hangs safely with the cable out of the way for the next step NOILVTIVLISNI d31S A8 d31S Ajuo sue1314131 4104 NOILVTIVLSNI d31S A8 d31S Aluo sue1314131 4104 12 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 13 LOWER MOUNTING HOLE Insert the supplied socket head screw and flat washer through the lower hole in the back of the Charging Dock into the lower mounting hole of the mounting plate Tighten both screws to 50 in lb 5 65Nm Lower mounting hole 2 t ud3ldV NOILVTIVLSNI d31S A8 d31S Aluo sue1314131 4104 udJLldVHO NOILVTIVLISNI d31S A8 d341S Aluo sue1314131 104 14 CONNECT CONDUIT TO ENCLOSURE Connect conduit and or cord grip to enclosure using appropriate hardware 15 TURN POWER OFF Turn AC power OFF at the main distribution panel Turn the power OFF at the Charging Dock dedicated circuit breaker at the power distribution panel to avoid electric shock Observe all safety precautions DANGER 16 CONNECT UTILITY WIRESAND CONDUIT Connect utility wires and conduit to the internal connections and to the Chargi
10. 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 stud mounting Suitable fasteners may be needed for other mounting types NOTE 5 DRILL HOLE FOR WIRE ENTRY REAR OR UNDERSIDE Only one service wiring entry point into the Charging Dock is permitted from the rear or the underside The hole in the rear allows rear wiring entry and the hole on the underside allows for lower wiring entry Identify the preferred wiring entry location in the Charging Dock and drill a hole at the preferred location dimple for the wiring entry Do not exceed the maximum limit on conduit size H3ldVHOD NOILVTIVLSNI d31S A8 d31S Aluo sue1314131 104 NOIIVITIVLISNI d31S A8 d31S Aluo 1 11 2 104 HOLE IN REAR OF CHARGING DOCK frontier revo A OTHER Rear View HOLE ON UNDERSIDE OF CHARGING DOCK Bottom View 6 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 7 USEMOUNTING PLATE AS A TEMPLATE AND DRILL SCREW HOLES Hold the mounting plate up against the wall with the two small holes over a wall stud as shown below
11. NOTICE TO ELECTRICIAN Leave this User Guide with the EVSE RS customer for future reference USER GUIDE with Installation Instructions for Your Electrician AeroVironment EV Solutions Charging Dock Model EVSE RS M aerovironment Face plate design may vary 2011 AeroVironment Inc All rights reserved AeroVironment EVSE RS 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 Charging Dock Model EVSE RS are representative 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 CUSTOMER SUPPORT 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 EVSE RS SERIAL NUMBER
12. O f POWER PRESENT neavvrocnaner START START RESUME VEHICLE CONNECTED 4f ce ore I ply peg STOP J VEHICLE CHARGING TROUBLE H31dVHO NOILVLS DNIDSYVHD YNOA ONISN H31dVHO NOILVLS DNIDSYVHD YNOA ONISN 32 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 TROUBLESHOOTING H31dVHO 9NILOOHSJI9NOYL 34 CHARGING DOCK IS NOT AVAILABLE 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 NOTE serviceable parts inside V Only an authorized service technician can perform repair or service on the Charging Dock NOTE or the Charging Dock Warranty may be invalidated Contact Customer Support for service V NOTE If the Charging Dock is not
13. ROUBLE 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 SCENARIO1 VEHICLE IS NOT CONNECTED POWER PRESENT READY TO CHARGE POWER PRESENT READY TO CHARGE VEHICLE CONNECTED VEHICLE CHARGING a STOP TROUBLE 1 VEHICLE CONNECTED VEHICLE CHARGING TROUBLE eoooo H31dVHO 9NILOOHS318n0HWL 1 H31dVH 9NILOOHSJI9NOYL 42 SCENARIO 2 VEHICLE IS CONNECTED gt POWER PRESENT READY TO CHARGE VEHICLE CONNECTED VEHICLE CHARGING TROUBLE 0000 POWER PRESENT READY TO CHARGE VEHICLE CONNECTED VEHICLE CHARGING trovere 1 Turn power OFF then ON at circuit breaker and disconnect switch if applicable 2 If the fault persists DO NOT USE the Charging Dock Contact Customer Support for service TROUBLELIGHT BLINKS TWO TIMES AND REPEATS 3 Caused by an error having to do with your electric vehicle 4 Turn the circuit breaker and the disconnect switch if installed OFF then ON 5 If the fault persists contact Customer Support for service TROUBLELIGHT BLINKS THREE TIMES AND REPEATS 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 rep
14. S N On label on underside 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 on the left underside of the enclosure Customer Support Phone 1 888 833 2148 Customer Support email evscs avinc com Serial number Document Number EVSE RS_UG_ENG_AVVER1 2 9 24 2010 TABLE OF CONTENTS CHAPTER 1 INTRODUCTION Introduction n sod ea 2 Electric vehicle compatibility Features Irmpertantisaletylins ruetions 4 SUMO USAR Certo eke ere 5 High voltage warning FCC information 11 Ventilation 13 CHAPTER 2 USING YOUR CHARGING STATION Overview a sma 16 ISI 17 Charging your vehicle n n 18 Check lights on front panel Remove the connector Connect to vehicle Automatic chargelstarts en e UE 21 Mo stopiaichargingi Cycle 22 Method 1 Preferred Method 2 Chargeicomplete a ae 26 Return connector to Charging gn Auto restart Power outage recovery Time of use metering CHAPTER 3 TROUBLESHOOTING Charging Dock is not available POWER PRESENT light does not turn ON READY TO CHARGE VEHICLE CHARGING and TROUBLE lights do not turn 37 VEHICLE CONNECTED light does not turn ON when
15. TART IS SUCCESSFUL 0000 POWER PRESENT READY TO CHARGE EHICLE CONNECTED VEHICLE CHARGING TRousie zZ d31dV HOD NOILVLS DNIDSYVHD YNOA ONISN 29 H31dVHO NOILVLS 9D9NI983VHD2 YNOA ONISN 30 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 is resumed The VEHICLE CHARGING light blinks and charging will re start automatically after POWERPRESENT a randomly assigned time ranging READYTOCHARGE from 0 to 20 seconds VEHICLE CONNECTED e viy BLINKS gt VEHICLE CHARGING lt AFTER POWER Ze IS RESTORED TROUBLE QO POWER PRESENT READY To OSTART VEHICLE CONNECTED VEHICLE CHARGING STOP To override the automatic random delay after utility power is restored press the START button on the Charging Dock to resume charging POWERPRESENT READYTOCHARGE
16. THE CHARGING DOCK IS CONNECTED TO THE VEHICLE ils Unplug the Charging Dock connector and reinsert it fully into the electric vehicle receptacle Make sure the connector latch engages in the receptacle Inspect the Charging Dock cable and connector terminals for damage If damaged discontinue using immediately and contact Customer Support for service Inspect vehicle receptacle for damage If damaged discontinue using immediately and report the problem to your nearest service dealership VEHICLE CHARGING LIGHT DOES NOT TURN ON ile If this occurs when the vehicle is connected and is charging contact Customer Support for service 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 If a charge cycle starts contact Customer Support for service gt If a charge cycle does not start report the problem to your nearest vehicle service dealership udJLldVHO t 9NILOOHS318nOuU1 39 H31dVHO ONILOOHSITESNOUL 40 TROUBLE LIGHT IS ON SOLID The Charging Dock is one part of the Electric Vehicle s charging system A charger on board the vehicle is the other part TROUBLE light may be triggered by several sources NOTE including the Charging Dock the utility service the vehicle or temperature extremes See Troubleshooting tips below The T
17. a WARNING 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 AN WARNING Charging Dock and ALWAYS stow the output cable after use AUTO RESTART The 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 Contact Customer Support for service POWER PRESENT READY TO CHARGE VEHICLE CONNECTED VEHICLE CHARGING fs TROUBLE THIS LIGHT GOES OUT WHEN AUTO RES
18. ase and neutral grounded or a 208VAC 2 phases and neutral grounded 40 amp dedicated circuit This circuit must be routed directly from the power distribution panel to the Charging Dock location FEATURES e SAE J1772 Compliant Underwriters Laboratory UL compliant Auto restart in event of power outage or ground fault Optional pedestal mount Integrated cable stowage with cable hanger Quick read status indicators L 83L1dVHO NOILINGOUINI Luu3ldVHOD NOILINGOUINI 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 information and warnings in this guide to be aware of any hazards and risks associated with installing and using the Charging Dock NOTE any missing parts and contact AV Customer Support for assistance on obtaining NOTE replacement parts v DANGER WARNING N k NOTE SYMBOLUSAGE Take special note of all information marked with the following symbols DANGER indicates information about safety practices which if not followed may result in serious injury or death WARNING indicates information about safety practices which if not followed could result in personal injury or are necessary to p
19. d 73 Install 40 amp circuit breaker 75 Turn the power ON Self test Inspection u 78 Return warranty information 78 To re open the charging dock electrician only cs S s 79 CHAPTER5 FOR YOUR RECORDS Specifications Warranty INIRODUCIION Lu3ldVHOD NOILINGOUINI INTRODUCTION Thank you for purchasing the AeroVironment AV Charging Dock Model EVSE RS for use with your plug in electric vehicle This user guide shows how to use the Charging Dock and contains installation instructions for the electrician It is recommended 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 A N WARNING NEC and all local codes In cases of conflict between local codes and the NEC local codes shall take precedence ELECTRIC VEHICIECOMATIBlI Y The Charging Dock is designed to charge all SAE J1772 compliant vehicles including Electric Vehicles EVs and plug in hybrid electric vehicles PHEVs SAE J1772 is an electric vehicle charging standard that has been developed by the Society of Automotive Engineers SAE the governing body of Automotive Standards in the USA The Charging Dock requires either a 240VAC split ph
20. d in shipping File a claim with the freight carrier and or insurance company in the event of shipping damage HARDWARE KIT CONTENTS 1 Mounting plate assembly 2 M10 1 5x25mmsocket head screw 2 22mmtlat washer 2 3 8 21 2 lag bolts 2 13 32 flat washers CHARGING DOCK 9 Stainless steel cover screws a 2 8 21 2 painted head wood screws m OUTER TTT tte TRIMRINGFOR FRONT PANEL z USER GUIDE 4 USER GUIDE gt gt _ 2 i CABLEHANGER HARDWAREKIT Wl WITH SCREWS NUTS BOLTS eo I WASHERS Qu ou J NOILVITVISNI d31S A8 d31S FRONT PANEL AND ENCLOSURE ENCLOSURE HOUSING FRONT PANEL COVER INSTALLING THE CHARGING DOCK Power distribution 1 OBTAIN PERMITS panel 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 residential utility power distribution panel with a circuit breaker and a disconnect switch if required by local permitting authority 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
21. e Charging Dock will illuminate the TROUBLE light and not provide power to the vehicle Contact Customer Support for additional information Luu3ldVHOD NOILINGOUINI CHAPTER1 INTRODUCTION 14 USING YOUR CHARGING STATION Z H31dVHO NOILVLS DNIDSYVHD YNOA ONISN 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 O 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 the Charging Dock has detected an error and requires you to take action See the Troubleshooting chapter on page 33 READY TO CHARGE This light turns when the Charging Dock is ready to be connected to your vehicle 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 1 POWER PRESENT ausvaoiotinae OSTA Lt VEHICLE CHARGING 5
22. e access to the Service Tool H3ldVHOD NOILVTIVLSNI d31S A8 d31S Ajuo sue1314131 4104 t HJLdVHO NOI1V11V1SNI d31S A8 d31S Aluo sue1314131 104 22 INSPECTION Schedule an appointment with an electrical inspector for your local permitting authority 23 RETURN WARRANTY INFORMATION CARD Installation is complete Return the enclosed Warranty Information Card WARNING DANGER A TO RE OPEN THE CHARGING DOCK ELECTRICIAN ONLY Turn the power OFF at the Charging Dock dedicated circuit breaker to avoid electric shock Observe all safety precautions NOILVTIVLISNI d31S A8 d31S Ajuo sue1314131 4104 NOIIVITIVLISNI d31S A8 d31S Aluo 1 11 2 104 eu m mW Remove the Outer Trim Ring by 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 front panel off the enclosure Hang front panel as shown in the pictures on page 64 Put the front panel back on the Charging Dock after inspection is complete as shown in the Final assembly on page 70 Replace outer trim ring Access hole Outer ring CHAPTER 4 STEP BY STEP INSTALLATION for elctricians only FOR YOUR RECORDS SPECIFICATIONS Model Connector Car charging dock communication protocol Dimensions Voltage Current output power C
23. er stepped on tripped over or otherwise damaged or stressed while in use To prevent personal injury A N WARNING and damage to the Charging Dock and cable ALWAYS stow the output cable after use 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 N WARNING Dock Close supervision of children is necessary when the Charging Dock is used 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 WARNING State of California Proposition 65 Warnings This product contains a chemical known to the State of California to cause cancer This product contains a chemical known to the State of California to cause birth defects or other reproductive harm NOIL2nGOMLlNI Luu3ldVHOD NOILINGOUINI FCC INFORMATION This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions This device may not cause harmful interference 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 RFD However there are some instances where high powered radio signals or nearby RF producing equipment i e digital phones RF communica
24. ircuit 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 EVSE RS SAE J1772 compliant SAE J1772 compliant 12 Hx 12 W x 8 D approximately 208 240 Volt AC VAC single phase 30 Amp Maximum 40 Amp Do NOT use a Class A circuit breaker with the EVSE RS Charging Dock 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 Ibs 7 94 kg 22 F to 122 F 30 C to 50 C 40 F to 140 F 40 C to 60 C Up to 90 non condensing NEMA Type 3 enclosure rain tight with mounting plate UL FCC part 15 subpart B Specifications are subject to change without notice u3ldVHO s SNOIL1VOlI4I23dS 83 udJLldVHO S ALNVHUHVM 84 HOME CHARGING DOCK MODEL EVSE RS LIMITED WARRANTY The AeroVironment Inc CAV 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
25. let receptacle LATCH RELEASE The POWER PRESENT and READY TO CHARGE lights are ON as shown below POWER PRESENT READY TO CHARGE VEHICLE CONNECTED VEHICLE CHARGING TROUBLE OO Oe READY TO CHARGE I VEHICLE CONNECTED VEHICLE CHARGING power PRESENT trousie OSTART d31dVHO NOILVLS DNIDSYVHD YNOA ONISN 25 H31dVHO NOILVLS 9D9NI983VHD2 YNOA ONISN 26 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 POWER PRESENT READY TO CHARGE VEHICLE CONNECTED VEHICLE CHARGING TROUBLE Oc eee 6 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 The POWER PRESENT and READY TO CHARGE lights are ON as shown below LATCH RELEASE POWERPRESENT READY TO CHARGE VEHICLE CONNECTED VEHICLE CHARGING TROUBLE OOO power PRESENT READY TO CHARGE voff VEHICLE CONNECTED VEHICLE CHARGING Y A Trouvere OSTART DsTOP NOILVLS DNIDSYVHD YNOA ONISN 27 d31dVHO NOILVLS DNIDSYVHD YNOA ONISN 28 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
26. 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 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 and or its installation is limited to a 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 o
27. ng Dock enclosure as follows 1 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 lb 2 2 Nm 2 Connect green Ground Utility wire to the Ground Strip Torque the ground strip screw to 20 in lb 2 2 Nm Note 240VAC delta connection with high C may be used as long as ground to black outside input wire measures 120VAC Upper Ground Terminal Strip Terminal Block Line 1 black outside wire Line 2 white inside wire ux XS ey Lower Ground Terminal Strip EK Service Ground Wire Power Phase Wires Line 1 EVSE Terminal Block black wire outside Line 2 EVSE Terminal Block white wire inside HJLdVHO NOILVTIVLISNI d31S A8 d31S Aluo sue1314131 104 t H3ldV HOD NOI1VT11V1SNI d31S A8 d31S Aluo sue1314131 4104 17 FINAL ASSEMBLY 1 Complete inspection To avoid having to reopen the Charging Dock panel it is recommended to have 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 Do not over or under torque screws Use calibrated torque wrench NOTE AN WARNING A WARNING Verify that the wires from the front panel circuit b
28. ns 2 REMOVE THE CONNECTOR Press the latch release and remove the connector from the Charging Dock LATCH RELEASE NOILVLS DNIDSYVHD YNOA ONISN 19 NOILVLS DNIDSYVHD YNOA ONISN 20 3 CONNECT TO VEHICLE Plug the connector into your vehicles s charging receptacle and let go of the connector allowing the latch release to click and pop up into the latched condition to achieve a proper connection When letting go of the connector the latch release must click and come back up into position when connected to make a proper connection The connector does not disconnect without pressing the latch release The VEHICLE CONNECTED light turns ON when a proper connection is made LATCH RELEASE POWERPRESENT READYTOCHARGE VEHICLE CONNECTED VEHICLECHARGING CHARGING _ TROUBLE RECEPTACLE POWER present READY TO CHARGE ff VEHICLE CONNECTED VEHICLE CHARGING 4 AUTOMATIC CHARGE STARTS The vehicle automatically starts charging and the Charging Dock supplies power as needed e POWER PRESENT VEHICLE CONNECTED and the VEHICLE CHARGING lights stay on when charging e VEHICLE CHARGING light blinks when the vehicle is approaching the end of the charging cycle e VEHICLE CHARGING light goes out when vehicle is fully charged Look for a gauge on the vehicle that verifies the vehicle is fully charged See the owner s manual that came with the vehicle to find out where the gauge
29. o 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 AN WARNING Electric Code NEC and all local codes In cases of conflict between local codes and the NEC local codes shall take precedence DANGER DANGER SAFETY INSTRUCTIONS SHOCK CAN KILL Touching live electrical parts can cause fatal shocks or severe burns The input power circuitry and internal circuits are live whenever input power is on An incorrectly installed or improperly grounded unit is a hazard Read all instructions and cautionary markings on the Charging Dock assembly Warranty is void if the Charging Dock is wired improperly ELECTRICAL CAPACITY REQUIREMENTS The Charging Dock requires either a 240 VAC split phase and neutral grounded or a 208 VAC 2 phases and neutral dedicated grounded circuit t udJ3ldVHO NOILVTIVLISNI d31S A8 d31S Ajuo sue1314131 104 NOILVTIVLSNI d31S A8 d31S v u3ldV Aluo sue1314131 4104 GROUNDING INSTRUCTIONS This unit is to be connected to a grounded metal permanent wiring system or an WARNING P equipment grounding conductor is to be run with the power circuit conductors and connected to an equipment grounding terminal or lead on Charging Dock ground strip Connections to the Charging Dock shall comply with all local codes and ordinances WARNING 5 o z o 2 e o
30. oard are routed to prevent pinching between the housing and front panel during assembly lt sI m N TA M z gt NOTE Tighten front panel screws by hand within torque range Do not use power screw V driving equipment o z Aluo sue1314131 104 NOI1VT11V1SNI d31S A8 d31S Aluo sue1314131 4104 Outertrimring goes here Screw holes Outertrimring Frontpanel nine 9 total 3 Install the outer trim ring by snapping it into the groove in the Charging Dock front panel To remove the trim ring insert a flat head screw driver into the opening at location as shown on page 80 WARNING A N NOTE 18 MOUNT CABLE HANGER TO WALL STUD OR DRY WALL AND HANG CABLE Using two painted head provided fasteners attach the output cable hanger to the wall stud dry wall masonry wall surface or pedestal 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 t H31dVHOD NOILVTIVLSNI d31S A8 d31S Aluo sue1314131 104 NOI1VT11V1SNI d31S A8 d31S Aluo sue1314131 404 CHARGING DOCK CABLE HANGER Front view Mounting holes Back view NOTE 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
31. ort issue to utility company H31dVHO ONILOOHSITSNOUL 43 H31dVHO ONILOOHSITSNOUL 44 TROUBLE LIGHT BLINKS FOUR TIMES AND REPEATS 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 If the 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 3 If IROUBLE light turns ON a Turn power OFF at circuit breaker and disconnect switch if applicable b Disconnect from vehicle c Contact Customer Support for service B 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 ud3ldVHO t 9NILOOHS318nOuU1 45 CHAPTER 3 TROUBLESHOOTING 46 a pr INSTALLATION udJLldVHO NOILVTIVLISNI d31S A8 d341S Aluo sue1314131 404 INTRODUCTION Read these installation 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 T
32. perating 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 INDEX A auto restart 29 B broken part 52 C cable 3 7 8 11 12 17 28 38 45 52 53 65 73 83 cable hanger 3 17 28 53 73 74 CC amp Rs 55 children 8 28 cleaning 6 20 connector 7 11 12 17 19 20 24 27 38 customer support ii D damaged parts 52 document number ii E electric shock 11 12 68 75 79 emergency portable cord set 35 36 39 enclosure 11 54 64 68 69 80 83 environmental rating 83 F features 3 17 front panel 16 17 18 54 64 65 71 72 80 front panel cover 54 64 G GFCI 11 29 36 ground fault circuit 11 36 H high voltage 6 36 51 hook 65 installation 47 55 insulated 11 latch release 17 19 20 24 27 M missing parts 4 52 model ii 83 N NEMA 83 0
33. revent fire or equipment overheating NOTE indicates helpful information for installation or usage but does not contain personal injury or equipment safety related information NOILINGOUINI u31dV NOIL2nGOMLNI HIGH VOLTAGE WARNING High voltage is present in your electric meter housing and power distribution service panel WARNING Contact with high voltage can cause death or serious personal injury To clean the Charging Dock 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 Turn off the power to the Charging Dock at the circuit breaker and disconnect switch if applicable before cleaning it DANGER DANGER Do not operate your Charging Dock with a visibly damaged output cable or housing Visually inspect the output cable including the connector and housing for damage 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 switch if applicable and immediately contact Customer Support for service DO NOT use your Charging Dock until the problem is identified and corrected HJ31dVHO NOILINGOUINI NOILINGOUINI ALWAYS position the Charging Dock output cable so that it will not be driven ov
34. temperature ranges see the Specifications section on page 83 In addition to local building codes and ordinances certain neighborhood 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 Disconnect switch if applicable IL Charging Dock Wall stud NOI1VT11V1SNI d31S A8 d31S Aluo sue1314131 104 NOI1V11V1SNI d31S A8 d31S Aluo sue1314131 4104 Do not use the Charging Dock with a Class A circuit breaker AV recommends that the Charging Dock not be installed in a location that exceeds the operating temperature A N WARNING k NOTE 3 PREPARE TOOLS REQUIRED FOR INSTALLATION Have the following tools ready to use Standard Screwdriver Measuring Tape Phillips Screwdriver Utility Tape Electrician Screwdriver Multimeter Torpedo Level Torque Screwdriver Torque Wrench Small Hammer Ratchet Set Duct Tape Channel Lock Pliers M8 Allen Head Adapter Wire Stripping Pliers 1 25 Hole Saw Cutting Pliers 3 2 Electric Drill 3110 Torx Drive Screwdriver HJLdVHO NOI1VT11V1SNI d31S A8 d341S A uo sue1314131 104 t HJLdVHO NOI1VT11V1SNI d31S A8 d31S Aluo sue1314131 4104 4 CHOOSE LOCATION Choose a location to install the Charging Dock Find the vertical stud in a
35. the Charging Dock is connected to the vehicle 38 VEHICLE CHARGING light does not turn ON 39 TBOUBEE Tight 40 TROUBLE light blinks two 43 TROUBLE light blinks three 43 TROUBLE light blinks four times and repeats TROUBLE light is rapidly blinking CHAPTER 4 STEP BY STEP INSTALLATION for electricians only Introduction Safety instructions Personal protection equipment PPE Package contents eee e ES 52 Front panel and enclosure Installing the Charging Dock Obtain permits Meriby DulldingiCodes mun 55 Prepare tools required for installation Ghoose lo catiemsn n 2 a nn a Drill hole for wire entry rear or underside Route wiring and or conduit Use mounting plate as template maan 61 Install mounting plate to wall torque bolts 62 Pull wires out of wall and plate 63 Attach Charging Dock to mounting plate Prepare Charging Dock Remove front panel and hang on rim of Charging Dock Upper mounting hole Lower mounting hole sese 67 Connect conduit to 68 Turn power OFF Connect utility wires and conduit Final assembly Mount cable hanger to wall stud or dry wall an
36. tions equipment etc could affect operation Important Changes or modifications to this If you suspect your Charging Dock is receiving interference take the following steps roduct by anyone other before contacting Customer Support for service P y ny than an authorized service 1 Relocate nearby electrical appliances or equipment during charging provider will void FCC 1 Turn off nearby electrical appliances or equipment during charging compliance 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 with a Ground Fault Circuit Interruption GFCD reaction System to protect against electric shock If the system 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
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